PRODUCTS CATALOGUE - Columbia Machines

Transcription

PRODUCTS CATALOGUE
About
THE COMPANY’S HEADQUARTER AND MECHANICAL PRODUCTION HALL
The TECHMATIK Plant was built in the summer of
2004 in the Radom sub-zone of the Tarnobrzeg Special Economic Zone, in response to high domestic
and foreign market demand for moulds and highperformance plants for production of concrete
products.
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The TECHMATIK offer includes: moulds for production of paving blocks and decorative concrete products; modern, high-performance concrete block
machine; complete process plants; concrete mixing
plants; and various machines used for manufacture
of vibrated & pressed, as well as ready-mixed concrete. All production lines are equipped with advanced, state-of-the-art machines ensuring high
output and repeatability of production and superior quality of products. Our machines, devices and
moulds are designed for high-performance and
efficiency production with the use of steel pallets.
This solution ensures the best product properties
by through compacting and significant lowering of
production costs by reducing the amount of cement
used for concrete mix.
Production control systems complete the offer. These
are control modules for each of the production stages
or integrated control systems for the whole production line. TECHMATIK also offers mould repair, regeneration and maintenance services. The company is
constantly expanding their machine portfolio.
All machines are thoroughly tested in their own experimental plant in Radom before they are launched
on the market.
MECHANICAL PRODUCTION HALL
The Company constantly expands its product portfolio by launching new machines and devices, which
are thoroughly tested in the Company’s own testing
facility in Radom.
The superior quality confirmed by ISO 9001-certified
quality management system, the performance and
output levels of machines and moulds produced,
and competitive prices - these are the reasons why
the Company successfully gains new markets and, as
the supplier of machines and plants for manufacture
of paving concrete blocks, has the leading position
in Poland and a few other countries (it is worth mentioning that Poland is one of the biggest markets for
paving concrete blocks, with total production of more
than 80 million square metres per year). The Company delivers its solutions directly to customers in many
European and Asian countries and, following the contract signed with the American company Columbia
Machine Inc. the moulds marked with COLUMBIA TECHMATIK logo are distributed to manufacturers of
vibrated concrete products in both Americas as well
as in Australia and New Zealand.
Our modern approach combined with long-term experience in concrete products production, innovative
and high quality machines and moulds, has already
been appreciated by hundreds of clients from over 50
countries on almost all continents.
Employing over 400 people, the Company is one of
the largest employers in the Radom city area.
Contents
techmatik r&D department
products
Manufacturing plants for concrete paving blocks & decorative products
MUTLI 600 PRO universal concrete block machine
MUTLI 1200 PRO universal concrete block machine
HP 3000 concrete block machine
HP 5000 PRO concrete block machine
SHP 5000 PRO C concrete block machine
Stacker and unstacker
Transporting cars: finger car, transfer car
The racking system
ROBOMATIK cuber
Automatic stretch wrapper
Pallet dispenser
Crossover conveyor
Slip sheet dispenser
Product dump station
WASHMATIK - product washing station
Tumbler
Techmatik multifunctional splitters
Planetary concrete mixers
Concrete mixing plants
Line for automatic dispensing of raw materials
Automatic screening plant for raw materials
Moulds for concrete paving blocks and decorative products
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SERVIces
Heat treatment
Machining
Quality control
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CONTACt
Contacts
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Manufacturing lines for concrete
paving blocks & decorative products
complete production line with compact design
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n our offer you will find modern high-performance machines and equipment for manufacture
of concrete paving blocks and concrete decorative products as well as complete processing lines
controlled by an integrated computer system that ensures the superior quality of products and
repeatability of production.
ADVANTAGES & BENEFITS OF THE LINE
• Reliability, energy savings, flexible applications
• Innovative engineering solutions
• Modern manufacturing processes
• Compact design
• Low noise emission level
• Competitive price.
Interesting solutions used in the
production line
linear bearings
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precise positioning
longer lifetime
quiet operation
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TOOTHED BELT FOR DRIVE TRANSMISSION
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quiet operation
precise positioning
HYDRAULIC BLOCKS
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BEARING HOUSING
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in-company developed and executed structure
longer lifetime
in-company developed and executed
structure
precise execution
reliable operation
HYDRAULIC CYLINDERS
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in-company developed and executed structure
longer lifetime
reliable operation
HYDRAULIC STATION
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compact construction
integrated with the
concrete block machine frame
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VIBRATION TABLE
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individual table construction
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limited vibrations of the concrete block machine
SCHEME OF THE PRODUCTION LINE WITH multi 600 pro
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Key
1. 1.
1.2.
1.3.
1.4.
1.5.
Five-chamber tank with aggregate feeders 25m3
Aggregate batcher
Belt conveyor B = 1000; L~6.5 m
Belt conveyor B = 1000; L~32 m
Silos with supporting structure, capacity 80 tons
(2 pieces)
1.6. Silos filter
1.7. Batching plant steel construction
1.8. Cement batcher
1.9. Mixer 2250 l
1.10. Aggregate buffer
1.11. Concrete hopper
1.12. Liquid chemical batcher
2.1. Concrete block machine MULTI 600 PRO
3.1. Transfer car
4.1. Batching plant control panel
SCHEME OF THE PRODUCTION LINE WITH multi 1200 pro
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Key
1.1. Five-chamber tank with aggregate feeders 25m3
1.2. Aggregate batcher
1.3. Belt conveyor B = 1000; L~6.5 m
1.4. Belt conveyor B = 1000; L~32 m
1.5. Silos with supporting structure, capacity 80 tons
(2 pieces)
1.6. Silos filter
1.8. Cement batcher
1.9. Mixer 2250 l
1.10. Aggregate buffer
1.11. Concrete hopper
1.13. Granulated pigments batcher
2.1. Concrete block machine Techmatik MULTI 1200 PRO
2.2. Rails area
3.1. Transfer car
Storage area = 756m²
(e.g. shelter, foil, tent)
192 racks
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VARIANT II
Forklift transport system for pallet racks (up to 15 storey high) - steel or wooden
pallets
VARIANT I
Forklift transport system for pallets (up to 10 storey high) - steel or wooden pallets
Racks
Scale 1:60
HP 3000 PRO production line scheme
Key
1.1. Five-chamber tank with aggregate feeders 5x25 m3
1.3. Belt conveyor
1.4. Belt conveyor
1.6. Silos filter
1.8. Cement batcher with divider
1.9. Mixer 1750 l
1.10. Mixer 500 l
1.11. Aggregate buffer with divider
1.12. Base mix concrete hopper
1.13. Face mix concrete hopper
1.15. Base mix belt conveyor
1.16. Face mix conveyor
2.1. Concrete block machine HP 3000 PRO
3.1. Wet line V-belt conveyor
3.2. Sweeping brush
3.3. WASHMATIK wash station
3.4. Stacker
3.5. Unstacker
3.6. Dry line pallet feeder
3.7. ROBOMATIK cuber
3.8. Chain conveyor
3.9. Automatic stretch wrapper with logo stretch
4.1. Transportable racks
5.1. Block machine and wet line control panel
5.2. Cubing line and dry line control panel
HP 3000 PRO double production line scheme
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Key
1.1. Five-chamber tank with aggregate feeders 5x25 m3
1.3. Belt conveyor
1.4. Belt conveyor
1.6. Silos filter
1.9. Mixer 3000 l
1.10. Mixer 500 l
1.16. Face mix belt conveyor
1.17. Reverse belt conveyor
1.18. Reverse belt conveyor
3.2. Sweeping brush
3.4. Stacker
3.5. Unstacker
3.6. Dry line pallet feeder
3.8. Chain conveyor
SCHEME OF THE PRODUCTION LINE WITH hp 5000 pro
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Key
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
Five-chamber tank with aggregate feeders 5x25 m3
Aggregate batcher
Belt conveyor
Belt conveyor
Divided silo with supporting structure - capacity
2 x 40 tons
1.7. Silos filter
1.10. Mixer 3000 l
1.11. Mixer 500 l
3.2. Sweeping brush
3.4. Product dump station
3.5. Stacker
3.6. Unstacker
3.7. Dry line V-belt conveyor
3.8. Slip sheet dispenser
3.10. Wood pallet dispenser
3.11. Chain conveyor
3.13. Walking beam conveyor for 8 pallets
3.14. Chain conveyor
3.15. Crosswise conveyor
SCHEME OF THE PRODUCTION LINE WITH shp 5000 pro c
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Key
1.1.
