TWO-COLUMN BAND SAW MACHINES FOR VERTICAL CUTS:     

850x1000 HERKULES X-CNC

A highly productive automatic, hydraulically manipulated two column band saw machine with a material feeder. The machine uses the extremely robust construction and the arm which is 25 degrees sloped.   These characteristics together with the more poweflull planet drive and with the blade of 54 mm hight ensure the maximum possible efficiency.  
X version in the basic solution offers 64-bits control system with posibilities of  automatic regulation of the arm movement towards the cut that  depends on cut resistance of the material, electronic setting of  upper and down position of the arm, on display you can see cutting speed. The control system is prepared for comunication with other external accesories.
The machine is designed for vertical  cuts.
It is suitable for serial production in industrial premises. Thank to its robust construction enables to cut wide range of materials including full materials stainless steels and tool steels.

Construction:

• The band saw machine has a robust construction which determines Herkules machines for use of carbide blades. The machine is designed so that it answers the extreme exposure in production conditions.
• Tough frame of machine with columns situated as near the clamping vice as possible minimizes vibrations and enables max. cutting performance.
• An arm is a rugged weldment and it is designed so that a toughtness and a precision of cut was secured.  Arm moves on  two columns by a help of  a four row linear leading with a high loading capacity.  Arm movement by a help of two hydraulic cylinders.
• he robust steel pulleys sloped of 25 degrees regarding the level of the cut. Thanks to sloped arm the twist of the blade is eliminated and these is possibility to bring the blade closer to the minimal distance from the linear leading on columns. This arrangement eliminates vibrations and enables the max. cutting performance of the machine.
• Arm of machine has a an automatic sensor for a measuring of a position over material  and there is also an end stop for setting a down position.  . The upper working position of the arm is set automatically  by the controlling system after pressing the button on the controlling terminal. The controlling system asks the hight of the material when starting every cut. By this the human error or microswitch failures are minimized.  
• The main vice is on the output side ( position: feeder – blade – firm vice).
• Both vices ( main vice and feeder vice) are robust steel weldments. Jaws ensure safe clamping of the material.  Jaws move on two rails of linear leading thanks to hydraulic cylinder. One jaw is longstroke ( the movement by longstroke hydraulic cylinder), one is shortstroke (it releases its position when feeding the bar, the jaw is not worn out, the material does not slip). Shortroke jaw of he feeder and main vice with the short stroke rebound, it means contactless feeding of the crooked material.
• Very rigid feeder with the feeding step 1000 mm moves on four rails of the linear leading by  hydraulic cylinders. There are two speeds of the feeder (miscro feed when approaching the position). Incrementally straight sensor for indication of the position of the feeder and GTO (go to position) function.  
• The feeder is equipped by the additional hydraulic Zimmer brake, which is situated on the rail of the linear leading of the feeder. This brake fixes the feeder in the exact position.
• The roller conveyer goes through the whole machine and supports the material in all its lenght. The roller conveyer of the feeder : bearings houses of the rollers are mounted into the basement – big robustness and precision.
• Electro-hydraulical equipement of a blade tension with an end switch ensures a constant tension and enables to keep ideal cut conditions.  
• Adjustable quides with hardmetal plates and upper blade leading  by a harden ring on a needle bearing.  
• A cleaning brush is driven by an electroengine and ensures perfect cleaning of a blade.
• There is a planet gear box drive and a three-phase electroengine, a fluent regulation of a circumferential blade speed  by a frequency converter for a fluent change of blade speed. Attention: Drive with planet gearbox coresponds with drive with worm grearbox and engine of cca double multiple power.
• Machine is equipped with a cooling systém for emulsion distributed to blade quides.
• Robust base with a tank for chips and with a worm chip extraktor.
• Indication of  blade tightening and opening of the cover.
• Control terminal with a microprocessor, control 24V.
• The machine is equipped by the controlling MAHLER terminal, which controls the cut of the machine in two basic regimes : BIMETAL and CARBIDE.
• BIMETAL regime is suitable for optimalization of the cutting feed when cutting profiles by bimetal blades. The cutting feed is realized by PEGAS ARP system which automatically regulates cutting feed depending on the resistance of the material. The cutting feed is higher if the blade cuts sides of the prifile. As the blades reaches the full material, the system reduces the cutting feed automatically so that teeth gap of the blade would not be filled.
• CARBIDE regime is suitable for cutting of full bars by bimetal or carbide blades.  The controlling system regulates the cutting feed automatically ( 75% feed) at the beginning of the cut. The aim is to eliminate vibrations and the load of the blade teeth at the beginning of the cut. The cutting feed is constant during the cut, 15mm before the end of the cut the systems reduces the cutting feed automatically. Higher bladelife is achieved. Controlling system in CARBIDE regime uses the regulation of the cutting feed during excessive load of the blade (systems reads the load of the blade drive in Ampers). The regualtion is not active, it serves as a fuse if the blade is not worn out. The controlling system reduces the cutting feed to one half and finishes the cut.  
• "The regulation of the cutting feed is realized by a hydraulic valve controlled by servoengine. Thanks to this a very precise cut is achieved. The operator inserts the desired cutting feed (mm/min)  into the programm  and the machine sets this feed very exactly. This way of control depends on the temperature (viscosity ) of hydraulic oil. 
• A controlling systém of machine represents a working states as circumferential blade speed, speed of arm movement to cut and a state of single working movements. A part of a system are also inputs and outputs for connection of an abovestandard accessories.
• Safe  model with autodiagnostics.
• Working movements are regulated by hydraulic system. There are regulation valves for setting a vice pressure in hydraulic systém.

Basic equipment:

• light above the working place
• frequency converter
• blade
• set of tools
• manual instructions

Operating cycle:
Vices clamp after starting the machine, the machine makes the cut by a set speed, the cutting zone in the down position of the arm is released – the shortstroke and consequently the longstroke jaw of the firm vice open, the feeder moves the material to the firm vice, the arm lifts up to the set upper position. The material is moved by the feeder – periodic regime (feeder moves between zero position and the position of the set lenght of feed)  or consecutive regime (feeder moves to the value of 1000 mm) and clamps the material and feed it to the cut consecutively. The main vice clamps the material, the vice of the feeder is still closed and the whole procedure repeats. The operator only loads the material and removes the cut material. It is possible to regulate the cutting speed of the arm and the blade speed during cutting.