Machinery Function Features
LEVIBRETON KFG 4600:THE TRENDSETTING IN MARBLE POLISHING
The Levibreton KFG 4600 polishing lines for marble are the soundest investment for companies requiring extreme productivity, top quality and operational simplicity, while maintaining budget-friendly operating and maintenance costs. Breton was the first company to develop machines for the continuous polishing of marble slabs, effecting a radical change in the sector. Today, thanks to its unrivalled years of experience,emerging concepts in automation, and digital/PC integration, increased and experience based qualitysimple maintenance procedures and low operating costs continue to be our high standard of value we achieve for our customers. This standard is expertly applied to our latest version Levibreton KFG 4600.
Levibreton KFG is a worldwide success with customer satisfaction unparalled in the contemporary market.
High Resale Value: thanks to their inherent quality, their ability to remain high-performance machines during all their service life and the readily available spare parts guaranteed by Breton, Levibreton KFG are much appealing to the second hand market and maintain a very high resale value even after several years (a fact not to be ignored when the purchase of a new polishing machine is considered).
This factor markedly improves the dynamic assett value of our client’s business.
Honing-polishing units
Made of anodized aluminium alloy,the spindles are specially designed for weight reduction and increased rigidity. The raising-lowering system is perfectly balanced
thanks to a pair of pistons with protected internal rods. The plates rise and lower in a flash, with a optimal contact with the slab surface, therefore slab edges are perfectly polished and the operating speed is maximized.Each head is equipped with a pressure regulator displaying the operating pressure on an analogue display, for simple monitoring and setting according to the optimal parameters for the material at hand.
Special Breton plates
For high efficiency, each spindle is equipped with a specifically engineered, Breton abrasive holding plate with a diameter of 550 mm and holding 9 abrasives,which ensures an extremely high removal capacity and work stability for a perfect and uniform polishing even up to the edges of the material. The special Breton plates are provided with an exclusive one-way shock-absorbing system ensuring the correct flexibility and a homogeneous and optimal working pressure. The results are an unequalled polishing quality as well as a lower consumption of abrasives.
Beam
The arc-welded steel beam has an ideal design with a box-type section in order to reduce weight and provide high stiffness. Interestingly, the beam is not drilled (and therefore weakened) to insert the honing units, which are fixed to the beam and contribute to increase its flexural strength. The spindle/beam assembly is thus extremely light and dynamic and enables fast acceleration/deceleration ramps.
Beam Drive
The beam is actuated by two rack and pinion systems driven by two gearmotors, which are fixed at each end of the beam and are mechanically synchronized. The gearmotors are driven by two brushlesstype motors controlled by special drives, which, besides enabling a sine movement of the beam, make it possible to keep the number of the beam strokes constant even when the slab width changes; this ensures a better polish quality and uniformity on the whole surface of the slab, edges included.
This system is extremely reliable and results proven, guaranteeing highly dynamic movements without stressing the mechanical components resulting in maximum uptime and maximum lifecycle. The beam working speed reaches 70 m/min. Furthermore, energy saving ensues from “energy recovery” drives that transfer to the electrical grid the energy generated by the braking when the beam motion slows down.
LEVIBRETON KFG 4600:
CLOSE TO PERFECTION
Levibreton KFG 4600 was designed on the basis of the extensive experience acquired on more than 1.300 “Levibreton” polishing machines sold throughout the world, using the latest design techniques.
Quality Function Deployment - QFD
The new Levibreton KFG 4600 originated from the Customers’ needs, from what the Customer really expects from the ideal machine.
Finite Element Method - FEM
All the critical components of the machine have been checked out using the Finite Element Method (FEM).
Failure Mode & Effect Analysis - FMEA
Particular care was given to the early detection of all the potential defects/critical points which may occur during the service life of the machine, identifying and implementing the appropriate corrective actions.