1.2.
1.3.
1.4.
1.5.
1.6.
Five-chamber tank with aggregate feeders 5x25 m3
Aggregate batcher
Belt conveyor
Belt conveyor
Divided silo with supporting structure - capacity
2 x 40 tons
1.7. Silos filter
1.10. Mixer 3000 l
1.11. Mixer 500 l
2.1. Concrete block machine SHP 5000 PRO C
3.2.
3.3.
3.4.
3.5.
3.6.
3.7.
3.8.
3.9.
3.10.
3.11.
3.12.
3.13.
3.14.
3.15.
3.16.
3.17.
3.18.
4.1.
5.1.
5.2.
5.3.
Sweeping brush
WASHMATIK wash station
Stacker
Finger car
Transfer car
Unstacker
Dry line V-belt conveyor
ROBOMATIK cuber
Wood pallet dispenser
Chain conveyor
Automatic stretch wrapper with logo stretch
Walking beam conveyor for 8 pallets
Chain conveyor
Crossover conveyor
Pallet accumulation conveyor for 30 pallets
Kilns rack system
Block machine and wet line control panel
Cubing line and dry line control panel
Batching plant control panel
MULTI 600 PRO
Universal concrete block machine
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ADVANTAGES THE MACHINE
• combines the functionality of a walking and a stationary concrete block machine
• production possible without tracks
• flexibility of production, depending on individual customer requirements
• simplified and compact design of the concrete block machine allows to minimize the required installation area
DESCRIPTION OF OPERATION
The MULTI 600 PRO concrete block machine is designed for the production of monolayer blocks in the egg-layer system.
The machine is equipped with moulds connected to vibrators. The products may be formed either directly on the floor or
on production pallets placed along the travel way of the machine.
The concrete block machine has an integrated hydraulic station and an electrical switchbox with a console for the complete visualization of the production process.
In addition, the machine is fitted with proven solutions, such as:
• hydraulic drives for the trays and the carriage system
• mechanical compression head and mould mounting
• linear bearings
• precisely mating mould and compression head elements
TECHNICAL DATA
DEGREE OF AUTOMATION
Fully automatic moulding process
MAXIMUM PRODUCT HEIGHT
600 mm
MINIMUM PRODUCT HEIGHT
190 mm
PRODUCT STRUCTURE
Single layer products
CONNECTION POWER
approx. 36 kW
MAXIMUM FORCE OF THE VIBRATION IMPACT
180 kN
MAXIMUM COMPRESSION HEAD PRESSURE
150 kN
MAXIMUM OUTPUT
(NUMBER OF PRODUCTION CYCLES PER HOUR)
OVERALL DIMENSIONS OF MECHANICAL STRUCTURE
TOTAL WEIGHT
approx. 95 cycles for a 600 mm palisade
2500 x 4100 x 4670 mm
approx. 12 000 kg
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MULTI 1200 PRO
universal concrete block machine
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ADVANTAGES & BENEFITS
• combines the functionalities of mobile and stationary concrete block machines;
• flexible production: concrete blocks may be produced in a stationary or egg-layer system depending on the individual
needs of the customers who can rely on more than only one production system;
• enables the production of various concrete products, starting from concrete paving stones and slabs, through curb stones and edgings to high landscaping units such as palisades, retaining wall units and other road construction elements,
such as pipes, culverts, etc., from 4 cm up to 120 cm high;
• concrete products may be produced without machinery and equipment used for complete production lines, although
it is possible to integrate the machine within such a line.
The design of the concrete block machine features many well proven engineering solutions, such as: • the compression head and the mould are guided on linear bearings;
• the feed drawers are driven by hydraulic motors;
• self-designed bearing mountings which ensure a long-term, reliable operation.
Other new solutions are:
• the proportions of the main frame and the parameters of the compression head and mould mounting units are selected in such a way, that the production is possible in both, egg-layer and stationary modes. The parameter values are
protected by a patent application;
• oil-lubricated vibration box with START/STOP system.
DESIGN SOLUTION
Other design solutions ensuring high production efficiency:
• Feed drawer drive - previously the feed drawers where
driven indirectly by hydraulic cylinders and a lever mechanism; now the hydraulic motors drive the drawers directly through gears and toothed bars. In consequence,
the dimensions of this part of the machine are reduced
and the movements of the drawers consume less energy.
The toothed wheels resulted in an improvement of the
feed drawers' operation dynamics. Plastic wheels contribute to a lower noise emission and protect other, more
expensive and important components against damage,
while simultaneously reducing their wear.
• Linear bearings - this solution for accurate guiding
and positioning of the cooperating mould and
compression head components reduces the wear of
the moulds. This contributes to a longer life of the mould
cavities and shoes.
• Compression head and mould synchronization
mechanism - fixes the compression head in a set position
with respect to the mould while the latter travels to the
demoulding position; consists of chains, brake beams
and hydraulic cylinders.
• Machine drive - two hydraulic motors synchronized
with a flow divider, positioned in the structural concrete
frame. Two hydraulic brakes ensure stopping and fixing
of the machine during production.
• Mould and compression head shaft units - driven by
hydraulic cylinders; strong, durable design combined
with high-quality bearings with self-designed mountings guarantees a reliable use. The parameters of the
units are selected in such a way, that the production
is possible in both, egg-layer and stationary modes
(Techmatik patent).
• Frame lifting unit - 4 screws synchronized with a chain
and driven by a hydraulic motor. They ensure a reliable
and easy adjustment of the distance between the floor
and the mould.
• Concrete hopper - its bended plate design combined
with a special engineering technology provide an excellent concrete discharge into the feed drawers.
SPECIFICATIONS
1200 mm
40 mm
PRODUCT STRUCTURE
SIZE OF PRODUCTION PALLETS
THICKNESS OF PRODUCTION PALLETS
(DEPENDS ON THE MATERIAL USED)
Single or double layer product
1400 x 1100 mm
from 12 to 55 mm (stationary mode)
INSTALLED POWER
48 kW
MAXIMUM FORCE OF VIBRATION IMPACT STROKE
(VARIABLY ADJUSTED)
250 kN
150 kN
MAXIMUM OUTPUT
TOTAL WEIGHT
ca. 120 cycles for double layer paving stones (mobile egg-layer mode)
ca. 180 cycles for double layer paving stones (stationary mode)
ca 100 cycles for palisades 800 mm height single layer product
(mobile egg-layer mode)
2490 x 6900 x 5700 mm
39 000 kg
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HP 3000 PRO
universal concrete block machine
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This is the smallest of our concrete block machines, cheap to buy and operate, easy to use and at the same time reliable
as well as robust, due to proven structural solutions.
The HP 3000 PRO concrete block machine is designed for the production in a stationary system. It is fitted with a vibrating table and works with typical production line equipment.
It the standard version the machine is designed to produce mono-layer blocks. The machine can be fitted with an additional face layer feeding system for the production of two-layer concrete products.
•
feeding box drives – hydraulic motors drive the boxes directly through toothed bars, therefore the dimensions of
these components are reduced and the movements of the boxes consume less energy
•
linear bearings – these components allow the accurate guiding and positioning of the cooperating mould components – the tamper and the mould die – which ensures their longer life
•
mechanical tamper and mould fixing – due to simple screw connections the design could be simplified
•
mechanical frame lifting – due to a toothed jacking device the drive design and its maintenance could be simplified
Proven structural solutions
•
•
Feeding box drives - hydraulic motors drive the
boxes directly through toothed bars, therefore the
dimensions of these components are reduced and
the movements of the boxes consume less energy.
Linear bearings - these components allow the accurate guiding and positioning of the cooperating mould
components – the tamper and the mould die – which
ensures their longer life.
•
Mechanical tamper and mould fixing - due to simple screw connections the design could be simplified.
•
Mechanical frame lifting - due to a toothed jacking
device the drive design and its maintenance could be
simplified.
