Over two years ago this magazine published a survey on multi-wire machines, and the article was well received by our readers. Being a new, evolving technology, during this period the different manufacturers have brought out new, improved models of this machinery, and we have found it appropriate to publish an updated version of the survey. The questions were sent to the different companies and we publish here the replies of those who answered them.
1.- Is your machine supported on 2 or 4 columns?
2.- Describe briefly the tension system of the wire of your machine. Specify whether it is individual or collective, whether it is hydraulic, mechanical, or pneumatic?
3.- How is the deterioration and the performance of the wire controlled?
4.- How many wires are mounted on your machine, and why?
5.- What is the average monthly production of the machine?
6.- As objective data, what is the average consumption in m2/ ml? In Euros/ml?
7.- What characteristics allow your machines to obtain these consumption levels, and what others characteristics would like to highlight?
1.- The machine is supported on 2 columns.
2.- Tension system of the wire: hydraulic and individual.
3.- Laser system broken wire.
4.- 70 Wires Machine – Gold 2000/6/V/70, 2 meters wide to make possible the cutting of any granite block. We also produce Multiwire machines 1000mm wide (they cut ½ block 2 meters wide) and Multiwire Machines 800 mm wide (they cut ½ block 160 cm wide- the common production in Galicia)
5.- Production: 0.8 to 1 m2 for one hour work, around 25000 m2 per month with a 70 Wires Machine
6.- Consumption: All the Wire Manufacturers indicate that the average consumption, depending on the hardness of the material is 7 to 11 m2 around.
7.- Other characteristics:
• Independent tension wire
• Removable Profiles
• Aligned wires, without deviation
1.- The machine is supported on 2 columns
2.- Individual tensioning. Patented gas tensioning, which offers more elasticity and increases the wire life.
3.- Every cut is monitored, hours and square meters calculated for each wires.
4.- We offer the following models: 11, 25, 35, 55 and 65 wires. All of our machine can cut variable thicknesses. The biggest machine can cut 1,85m in width and produce 64 slabs of 2cm.
5.- Production: from 7000 to 10000 square meters per month depending on the material. Based on one 8 hour shift.
6.- The consumption of the diamond wire varies greatly based on the material that is being cut.
7.- Thanks to the flexible patented gas tensioning system and the fact that the wires goes around only 4 wheels, increases greatly the life of the diamond wire.
• The machine is equipped with all the latest technology that actively monitors the cutting, tensioning, bearing temperatures, production and much more.
1.- Our machine is supported on 2 columns.
2.- Our solution is a double hydraulic tensioning system, we make first a collective tensioning of all pulleys by 2 big cylinders placed on the sides of the structure housing the pulleys, then we make the individual adjustment of each one (pulley by pulley).
4.- We produce a wide range of machines: 24 , 34, 40, 52 , 68 – 70 ( N° of wires)
5.- The monthly production of our largest machine is around 25.000 m2
6.- Average consumption: Up to 12 m2/ml
7.- Other characteristics:
• Reduced number of idle pulleys and bearings
• Bearings completely sealed and with permanent grease (no need lubrication system)
• Simplest machine geometry
• Frame structure to support the axes and the stress of tensioning
• All rubbers are interchangeable • Bus technology
• User friendly touch screen interface
1.- Currently 2 models of machines are manufactured: a model NDF-6035 up to 35 wires which is supported on 2 columns, and another model NDF-6068 up to 68 wires the structure of which is supported on 4 columns.
2.- The 2 machines models have double tension system for the wires, a primary tension acts at same time on the whole pulley systems for pre-tension of the wires, activated by a couple of spindles and electric motor-reducers. Once the wires are compensated and pre-tensioned, they adjust with the second set of hydraulic tension that acts individually over each tensioning pulley, assuring in an independent manner that each one of the wires has the same tension compensating the differences in length that exist between the totality of the wires that are installed in the machine.
3.- The machine has a control system which allows to control in real time the cutting parameters, which is the working tension and the individual arrow of each one of the wires, and therefore the machine is capable of adapting and correcting the parameters of cutting in function of the behavior of each wire, in this way the performance of the machine is optimized.
4.- The machine NDF-6035 can cut with maximum of 35 wires and the big model NDF-6068 up to 68, which means there is possibility of cutting a commercial block of granite of 2 cm thickness, in one sawing in machine of 68 wires and in 2 sawings of half size blocks of 35 wires.
5.- The machine of 35 wires obtains monthly production of between 8000-10000 m2. The machine of 65 wires obtains average monthly production of 16000-20000 m2.
6.- The average performance of wire in our machines has approximate ratio of 8 m2/ml. The average cost of diamond wire is around 32 euro/ml.
7.- Other characteristics:
Our machines are characterized mainly for having low maintenance costs, low rates of breakdowns, and therefore few stopages owing to these reasons. One can highlight, moreover, the excellent finishing and plain surfaces in cutting, as well as perfect homogeneity in the thickness of the slabs. The managing and programming of the machines is very simple and easy, all these make it one of the most productive and profitable machines in the market.
1.- The structure of the multiwire Pedrini Jupiter GS200-72 is composed of two columns strongly fixed to foundations and one connecting "Arco" structure, that have been built with wide closed section in large thickness normalized steelwork. All the structural parts have undergone structural checks in accordance with FEM (Finite Elements Methods).
2.- The individual tensioning action of the wires is powered through one oleo-dynamic pump. The system performs the displacement necessary for diamond wires replacement, for slabs thickness change, holds programmed tension equal on each wire and balance wire elongation during the cut.
3.- The tensioning pulley of each wire is constantly controlled. The machine is able to check the eventual excessive stretching of each wire. The down-feed, the cutting speed and the power consumption are displayed on the monitor.
4.- 72 wires can be installed on the machine, to produce slabs with thickness 2 cm, for a total coverage of 2 m. The machine is flexible: it can produce any thickness by appropriately placing the wires into the grooves guide.
5.- Production: - 2 cm granite slabs: 15000 m2/month. - 3 cm granite slabs: 11000 m2/month. The production of the machine depends on the type and hardness of the material.
6.- Wire yield m2/m: It depends on the kind of granite, on the 6,3 or 7,3 diameter of the wire. The range in normal conditions is 7÷12 m2/m.
7.- Other characteristics:
• It is precise: it represents the perfect synthesis between structural rigidity, dynamic balancing and accuracy in displacing and sliding.
• It's a hi -tech machine: it has recourse to exclusive and advanced patents which make it unique in its line.
• It's reliable: it proposes simple technical solutions, without using delicate or risky mechanical elements.
• It's functional: it is designed and manufactured to optimize the yield of diamond wires.
• 1t's versatile and suitable for all production requirements: it is available in the models with 8 to 72 wires, for 6,3 mm and 7,3 mm wires. • It's flexible: it allows the simultaneous cutting of slabs with different thickness; from 2-10 cm.
• It's rational: thanks to a "user-friendly" interfaces it facilitates the operators to manage the diamond tool and the machine as well.