of the rollers on top of each other for each press of the rollers. A self-supporting rack enables the avoidance of misalignment

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Beverly Wilcox
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Products for levelling and shaping band saws, guide rails, circular saws and circular knives MR 0 The MR 0 is conducive to the levelling of saw bands and guide rails.

It distinguishes itself from others by the following properties: Its special structure provides for the exact positioning of the rollers on top of each other for each press of the rollers.

MR 3 MR 4 The MR 3 is conducive to the levelling of circular knives and circular saws. It can be integrated into automated process cycles.

1 Products for levelling and shaping band saws, guide rails, circular saws and circular knives MR 0 The MR 0 is conducive to the levelling of saw bands and guide rails. With the addition of an auxiliary part, it can also be used for rolling small saw blades. It distinguishes itself from others by the following properties: Its special structure provides for the exact positioning of the rollers on top of each other for each press of the rollers. A self-supporting rack enables the avoidance of misalignment of the rollers. The roller pressure is generated via an adjustable pneumatic cylinder. MR 3 MR 4 The MR 3 is conducive to the levelling of circular knives and circular saws. It can be integrated into automated process cycles. It distinguishes itself from others by the following properties: Its special structure provides for the exact positioning of the rollers on top of each other for each press of the rollers. The controlled roller pressure enables constant in-feed regardless of the material. An integrated control concept enables precise and reproducible roller-groove depths. The blade in-feed via power motor renders end stops unnecessary. The top-quality materials used in constructing the rollers enable a long service life. The straight rolling machine MR 3 is geared to a material-handling system or to a robot. TEST PLATFORMS The test platforms MR 4 - Types 1 to 5 are conducive to the verification of the results of rolling and levelling work performed on saw blades and circular knives. Five different types comprise the most commonly used design forms in practical application. Shorter processing and testing intervals Extensions with a motorised actuator, vibration-gauging equipment ort he setup of a unit for testing the blade thickness and conicity as well as generally documenting the gauged data are available.

MR 0 for saw bands, narrow guide rails or smaller saw blades With the rolling and levelling machine MR 0, saw bands or narrow guide rails can be shaped straight in order to level them in a targeted

2 MR 0 for saw bands, narrow guide rails or smaller saw blades With the rolling and levelling machine MR 0, saw bands or narrow guide rails can be shaped straight in order to level them in a targeted fashion. With the addition of an auxiliary part, it can also be used for rolling smaller saw blades. The design principle warrants that the rollers are positioned exactly on top of each other with each press of the rollers which guarantees the reproducibility of the rolling results. In addition, custom-made guide mechanisms were used in a self-supporting rack to avoid misalignment of the rollers and attain exact reproducibility of the roller groove. The levelling process is then rendered more precisely and begins even after the first millimeters. The roller pressure is generated via an adjustable pneumatic cylinder. All relevant adjustment sizes can be recorded on the work documentation. This reduces rigging intervals, and rolling attempts can be omitted. Without auxiliary fixtures, the machine can also be used as a transport or feed module. A series of different bottom panels with channels and linear modules makes the die MR 0 suitable for the straight rolling of saw bands or guide rails, as well as for the straight rolling of saw blades. In both versions, the midpoints of the middle of the roller are always positioned at the middle of the channel. METHOD OF OPERATION Rigging work can be performed without roller in-feed, since the pneumatic cylinder functions independently, without the electrical system being switched on. The pressure is variably adjustable and can be read on the indicator. With the electrical system switched on, the rollers are not moved until the pneumatic cylinder attains the desired pressure level. The roller RPM rate is continuously adjustable.

(new) Available roller radii Roller stroke table-top device depth 500 mm, width 450 mm, height 510 mm 106 kg (without auxiliary devices) 1 10 bar / 1.

3 MR 0 for saw bands, narrow guide rails or smaller saw blades Technical Data setup approx. dimensions weight connection values (pneumatic cylinder) electrical system Gear motor, continuously adjustable Gear motor output (input speed) Band speed Roller diameter (new) Available roller radii Roller stroke table-top device depth 500 mm, width 450 mm, height 510 mm 106 kg (without auxiliary devices) 1 10 bar / kp at 10 bar three-phase alternating current, 400 V (AC) 3N 50 Hz or 100 Hz 0.37 KW / max. 1,360 RPM or 2,720 RPM max. 91 RPM or 182 RPM max. 21 m/min or 42 m/min 75 mm 2 mm to 500 mm (to be specified by customer) variable Subject to design changes. We reserve all rights to the MR 0.