SPECIFICATIONS
AUTOMATION LEVEL
300 mm
40 mm
PRODUCT STRUCTURE
Mono-layer or two-layer
PRODUCTION PALLET DIMENSIONS
1400 x 1100 mm
PRODUCTION PALLET THICKNESS
from 12 to 55 mm
INSTALLED POWER
approx. 56 kW
MAXIMUM IMPACT FORCE
180 kN
150 kN
MAXIMUM OUTPUT
(NUMBER OF CYCLES PER HOUR)
TOTAL WEIGHT
approx. 180 for two-layer pavers
2500 x 5600 x 4670 mm
approx. 16 000 kg
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HP 5000 PRO
concrete block machine
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ADVANTAGES
• more economical version of SHP 5000 PRO C machine
• energy consumption reduced by approx. 30%
• implemented solution proven in SHP 5000 PRO C and MULTI 1200 PRO machines.
- suitable to manufacture a wide variety of products with heights from 40 mm up to 500 mm
- low energy consumption thanks to innovative drives and kinematics pairs
- lower noise level achieved by acoustic insulation of the most noisy components
- designed for production on steel pallets - facilitate achieving high quality of concrete products
- compact design – hydraulic unit integrated with the machine
- fully automatic operation with visualization of all production stages.
INNOVATIVE SOLUTIONS
In the new Techmatik HP 5000 PRO concrete block machine innovative engineering solutions are applied, which ensure
effectiveness and keep production costs at reasonable level.
• Oil lubricated vibrator box with START/STOP system
• Mechanical adjustment of vibration
PROVEN SOLUTIONS
Moreover, Techmatik HP 5000 PRO machine utilizes thoroughly tested and proven solutions from SHP 5000 PRO C
and MULTI 1200 PRO machines such as:
• Linear bearings - this solution for accurate guiding and
positioning of the working elements of mould and compression head reduces wear of moulds; the lifetime of die
cavities and shoes will be longer.
• Mould and compression head shaft units - driven by
hydraulic cylinders; strong, durable design combined
with high-quality bearings with self-designed mountings guarantees a reliable use.
• Drive of feed drawers - previously the feed drawers
were driven by a lever mechanism, now the motors drive
the drawers directly through gears and toothed bars; dimensions of this part of the machine are reduced, therefore moving the drawers requires less energy. Due to
smaller dimensions of gears, the dynamics of the drawer
operation is much better.
• Compression head clamp - innovative solution in the
form of a hydraulic clamp with two motors prevents displacement of compression head relatively to the mould,
thus enhancing the mould lifetime.
• Mould change fork frame - the previous, hydraulically
driven mechanism is replaced by the new one that is less
complicated and easier to operate; now the operation of
mould replacement is much easier.
• Pneumatic system of front feed drawer floor lifting the hydraulic system is replaced by four bellow - type
pneumatic actuators combined with floor guiding system based on linear bearings.
SPECIFICATIONS
500 mm
40 mm
PRODUCT STRUCTURE
1400 x 1100 mm
12 - 55 mm
INSTALLED POWER
94 kW
(VARIABLY ADJUSTED)
250 kN
150 kN
MAXIMUM OUTPUT
TOTAL WEIGHT
approx. 200 cycles
2600x7460x5200 mm
25 000 kg
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SHP 5000 PRO C
concrete block machine
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• Possibility to manufacture a wide variety of products with heights from 40 mm up to 550 mm
- production may be adjusted to the customers’ needs;
• Low energy consumption – innovative drives and kinematic pairs;
• Lower noise level achieved by acoustic insulation of most noisy components;
• Designed for production with using steel pallets, thus allows to achieve high quality of concrete products;
• Equipped with COLORMIX system for manufacture of concrete products with coloured surface layer;
• Compact design – the hydraulic unit is integrated with the machine.
INNOVATIVE SOLUTIONS
In our new concrete block machine, Techmatik SHP 5000 PRO C we have applied the innovative engineering solutions
that ensure effective production and keep the costs at a reasonable level.
• Compression head counterweight - structural members moving inside the body of the machine counterbalance the weight of the compression head; in this solution the energy required to move the stamp is reduced,
similarly the power of the hydraulic unit supplying
the machine is lower and just one hydraulic cylinder is
enough to drive the compression head mechanism instead of two.
• Linear bearings - this solution for accurate guiding and
positioning of the working elements of mould and compression head reduces wear of moulds; the lifetime of die
cavities and shoes will be longer.
• Oil-lubricated vibrator assembly - the new vibrator
assembly is not permanently attached to the machine’s
structural elements, therefore vibrations transferred to
the machine are significantly reduced; oil lubrication system extends the lifetime of assembly and considerably
reduces the scope of the operator’s work.
• Drive of feed drawers - previously the feed drawers
were driven by a lever mechanism, now the motors drive
the drawers directly through gears and toothed bars; dimensions of this part of the machine are reduced, therefore moving the drawers requires less energy. Due to
smaller dimensions of gears, the dynamics of the drawer
operation is much better.
• Mould change fork frame - the previous, hydraulically
driven mechanism is replaced by the new one that is less
complicated and easier to operate; now the operation of
mould replacement is much easier.
• Colormix - a set of devices for feeding the coloured
concrete to the surface layer of concrete products that
can be manufactured in a mixture of colours; a special
system ensures uniform filling of drawers with multicoloured concrete mix and, therefore, the repeatability
of product colours.
• Compression head clamp - innovative solution in the
form of a hydraulic clamp with two motors prevents displacement of compression head relatively to the mould,
thus enhancing the mould lifetime.
• Compression head stabilisation elements - the improved head stabilisation mechanism is much simpler;
the previous solution is replaced by two toothed bars
which drive two gears mounted on a common shaft.
• Pneumatic system of front feed drawer floor lifting the hydraulic system is replaced by four bellow - type
pneumatic actuators combined with floor guiding system based on linear bearings.
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SPECIFICATIONS
550 mm
40 mm
PRODUCT STRUCTURE
1400 x 1100 mm
12 - 55 mm
INSTALLED POWER
139 kW
(VARIABLY ADJUSTED)
250 kN
150 kN
MAXIMUM OUTPUT
TOTAL WEIGHT
approx. 250 cycles
2660x7600x5260 mm
32 000 kg
finger car ROTATING ON LOWER
TRansfer car
Stacker and unstacker
stacker and unstacker
STACKER IN OPERATION
Two devices are installed in the production line.
In the so called wet line the stacker receives and stores the
appropriate number of pallets with moulded products
which are then sent to the kiln for curing.
The unstacker installed in the so called dry line receives
pallets with the cured products and transfers them to the
packing section of the production line.
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SPECIFICATIONS
Installed power
Working load
Feed rate
Dimensions
8 kW
11700 kg
0.1 m/s
Height - 7650 mm
Width - 2600 mm
Length - 2200 mm
Adequately selected driving components ensure quiet and
smooth operation of equipment.
Transporting cars
In the production line the finger car delivers the concrete products to the kiln
area or receives them from there, working in combination with transfer car and
stacker and unstacker.
The finger car features an innovative solution of a telescopic mast with linear
bearings and the oil tank of the hydraulic station integrated with the frame.
Lower transfer car features compact design and innovative positioning system.
The lower rotating finger car group is characterized by a compact design and
a modern positioning system.
SPECIFICATIONS
Finger car
Installed power
Dimensions
15.2 kW
Height - 6900 mm
Width - 1300 mm
Length - 2600 mm
transfer car
Installed power
Dimensions
7 kW
Height - 1260 mm
Width - 3100 mm
Length - 3900 mm
FINGER car ROTATING ON LOWER
TRansfer car
The racking system
The racking system
The racking system has a strong, durable and stable construction made of galvanized steel elements, which ensures its corrosion resistance. It has a high load capacity. The
supporting structure is made of steel profiles and features
a fast and easy installation without the need to use any lifting equipment.
SPECIFICATIONS
3900 pallet positions, 10 entrances, 30 storeys
h x w x l 7 x 17,6 x 15,3 m
Loading with pallets with concrete products: 3,4 kN/m2
For pallets with the dimensions of 1400 x 1100
The racking system allows to store pallets with concrete
products during their initial curing process. It may be provided with automatically controlled roller doors. The rack
may be also insulated with sandwich panels. A dedicated
space for the climate control system constitutes another
advantage of the racking system.
The racking system
The racking system
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ROBOMATIK - cuber
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The task of the robot is to pick ready concrete products from the dry line V-belt
conveyor, move and deposit them on the trade pallets.
While designing this machine very sophisticated engineering solutions
were applied, until recently used in high-precision industrial machines only.