Support structure
The support structure is a distortion-proof,arc-welded steel monobloc provided with 12 sturdy supporting legs.The conveyor belt slides upon a thick steel top, which is milled all in one go to ensure perfect flatness, and is driven by a brushless type motor that guarantees a better control of the feed speed.
Beam sliding bridges
The beam ends are fixed to two shoulders sliding along sturdy, cast-iron bridges, which house hardened, ground and thick slideways with large diameter roller runners in an oil bath, and a micro pinion. The sliding components are protected by stainless steel labyrinth guards.
Slab profile and thickness detection
A photoelectric barrier reader detects the slab profile with 10x10 mm resolution while a sonar reader senses its thickness. This system allows to process even slabs with a polished surface (such as already polished or resin-treated slabs).The system controlling the automatic head liftinglowering,ensures the self-adjustment of the beam travel to the slab width and guarantees that the front,anti-splash and sound-deadening barriers are positioned automatically to match the slab thickness.
Water plant
Water is supplied to the heads by a common,large-diameter PVC piping that is stiffly fixed behind the spindles and connected to the spindle units by means of flexible, rubber pipes.An revolutionary system diverts water outside the spindle casing in the event of overflowing or clogging of the ducts, thus preventing excess water from coming into contact with the spindle internal components.
Automatic control of abrasives wear
This system performs continuous monitoring of the abrasive wear of each single head through video advice notes and warning signals before tools are completely worn out.
It also guarantees the minimal lifting of the heads at the forepart and rear end of the slab and their subsequent rapid descent, thus ensuring a better polishing of the edges and a higher operating speed.
Electric and electronic plant
The electric and electronic plant is wired with the “field-bus” technique that transmits digitally, through a single cable, all the PC signals to the different control units installed on the machine.Signal transmission is safe and identification of possible failures is greatly simplified.The stationary part of the machine is electrically connected to the mobile beam by a parallel sheathing system ensuring safer working conditions and a longer cable life.All the electric and electronic equipment, including the PC, is supplied by world top-brands, therefore the user can freely get technical assistance and spare parts directly from the manufacturer, virtually throughout the world.
Automatic centralized lubrication system
A centralized system, mainly consisting of a grease reservoir, a pump with double micrometer filtration system, sequential distributors and pipes for high-pressure, guarantees the automatic lubrication of either the spindle
units or the other moving parts of the machine. The system is warned about possible malfunctions by pressure sensors that easily pinpoint where the circuit is clogged.
Slab cleaning
A rubber wiper fixed at the back of the machine removes water from the slab surface.
A pneumatically controlled spindle, integral with the beam and holding a brush, cleans the slabs once they are polished. The spindle is raised and lowered automatically each time a slab passes through.
Accident-prevention,sound-deadening guards
A pressure regulator is installed on each single spindle in a high, ergonomic and safe position. Pressure is displayed on an analogue pressure gauge (upon request, manual selectors for lifting/lowering each single head can be supplied). The frontal, sliding panels for accident-prevention and sound-deadening have a sandwich-like structure and are made of ABS and polyurethane. Sound-deadening splash guards with a stainless steel sandwich-type structure are installed on the beam, in front of the heads, on the same level of the heads. Their positioning is motorized, vertical and automatic in order to match the slab thickness and they lift each time the abrasives need to be replaced.
Management and programming
The colour touch-screen and advanced, user-friendly software enable the main processing functions to be managed, including:
• option to store (and recall) different work programs for various types of material
• conveyor speed and synchronism of the whole line, including loaders and connection roller conveyors
• beam movement (speed, customized programming of the acceleration and deceleration
ramps)
• back-slipping correction on the anti-skid conveyor of badly-sawn or bent slabs, for both single slabs and packs of slabs
• continuous, automatic monitoring of the abrasive wear for each single head, with video advice notes and warning signals before the tool is completely worn out
• option of excluding all, some, or just one slab, or even a portion of a slab (head, end, corner).
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