The machine is of compact design, works quietly and with high dynamic
of movements, and ensures high positioning accuracy of transported products and virtually eliminates product damages during packaging.
A counterweight leads to energy savings in spite of the fast operation and heavy
loading.
SPECIFICATIONS
Installed power
Maximum load
Height
Working radius
28,7 kW
700 kg
5422 mm
1550 mm
ROBOMATIK - CUBER
ROBOMATIK - CUBER
Automatic stretch wrapper
AUTOMATIC STRETCH WRAPPER
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AUTOMATIC STRETCH WRAPPER
Automatic stretch wrapper combined with a logo tape strapping device. The device is able to simultaneously wrap products with stretch foil and strap them with a (non-adhesive) logo tape. Due to proven structural solutions, such as counterweights and linear bearings, the column structure of the wrapping device is compact and stable. Thanks to the
innovative logo tape strapping system the wrapping device is the first of this type on the market.
TECHNICAL DATA
Dimensions height
5,7 m
width
2,5 m
length
4,5 m
Max. product dimensions
height
1,92 m
width
1,0 m
length
1,2 m
Lifting speed 0,09 m/s
Turning speed
11,5 rpm,
inverter adjustable
Stretch foil width
LOGO tape width
Max. working stroke
Installed power
Weight
Standard working cycle
max. 0,7 m
max. 0,25 m
2,05 m
3 kW
5300 kg
min. 56 sec
3 stretch foil wraps + 1 logo foil and stretch
foil wrap + 2 stretch foil
wraps
Pallet dispenser
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PALLET DISPENSER
PALLET DISPENSER
The device feeds the pallets to the ROBOMATIK cuber which stacks the finished products on them. The pallet dispenser
is fitted with a pneumatic drive only, featuring FESTO actuators. The automatic operations of both machines are synchronized.
The dispenser is equipped with:
• a pallet store for 30 pallets which may be delivered by a forklift
• a reliable pallet conveyor.
Advantages of the pallet dispenser
• safer work environment due to the automation of the
pallet feeding process
• design simplicity
• compact design leading to smaller dimensions of the
production line
• innovative and reliable dispenser drive design
SPECIFICATIONS
Max. number of stored pallets
Height
Width
Length (with conveyor)
Working pressure
Weight
30 pcs
3990 mm
1770 mm
3700 mm
6 bar
2076 kg
Crossover Conveyor
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the crossover conveyor
The machine ensures storage and smooth circulation of
production pallets.
Thanks to its modern servomotors, belt transmissions and
linear bearings the machine works silently with high positioning accuracy of pallets transport and short operating
cycles.
SPECIFICATIONS
Installed power
Maximum load
Vertical stroke of gripping device
Horizontal stroke of gripping device
Dimensions Width Height min.
Height max.
Length of gripping device
7 kW
175 kg
300 mm
2800 mm
790 mm
2130 mm
2480 mm
1590 mm
THE CROSSOVER CONVEYOR IN OPERATION
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Slip sheet dispenser - designed to insert a geogrid sheet
between every two product layers to prevent their surface
from scratches.
SPECIFICATION
Geogrid coil drive Geogrid storage Material parameters
geogrid diameter
coiled length basis weight
width
Cutting device Pneumatic system pressure the power is transmitted
from a production pallet
2 pcs.
type P-50
approx. 500 mm
1000 m
0,7 g/m2
1100 mm
resistance wire 220 V
max. 7 bar
Slip sheet dispenser in operation
31
PRODUCT DUMP STATION
The product dump station is designed to remove any products qualified as rejects from production pallets. The tipper tilts the pallet to an angle at which products can easily
slide down. The device can be also used to remove excess
water from products after the washing process.
The tipper is located on the wet side of the production line.
It is equipped with side gates which are automatically lowered during the reject removal process to a position that
guarantees a controlled emptying of the pallet. The device
is characterized by a simple design and reliable operation.
Due to the belt drive transmission system and the special
design of the movable parts the noise during operation
has been significantly reduced.
ADVANTAGES
• Simple design ensures reliable and quiet operation.
• Double functionality (reject removal and initial drying –
excess water removal) reduces the production cycle.
• Increased work safety due to the automatic removal of rejects
from the production line.
PRODUCT DUMP STATION IN OPERATION
SPECIFICATION
Installed power
2,2 kW
WASHMATIK
- product washing station
32
Washmatik in operation
The WASHMATIK wash machine is installed in the process line for manufacture of concrete paving blocks and decorative
products and is used for production of noble-looking paving blocks and flagstones. The machine, through the system
of water and air nozzles, washes out the upper layer of product in order to expose decorative aggregate (granite, basalt,
marble and the like). Such distinguished-looking products are used for arranging elegant paths, alleys and squares, thus
enhancing their aesthetic and functional values.
Advantages
• Short washing time, high efficiency,
• Uniform washing of whole production pallet
(perfect product quality),
• Smooth adjustment of nozzles assembly,
• Intuitive and easy interface,
• Possibility to control each set of nozzles independently (economical use of water),
• Smooth adjustment of washing method,
• Easy adaptation to existing production lines,
• Operational reliability,
• Simple construction facilitating operation and maintenance.
SPECIFICATIONS
•
•
•
•
•
Total weight: 1700 kg
Dimensions:
- Length: 4000 mm
- Width: 1900 mm
- Height: 2400 mm
Installed power: 10 kW
Water consumption - approx 25 l per washing cycle ⁽1⁾
Air consumption – approx 1,21 m3 per cycle ⁽1⁾ ⁽2⁾
(1) – for 11 sec cycle
(2) – pressure 3 bar
Tumbler
33
The machine is designed for surfacing of concrete paving blocks in order to achieve the appearance of worn paving stones, so called vintage pavement effect.
Concrete paving stones are loaded into the main element of the machine, the rotary drum. During the finishing process
jagged edges and traces are created on the blocks imitating natural wear and tear formed through many years of use.
SPECIFICATIONS
• Installed power:
5.5 kW
• Dimensions of tumbler:
- Length:
6120 mm
- Width:
1770 mm
- Height:
3330 mm
Techmatik multifunctional splitters
34
Multifunctional splitters are devices representing a new product line of machines for splitting hollow brick-type concrete products. They answer the demand of the market for decorative concrete products. The bodies of machines and the
working elements (including the hydraulic actuators) have been designed and manufactured by Techmatik S.A. company. The automatic control components are supplied by reputable manufacturers.
Techmatik splitters are available in two options:
Multifunctional splitter with positioning
The advantages of multifunctional splitters with positioning:
• precise splitting of low and high concrete products to the
height of 317 mm
Multifunctional splitter for items of large
dimensions
The advantages of splitters for large items:
• precise splitting of large blocks
• faultless operation due to a simple design
• natural stone splitting option
• accurate positioning of items on the work table
• adjustable work table
Multifunctional splitter with positioning
Highest quality of stone splitting due to:
• top and bottom working actuators with 150 kN pressure rating and working stroke of 300 and 30 mm respectively
side actuators with 20 kN pressure rating and 300 mm stroke each
• hydraulic station with a nominal working pressure of 160 bar (steplessly adjustable) driven by a 7.5 KW electric motor
equipped with an oil cooling unit with a 0.12 kW fan.
The splitter is fitted with a double system for guiding the working jaws consisting of guide pillars and HIWIN linear guides.
Positioning actuators are equipped with guiding pillars and three sets of easily removable mountings with shears used
for stones of different height. The lower actuator is equipped with adjustable supports enabling adjustment of the position of the shears relative to the table. The machine is also fitted with adjustable limit switches for setting the working
stroke, depending on the dimensions of the split stone. The control cabinet allows operation in manual and automatic
mode. Synchronized control pushbuttons and emergency switches, as well as safety guards with adjustable clearance
ensure the safety of the operator. The working shears are made of tool steel and have the appropriate geometry of the
blade. The work tables are fitted with rollers to facilitate maneuvering stone blocks.
Intended use:
The machine is designed for splitting rocks and stone blocks (with positioning) with a width of 110 to 700 mm and
a maximum height of 317 mm.
Multifunctional splitter for items of large dimensions
Ergonomic use and versatility due to:
• the gantry design, where the system of two plunger actuators with a 50 mm stroke and two pulling actuators with
a 400 mm stroke is connected to the splitting jaws, which prevents the transfer of loads to the splitter’s frame. This
system also enables the splitting jaws to adjust to irregularly shaped stones. Adjustable height table allows the splitter to be built into existing conveyor lines.
The hydraulic station with a nominal operating pressure of 200 bars is driven with a 15 kW electric motor fitted with
an oil cooling unit with a 0.12 kW fan.
Intended use:
The machine is designed for splitting whole blocks of stones and irregularly shaped natural stone blocks.
SPECIFICATIONS
Multifunctional splitter
with positioning
Multifunctional splitter for
items of large dimensions
1860 x 1990 x 2100 mm
2120 x 2000 x 2150 mm
Table height
900 mm
900 do 1070 mm
Weight
1150 kg
2150 kg
Pressure force
300 kN
280 kN
Power supply parameters:
working pressure
160 bar
200 bar
(with positioning) 110-700 mm
maximum 317 mm
maximum 1200 mm
maximum 350 mm
Dimensions
Splitting parameters:
- stone width
- stone height
35
Planetary concrete mixers
36
STANDARD VERSION
•
•
•
•
•
2-month warranty with no limit in the operating hours
1
Special lining with hardness of Hardox 500, 600, 700
One hydraulically driven vertical discharge flap
Emergency opening by using a manual valve in case of power failure
Safety system for cleaning the mixer – door can’t be opened during
operation of the mixer
• AIR BAG venting system
• Mixing unit with polyurethane blades and scrapers
ADDITIONAL OPTIONS
•
•
•
•
•
T he system of washing nozzles with water dosing
HYDRO-MIX moisture content measuring probe
Additional hydraulically driven discharge flap
Hydraulically or pneumatically driven horizontal discharge flap
Sight glass
MIXERS
ADVANTAGES
•
•
•
•
•
•
Short mixing cycle due to the washing system with water dosing
Accurate mixing of concrete due to optimum number of mixing blades
Compact design, reliable drives manufactured by the SEW Company
Simple operation and easy maintenance
Low noise level
Integrated hydraulic system
jets
PLANETARY MIXERS - SPECIFICATIONS
MIXER TYPE
JEDN.
SPM-375
SPM-500
SPM-750
SPM-1125 SPM-1750 SPM-2250 SPM-3000 SPM-3750
Charging capacity
l/kg
375/600
500/820
750/1200
1125/1800
1750/2800
2250/3600
3000/4800
3750/6000
Output per cycle
m³
0,25
0,33
0,5
0,75
1,15
1,5
2
2,5
Minimum charge
kg
150
200
300
450
700
900
1200
1500
Weight of the mixer
kg
3100
3200
4100
4230
7350
7370
8900
13600
Driving power
kW
9,2
11
2x9,2
2x15
2x22
2x30
2x37
2x55
Number of discharge openings
pc.
1
1
1
1
1
1
1
1
Total height, including motor (A)
mm
2220
2220
2420
2420
2740
2740
2920
3275
Mixer height, including supports
(B)
mm
1325
1325
1520
1520
1690
1690
1720
1865
Mixer height with no supports,
with flange (C)
mm
920
920
1020
1020
1150
1150
1160
1335
Maximum total diameter (D)
mm
1940
1940
2200
2200
3000
3000
3220
3785
Mixer height (E)
mm
690
690
735
735
900
900
900
1030
Mixer inside diameter (F)
mm
1560
1560
1986
1986
2680
2680
2900
3455
37
Reduction motor
Main transmission
body
Main mixer I (planetary)
Main mixer II
(planetary)
Mixer
Corner scooper
Side scooper
Upper scooper
Rosette
Mixing blade
Rosette
Mixing blade
Upper scooper
Corner scooper
Shown drawings refer to the mixers SPM 1750, SPM 2250 and SPM 3000. Description of features for all models is specified in the chart below.
NUMBER OF PARTS
MIXER
SPM-375
SPM-500
SPM-750
SPM-1125
SPM-1750
SPM-2250
SPM-3000
SPM-3750
Number of rosettes
1
1
1
1
2
2
2
2
Number of mixer blades
2
2
2
2
4
4
4
6
Number of upper scoopers
-
-
1
1
2
2
2
2
Number of side scoopers
1
1
1
1
1
1
1
2
Number of corner scoopers
1
1
1
1
2
2
2
2
Concrete mixing plants
38
T
he wide range of TECHMATIK products also includes concrete mixing plants. Apart from
the systems designed for operation with machines producing vibrated concrete products,
the Company also offers concrete mixing plants for production of ready-mix concrete.
FIVE-CHAMBER Aggregate TANK
ELEMENTS OF CONCRETE MIXING PLANTS
Storage facility for raw materials
and additions, including:
• Multi-chamber aggregate tank,
five chambers 25 m³ each
• Cement silos, capacity 80 tons
• Proportioning device for feeding chemical additives
to the mixer
Transportation facilities for transporting
the weighed amount of raw material
to concrete-mixing plant, including:
FIVE-CHAMBER AGGREGATE TANK
• Aggregate weighing system
• Feeding belt conveyors
• Feeding screw
• Feeding belt conveyor which transports materials
into the plant
Concrete-mixing plant:
• Planetary mixer
• Cement weighing system
• Aggregate buffering tank with throttle valve
• Aggregate and cement dividers
CONCRETE-MIXING PLANT
Concrete receiving devices, including:
• Concrete discharge tanks
• Belt conveyors
• Wheeled transporters
TRANSPORTATION OF CONCRETE MIXERS TO CONSTRUCTION SITE
39
Line for automatic dispensing of
raw materials
40
ADVANTAGES OF THE SYSTEM
• batching accuracy (road safety)
• unobstructed loading (trailers do not get damaged by the loader)
• reduced costs associated with maintenance and operation of the loader
• control system ensuring continuity of production of aggregates and their loading
• operated by lorry driver
• safety during loading due to the signalling light system and the ultrasonic sensors
• a fully automated system for the production of aggregates
• a wide adaptive range
• may be used for dispensing different types of materials (aggregate, coal, etc.)
• reliable operation due to the use of electronic components supplied by reputable manufacturers
An example of an automatic raw material dispensing system with a crusher
Description of operation
•
•
•
•
The selected aggregate is transported from the crusher to the hopper (1) and moved further on conveyor belts (2)
and (3) onto the reversible conveyor (4) whose function is to dispense the aggregate into a suitable container (5).
Each of the four containers is provided with strain gauges, what enables controlling the weight of the dispensed
aggregate.
If the containers (5) are full, excess aggregate can be discharged onto a heap. When, during the loading of containers (5), there is not enough aggregate, the containers may be filled by the loader through the hopper (1) with the
aggregate accumulated in a heap. Such a system ensures continuity of line operation and vehicle loading.
When the reversible conveyor is in place above a given container and the filling begins, the signalling lights switch
on – red light informs about the lack of permission for parking the vehicle under the container. After filling the container, a green light indicates that a vehicle can be placed below the container. When the vehicle is parked under the
container, ultrasonic sensors signal the presence of the car, which highlights the green button on the control panel.
Pressing the button opens the container chute and the aggregate falls into the vehicle’s trailer.
Signal lights are positioned above the entrances; additionally, control boxes have been located in visible places
which make them readily accessible to the driver.
The standard Techmatik line for automatic dispensing of raw materials is equipped with:
(1) A hopper V = 8 m3; P = 0.25 kW; n = 2865 rpm (1 unit)
(2) A conveyor belt W = 1m; L = 14.6 m; P = 15 kW; n = 77 rpm (1 unit)
(3) A conveyor belt W = 1m; L = 15.9 m; P = 15 kW n = 77 rpm (1 unit)
(4) A reversible conveyor W = 1 m; L = 5.8 m; P = 0.37 kW; n = 7.3 rpm; P = 5.5 kW; n = 81 rpm (1 unit)
(5) An aggregate weighing container V = 22 m3; P = 0.25 kW; n = 2865 rpm (4 units)
41
Automatic screening plant for
raw materials
Operation description
1
2
1.The raw material – sand – is loaded into the special dosing unit (1), where it is on a tilting grate separated from
oversize contaminants. Then the raw material is dosed
with a belt conveyor to the conveyor (2).
2.The batch is transported to the screening machine (3) and loaded from the belt conveyor (2) to the hopper (9), where it
is initially sprayed with water and larger lumps of material are broken up.
2
3
9
42
3.The material is graded on a 3-deck screening assembly
(10) into homogeneous fractions determined by the
mesh size.
4.The vibrations and the inclinations of the screening machine cause the material to fall into specially designed
chambers (11) from which it goes to the appropriate storage places (7), (8) or to the conveyor belt (4), depending
on the grain size (2 - 4 mm, 4 – 12 mm or above 12 mm).
10
11
8
7
4
5.The smallest fraction (0 – 2 mm) is transported to the dewatering screw press (5) in which unwanted dust is washed out and the sand is dewatered and recovered.
6.The sand is transported on a conveyor belt (6) to the storage place (12).
12
6
5
The standard version of the automatic screening plant for raw materials consists of the following components:
(1) Special dosing unit; 5,75 kW; W=0,8 m; L=5,2 m
(2) Belt conveyor; 11 kW; W=0,65 m; L=24 m
(3) Screening machine; 30 kW
1
(4) Belt conveyor; 9.2 kW; W=0,65 m; L=15 m
(5) Dewatering screw press; 15 kW
(6) Belt conveyor; 13,2 kW; B=0,65 m; L=27 m
2
5
10
9
3
43
6
11
0 ÷ 2 mm
8
12
4
7
2 ÷ 4 mm
4 ÷ 12 mm
Advantages of the plant
over 12 mm
• Full automation of the screening process.
• Robust and durable design which at the same time ensures mobility. The plant can be easily moved from one site
to the other depending on the production needs.
• Low component wear due to abrasion resistant linings.
• Easy and practical screen change due to their modular design.
• High productivity ensured by the special concept of the double vibrating unit performing harmonic oscillations.
Moulds for production of concrete
paving blocks and decorative products
material quality is fundamental
Mould with heated tamper shoes
44
M
anufacture of moulds is focused on meeting individual requirements of our customers.
We also offer a full range of service jobs connected with mould repair and rework. We do
our best to manufacture moulds with the longest possible lifetime and ensure high-quality
of concrete products.
Moulds are produced on the basis of in-house quality standards. Through continuous improvement of manufacturing
processes our experienced and well-qualified team of designers and process engineers ensure top quality of our moulds
and high level of services related to mould servicing and maintenance. Implementation of new engineering solutions
is always preceded by tests carried out in specialised test centre, thus enabling to monitor the quality of moulds and
continuously improve the production process. We strive to recognise the needs and expectations of our customers on
a current basis and meet the increasing market requirements.
Mould with heated tamper shoes
The heated tamper shoes of the mould ensure a perfect antique finish of the
concrete products and help to gain a competitive edge on the market. The 3D-scanning technology allows to accurately capture all clients’ textures. The products have a surface which is almost indistinguishable from natural stone and
follow the current trends on the world market for pavers.
Production advantages with such moulds:
– closed surface of the final product
– less concrete build up on the shoe surface
– more precise reproduction of the shoes on the pavers
– possibility to increase the moisture amount in the concrete mix
TECHNICAL DETAILS
Maximum total power: 30 kW
Voltage: 400 V
Current consumption: max. 75 A
Temperature range: 20°C to 100°C.
MOULD PRODUCTION PROCESS
The quality of moulds depends not only on the manufacturing process itself, but also on the quality of material used for production. Quality control starts as early as
on the steel delivery stage. The quality of steel delivered
to our factory is examined by means of various methods
and tests, including ultrasonic examination of every steel
sheet used to manufacture moulds. Examination is made
by means of a dedicated cart with a transmitting/receiving
head and a flaw detector installed. The material is checked
for discontinuities such as delaminations, lappings, cracks
and chip weldings, the presence of gas bubbles and non-
ULTRASONIC EXAMINATION OF STEEL BY MEANS OF DEFECTOSCOPE
metallic intrusions. During the mould production process all welded joints are examined by means of ultrasonic
methods. The quality of joints is specified in the PN-EN
25817:1997 standard. Welded joints are examined for occurrence of flaws such as cracks, incomplete fusion, pinholes and gas bubbles. Ultrasonic examinations are also
performed during repair and rework jobs for moulds and
other devices. We buy steel exclusively from reliable suppliers who guarantee the premium quality of material.
MOULD DIES ARE CUT OUT BY MEANS OF THE MOST MODERN GAS
CUTTING MACHINES PRODUCED BY THE MESSER COMPANY;
THE MACHINES GUARANTEE THE BEST ACCURACY ALREADY ON
THE MOULD DIE CUT-OUT STAGE
Die cavities and stamp plates are machined on high class,
three- and five-axis CNC machining centres constructed by
machine tool manufacturers like FPT, Mori Seiki, and Hartford. The machines ensure a very precise machining process and, what is the most important for the quality of concrete products, high accuracy and repeatability of mould
cavity dimensions. Cavity wall surface is treated to facilitate
releasing of vibrated concrete and ensure reliable operation of the mould. Stamp plates are made with circumferential clearance of about 0.3 ÷ 0.4 mm for low moulds and
0.5 ÷ 0.6 mm for the high ones. Such small clearance guarantees top quality of concrete product and extends mould
lifetime.
45
MACHINING OF MOULD DIE ON THE FPT DINO FIVE-AXIS MILLING
MACHINE
FINISHING OF STAMP PLATES IS ALSO CARRIED OUT ON CNC
MACHINING CENTRES
MEASUREMENTS OF DIE CAVITIES ARE PERFORMED BY MEANS OF
WENZEL COORDINATE MEASURING MACHINE WITH A FUNCTION OF
AUTOMATIC DATA TRANSFER TO THE CNC CENTRE WHICH PERFORMS
MACHINING OF MOULD STAMP PLATES
The innovative DYNA HARD thermo-chemical treatment
process ensures long life of moulds. Depending on the
type of mould and its parts various thermo-chemical processes are carried out including carbonising, hardening
and nitriding processes. In case of moulds used for the production of high products the DYNA HARD PLUS thermochemical treatment process ensures hardness of the shaping part of the mould on the level of minimum 68 HRC,
whereas for low-height moulds, used to manufacture concrete paving blocks, the shaping part receives the hardness
of minimum 64 HRC. Therefore the DYNA HARD process
ensures high abrasion resistance and, consequently, long
lifetime of moulds. Moreover, a uniform distribution of
hardness in the 1.4 mm thick heat-treated layer is ensured.
Surface hardening by using DYNA HARD method is performed during the fully automatic and insulated thermochemical treatment process in furnaces with integrated
quenching tanks. Thanks to a suitable arrangement of dies
and stamp plates and proper temperature distribution
in furnace chambers guarantee proper quality of treated
mould part elements. Thus the lifetime of moulds can be
significantly extended and the customer gains significant
benefits by reducing production costs.
MOULD HARDENING PROCESS
46
AUTOMATIC WELDING OF MOULD ELEMENTS
Welding is one of the most important processes during
mould production. For welding of mould elements we
employ industrial robots which guarantee the highest
quality and strength of welded joints and repeatability
of welding operations. The robots are employed for joining of dies with housings and welding of stamp elements.
Specially designed, robust structure of stamp combined
with strong, high-quality welded joints is able to withstand high loads that occur in concrete block machines.
Upon completion of manufacturing and assembly processes, the mould is directed to the Quality Control Department, where all dimensions of the die and stamp are
checked, along with the flatness of mould top and bottom surfaces as well as aesthetic appearance of the entire
mould.
Mould dimensions are checked by using traditional
measuring instruments and the FARO portable measuring instrument. This device is equipped with a scanner
that allows measuring even complicated, irregular surfaces. The instrument arm is able to accurately scan the
shape of the finished concrete product and its plane.
Based on the measurement results, we are able to design
and manufacture any type of mould.
EXAMPLES OF PRODUCTS
“GRANITO LUX” PAVEMENT
“RING” PALISADE
KERB
47
Heat treatment
process repeatability means guaranteed quality
48
T
he heat treatment department was organised together with machining and production departments, in order to complete the entire manufacturing process for moulds and production
machines for concrete decorative products. Investments in modern, state-of-the-art equipment
and machinery were the prerequisite for manufacture of high-performance machines and plants.
Correct heat treatment ensures long life of our machines and moulds for production of concrete
paving blocks and decorative products.
The quality of our services is also appreciated by other companies. TECHMATIK co-operates with many
companies in Poland and abroad. Among our regular customers there are BOMBARDIER AEROSPACE, ABB,
IVA, ALSTOM, COLUMBIA MACHINE Inc. , HELLER, NORMET , TECAUMA, SHAPERS, ITM, FABRYKA ŁOŻYSK
TOCZNYCH - Kraśnik, BEFARED , BRUKPOL , PMP Poland , BRAT-MET , etc.
SERVICES
Our Company offers the following services from the heat treatment sector:
ITEMS
PROCESS
FURNACE TYPE
DIMENSIONS OF FURNACE HEATING
CHAMBER
[length x width x height]
MAXIMUM WEIGHT OF
TREATED ELEMENT
1.
Hardening
AFS-34
2250 x 1400 x 1000 mm
900 kg
2.
Normalising
AFS-34
2250 x 1400 x 1000 mm
1200 kg
3.
Carbonisation
AFS-34
2250 x 1400 x 1000 mm
1200 kg
4.
Cyanide hardening
AFS-34
2250 x 1400 x 1000 mm
900 kg
5.
Annealing
BREAW-34
2250 x 1400 x 1000 mm
1500 kg
6.
Nitriding
RM24/12/10/RVE
2250 x 1400 x 1000 mm
1500 kg
HARDENING SHOP EQUIPMENT
The heat treatment processes are carried out in chamber furnaces with endothermic atmosphere with adjustable carbon
potential; the furnaces are rated among the most modern
pieces of equipment in our region of Europe. We also run
heat treatment processes in the nitriding furnaces vacuum
atmosphere. Processes like hardening, carbonisation, cyanide
hardening and annealing are carried out in the process line
based on chamber furnaces with built-in SEALED QUENCH
quenching tank type CASE MASTER AFS-34. The line also includes auxiliary devices such as washing machine, furnace
for high-temperature tempering, endothermic atmosphere
generators and loading/unloading tables.
The hardening shop is also equipped with the process line
for ammonia nitriding, consisting of the furnace for ammonia
nitriding with vacuum evacuation and the washing machine
for cleaning the parts prior to the process.
HARDENING FURNACES AND LOADING/UNLOADING TABLE
The effects of heat treatment are evaluated in metallographic
laboratory where, using equipment such as devices for preparing the metallographic specimens, micro-hardness tester
and metallographic microscope, it is possible to evaluate the
structure and thickness of layers after thermo-chemical treatment and hardness distribution. The results of measurements
for individual processes are filed, and specimens with numbers of production orders are stored for one year.
The heat treatment process is controlled by a computer with
suitable software installed. Due to the endothermic atmosphere and appropriate control of the process we can guarantee the best quality of parts undergoing heat treatment,
a very good repeatability of processes, minimization of deformations during the hardening process and the absence
of soft skins and oxidized areas.
NITRIDING FURNACE AND WASHING MACHINE
CONTACT
Ireneusz Kowalski
Manager, Heat Treatment Department
mobile phone / fax e-mail
+48 668 122 208
+48 48 369 08 94
[email protected]
TECHMATIK SA
26-610 Radom
ul. Żółkiewskiego 131/133
Poland
ELEMENTS PREPARED FOR HEAT TREATMENT
49
Machining
unlimited potential
50
T
he machining department, being the core of the TECHMATIK company, offers a wide variety
of services carried out using modern metal working processes.
With its almost unlimited potential in metal working processes, the department carries out numerous
operations being an integral part of the mould production process and the concrete paving blocks machine building process. The department renders services and carries out subcontracted jobs for clients
from Poland and abroad.
SCOPE OF SERVICES
TURNING
MANUALLY CONTROLLED TURNING LATHES
MAXIMUM
TURNING
DIAMETER
(mm)
MAXIMUM
TURNING
LENGTH
(mm)
CENTRE
DISTANCE
(mm)
TUR 560
560
1000
1000
TUR 630
630
2000
2000
TUR 630
630
3000
3000
TR 135B3
1350
7600
6000
TYPE OF
MACHINE
TOOL
CNC TURNING LATHES
TYPE OF
MACHINE TOOL
MAXIMUM TURNING DIAMETER
(mm)
MAXIMUM TURNING LENGTH
(mm)
NL2500MC/1250
356
1298
TR 135B3 TURNING LATHE
MILLING
CNC MILLING MACHINES
TYPE OF
MACHINE
TOOL
TABLE DIMENSIONS
(mm)
AXES
(x,y,z)
MAXIMUM
LOADING
CAPACITY
(kg)
MAXIMUM
SPINDLE
SPEED
(rpm)
HB 3190
3100 x 1800
3000 x 1800 x 920
8000
6000
HB 4190
4000 x 1800
4000 x 1800 x 1200
8000
6000
HB 3150
3100 x 1500
3000 x 1500 x 920
8000
6000
NH 5000 DCG/40
500 x 500
730 x 730 x 850
500
14000
NV 5000 A1
1100 x 600
1020 x 520 x 520
1000
14 000
HCMC 18
2000 x 920
1800 x 920 x 700
3000
6000
FIVE - AXIS MILLING MACHINE, TYPE FPT DINO
SUMO 3100
3100 x 1000
3000 x 1000 x 700
3000
6000
TOS WHQN 13
2500 x 2500
3500 x 2500 x 1800
10 000
3000
FPT DINO
3000 x 1200
2800 x 2200 x 1000
8000
18 000
Zayer 200KF
2000 x 630
1741 x 804 x 862
1500
3500
Zayer 300KF
3000 x 1000
2500 x 1300 x 1200
2500
3500
MANUAL MILLING MACHINES
TABLE
DIMENSIONS
(mm)
AXES
(x, y ,z)
MAXIMUM
LOADING
CAPACITY
(kg)
MAXIMUM
SPINDLE
SPEED
(rpm)
TOS FGS 63
1800 x 630
1400 x 600 x 500
1000
3500
JAFO FWR 40
1400 x 400
1030 x 335 x 465
450
1800
TOS FREPD 4016
8500 x 1200
8000 x 1600 x 1500
10000
2500
TYPE OF
MACHINE TOOL
TOS WHQN 13 MILLING MACHINE
MORI SEIKI
51
5-axis machining centre with a pallet system with an integrated tilting rotary table of
the Japanese Mori Seiki company (type NMH10000DCG)
AXIS TRAVEL
X-axis travel
1 550 mm
Y-axis travel
1 600 mm
Z-axis travel
1 300 mm
TABLE
Pallet height from the floor surface
1 900 mm
Pallet working surface
1000 x 1000 mm
Pallet loading capacity
2 500 kg
Max. workpiece swing diameter
(1,000 for A-axis -95 O to + 120O)
MORI SEIKI MACHINING CENTER
φ 1 500 mm
Max. workpiece height
1 300 mm
SPINDLE
Max. spindle speed
10 000 rpm
Spindle power
30 kW
Spindle moment
600 Nm
AUTOMATIC PALLETE CHANGE (APC)
Number of pallets
2 pcs.
mori seiki machining center
GRINDING
CYLINDRICAL GRINDER
FLAT-SURFACE GRINDER
TYPE OF
MACHINE
PSGP
TABLE DIMENSIONS
(mm)
1500 x 2200
TYPE OF
MACHINE
RUP 280
MAXIMUM GRINDING LENGTH (mm)
MAXIMUM OUTER
DIAMETER (mm)
MAXIMUM INNER
DIAMETER (mm)
1000
280
200
segmental wheel GRINDER
TYPE OF
MACHINE
Table
diameter
(mm)
Magnetic
Table
diameter
(mm)
segmental
Wheel
diameter
(mm)
Lumsden 97ML
3048
3048
1625
segmental wheel grinder
THERMAL CUTTING
PLASMA AND GAS CUTTING MACHINES
TABLE
DIMENSIONS
(mm)
MAXIMUM WORKPIECE THICKNESS
(mm)
Kjellberg
(plasma)
3000 x 6000
50
Messer
(cutting in water)
3000 x 6000
240
RUR 3000
3000 x 6000
240
TYPE OF MACHINE
MESSER GAS CUTTING MACHINES
LASER CUTTING MACHINES
52
TYPE OF
MACHINE
TABLE DIMENSIONS
(mm)
MAXIMUM WORKPIECE THICKNESS
(mm)
LASER
POWER
(kW)
BYSTAR 3015
3000 x 1500
25
4,4 kW
BYSTAR L 4025
6000 x 2500
25
6,0 kW
LASER CUTTING MACHINE TYPE BYSTAR L 4025
bending of tubes and profiles
CAPACITY CHARTS
PROFIL TYPE
SIZE
(mm)
MIN.0
(mm)
100 x 20
30 x 10
TYPE OF
MACHINE
SIZE
(mm)
MIN.0
(mm)
1000
400
100x100x10
40x40x4
1000
550
160 x 35
80 x 5
800
400
100 x 11
30 x 4
1000
400
60 x 60
15 x 15
750
400
90 x 10
30 x 4
1000
400
0 75
0 75
800
450
100 x 11
30 x 4
1000
400
0 125 x 25
0 15 x 1
1400
450
UPN 160
UPN 30
800
400
0 4¨ x 6,02
0 ½¨ x 2,77
1000
450
UPN 160
UPN 30
800
400
100 x 40 x 4
25x15x2
1300
450
IPN 180
IPN 30
900
400
80 x 5
25 x 2
1500
450
HEB 100
1200
100 x 100 x 12
25 x 15 x 2
1000
700
PROFIL TYPE
HPK 100
bender HPK 100
shaft
Diameter
(mm)
rolls
Diameter
(mm)
speed
Working
(m/min)
100
315
7
Wire EDM Machines
TABLE FEED
RANGE
(mm)
CUTTING
HEIGHT
(mm)
ROBOCUT a-1ic (5-axis)
550 x 370
410
ROBOCUT a-1id (5-axis)
600 x 400
310
TYPE OF MACHINE
SHOT PEENING
• Volume 336.67 m3
• Length 11.7 m
• Width 5.75 m
• Height 5 m
• Purity class Sa 3
PAINTING
• Painting shop designed for water-soluble paints
• Length 11 m
• Width 5.5 m
• Height 5 m
TOOL SHARPENING
• Sharpening machine type NUA-25(HB) with digital
reader and CNC controller.
NUA-25(HB) SHARPENING MACHINE
53
For our customers we carry out manufacturing services
based on the expertise and experience of our team of professional engineers who improve process and design solutions on a current basis, using the Mastercam, Inventor, and
Ti-Flex software and the system for monitoring each stage of
the production process.
We cooperate with Polish and foreign customers such as
BOMBARDIER, HELLER, Kamet, Polmotors, Dermat, Polbruk,
Romasz, and Popielski companies.
Our solutions are tailored to individual customer requirements and needs and we do our best to offer top quality,
complex services.
ELEMENT MANUFACTURED FOR THE BOMBARDIER COMPANY
CONTACT
Sławomir Podsiadło
Jarosław Wróblewski
mobile +48 668 122 016
phone +48 48 369 08 91
fax
+48 48 369 08 09
[email protected]
mobile +48 512 028 031
[email protected]
Director, Machining Department
TECHMATIK SA
26-610 Radom
POLAND
Project Manager/Sales Specialist
Mariusz Dynarek
Sales Specialist, Machining Department
mobile +48 668 122 205
[email protected]
Quality control
ultimate precision
54
A
mong other areas, our company specialises in up-to-date methods of metal working. The experience we gain from co-operation with domestic and international enterprises is focused
on the precision and machine-building industry. Therefore, it is a must for us to make accurate
control measurements that help to determine if our products are of high quality.
Our measuring office uses state-of-the-art, precise measuring machines and instruments and the personnel has suitable qualifications and certificates of competence. From the beginnings of our company
we have been guided by the principle of client partnership focused on meeting customer requirements
and expectations in every aspect.
SERVICES
• Three-dimensional geometrical measurements made by means of the WENZEL coordinate measuring machine and
portable measuring arm type FARO (measurements of shape deviations, position, distance, diameter, roundness, parallelism, squareness, concentricity, angle etc.);
• Two-dimensional measurements made by means of high-accuracy measuring column (height meter) type TESA – the
device that measures in one or two axes; we use it to measure length, height, depth, steps and spacings on geometrical
elements with flat/parallel and cylindrical round surfaces and diameters of holes and shafts;
• Use of FARO laser scanner for creating a body model of physically existing product or structure (used for designing) and
comparing the real product against design model;
• Non-destructive testing of welded joints in steel structures and sheets:
- Visual tests (VT) carried out according to the PN-EN 970 standard; quality levels as per the PN-EN ISO 5817 standard;
- Ultrasonic tests (UT) for welded joint and sheets with a minimum thickness of 6 mm, carried out by means of the
KRAUTKRAMER flaw detector – detecting of internal flaws with the size above 0.01 mm, including surface and subsurface flaws (cracks, delaminations, material discontinuities etc.); the instrument is also able to measure thickness,
first of all for structures strongly exposed to corrosion, where conventional method measurements are not possible
(pipelines, tanks, silos etc.); examinations are carried out in compliance with the PN-EN 1712 and PN-EN10160 standards; quality levels as per the PN-EN ISO 5817 standard.
Our employees hold international metrological certificates and VT2 and UT2 licenses, issued by the Polish Institute of
Welding.
MEASURING RANGES AND ACCURACY LEVELS OF OUR INSTRUMENTS
WENZEL three-dimensional Coordinate Measuring Machine
• Measuring range:
- X-axis – 1200 mm
- Y-axis – 3000 mm
- Z-axis – 900 mm
• Accuracy of 0.0027 mm at full measuring range.
MEASUREMENT MADE BY MEANS OF WENZEL 3D MACHINE
55
FARO measuring arm
• Measuring range – 2400 mm
• Measurement accuracy – 0.02 mm at full measuring range
• Possible measurements of large-size products through transfer of co-ordinate system
FARO MEASURING ARM DURING MEASUREMENTS
56
TESA Micro Hite measuring column
KRAUTKRAMER ultrasonic flaw detector
• Measuring range – 600 mm
• Measuring range – no limitations
• M
easurement accuracy – 0.002 mm
at full measuring range
• Requirements for the element to be measured:
- Steel sheets with a minimum thickness of 6 mm
- Butt welds
• Measurement accuracy – detection of flaws with the size
not less than 0.01mm
TESA MICRO HITE MEASURING COLUMN
CONTACT
Marek Kabacik
Manager, Quality Control Department
phone +48 48 369 09 56
[email protected]
TECHMATIK SA
26-610 Radom
POLAND
MEASUREMENT MADE BY MEANS OF KRAUTKRAMER ULTRASONIC
flAW DETECTOR
Contacts
Anytime our professional consultants are ready to explain details of our offer, help you to select solutions tailored to your
needs and assist you in all business formalities. We are looking forward to cooperating with you.
CONTACT
sales Department
hotline +48 48 369 08 08
fax
+48 48 369 08 09
OFFICE
phone +48 48 369 08 00
fax
+48 48 369 08 01
[email protected]
ADDRESS
international SALES DEPARTMENT
Marcin Nowakowski
Manager, International Sales Department
mobile +48 608 422 300
phone +48 48 369 08 11
[email protected]
Andrzej Brzęczkowski
Contract Manager
mobile +48 512 028 027
phone +48 48 369 08 13
[email protected]
TECHMATIK SA
26-610 Radom
POLAND
Karol Jasiński
GPS
mobile +48 608 422 100
phone +48 48 369 08 08
[email protected]
N 51° 24.926’
E 21° 11.935’
VAT CODE: PL7962622903
www.techmatik.pl
DOMESTIC SALES DEPARTMENT
Paweł Kopyt
International Sales Manager - Eastern Europe and Asia
Mikołaj Pawlak
International Sales Manager - Western and Northern
Europe
mobile +48 608 422 700
phone +48 48 369 08 13
[email protected]
Marcin Ziębakowski
Manager, Domestic Sales Department
International Sales Specialist
mobile +48 608 422 600
phone +48 48 369 08 12
[email protected]
mobile +48 668 122 206
phone +48 48 369 08 08
[email protected]
Małgorzata Kwiecień
Ewa Jasińska
Domestic Sales Specialist
mobile +48 608 422 500
phone +48 48 369 08 12
[email protected]
International Sales Specialist
mobile +48 512 028 028
phone +48 48 369 08 08
[email protected]
7
Anna Szczepanowska
Domestic Sales Specialist
mobile +48 608 422 200
phone +48 48 369 08 12
[email protected]
12
12
7
9
57

PRODUCTS CATALOGUE - Columbia Machines

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