4 MR 3 The straight roller MR 3 is conducive to the levelling of circular knives and circular saws. To ensure the precision of the results of levelling work, it is essential that the rollers are positioned exactly on top of each other with each press of the rollers. This is why the channels are dimensioned with particularly high precision to avoid the misalignment of the roller when under a load. The controlled roller pressure warrants a constant in-feed, regardless of the resistance imposed by the material. The manner of design enables exactly reproducible roller-groove depths, which are then reflected in the levelling results. Overlapping in the roller grooves is thereby avoided. The material in-feed component utilises linear modules. These enable higher cycles and thereby reduce non-productive time intervals. The drawbacks of a pneumatic in-feed do not come into play here. The sequence of the rolling circle also may be selected freely. Higher-quality materials used in the construction of the rollers enable a long service life. Four different versions of the MR 3 (with roller-ring depth of up to 250 mm) are available: Standart (S) Module MR 3 and base frame Item no.: Linear unit, only with two rails, on fixed table to be moved via handwheel. Grid positions for various roller rings, only manually-adjusted rolling pressure possible. Actuation: switch on/shut off via a foot-operated switch. Standart Linear (SL) Module MR 3 and base frame Item no.: Lineareinheit mit Linearmotor und Drehgeber, Walzkreis programmierbar. Actuation: via pressure switch, retract by hand roll 360 degrees extend. Only a single roller stroke and manually-set pressure possible. NC Module MR 3 and base frame Item no.: Five continuously adjustable roller strokes in any length with different pressures. Actuation: on the control cabinet or on the machine, by hand. NCR Module MR 3 and base frame Item no.: As in the version NC however, with an additional controller for scraper saws. For the first time, discontinuous surfaces are possible in the automatic cycle. As an option, handling devices or robots can be connected. The actuator module is also available for frame saws however, with a different sub-frame. METHOD OF OPERATION Rigging work can be performed without roller in-feed, since the pneumatic cylinder functions independently, without the electrical system being switched on. The pressure is variably adjustable and can be read on the indicator.

Connection values Gear motor, continuously adjustable Roller rotation for both rollers Max. cycle speed Roller diameter (new) Available roller radii 2.000 x 750 x 1.

5 MR 3 Technical Data * Approx. dimensions Weight Current possible max. blade size Currently smallest roller stroke diameter Current max. roller-stroke depth Blade in-feed via linear motor Currently possible blade strokes per cycle Roller-stroke length Current roller pressure Pressure exertion per roller groove Controls (Siemens) Connection values Gear motor, continuously adjustable Roller rotation for both rollers Max. cycle speed Roller diameter (new) Available roller radii x 750 x mm approx kg 1000 mm 120 mm 250 mm continuously programmable 5 total programmable by degrees continuously programmable up to 5,200 kg continuously programmable touch-screen monitor, automatic error alert, rigging or individual production, serial production, program data can be stored 400 Volt / 32 A / 50 Hz / 3,5 KW 2,2 KW continuously adjustable up to 49 RPM as yet unknown 130 mm mm * The following data refer exclusively to the prototype which is currently in the fi nal production stage, which also has yet to undergo in-factory testing. It is possible that the data for the subsequent series will slightly deviate from the data shown here. Subject to design changes. We reserve all rights to the MR 3.

6 A A gleichmäßige Druckausübung The new, innovative positioning of the rollers Roller pair (A) in the rest position. The bottom shaft casing (Y) is screwed on downward and the top shaft casing (X) is screwed on in the upward direction - each on a single panel. The panels, in turn, are connected to each other via a patented guidance arrangement (attached to the sides). This enables the roller pairs (even when positioned at different height intervals) to always face each other at a right angle in all directions. X To move to the intended position for performing work, only the top shaft casing can move in the direction of the arrow (in a straight line). The properties of the roller-adjustment mechanism on older machines (such as the slantwise impact of the rollers and displacements at different operating pressures) no longer apply here. Y Even under different operating pressures between 0 and 7000 kg, the position does not change. A 100% reproducibility of the roller strokes is always possible. ROLLERS AND THEIR EFFECTS DESCRIPTION AND TECHNICAL DATA Excerpts from an expert s assessment: The larger the diameter and the lesser the gauge of a saw blade, the greater the risk that a cut with the saw misses its mark or that the circular-saw blade could be damaged. Since the customer, however, seeks to minimise cut loss, saw blades are becoming increasingly thinner. The stability of the circular-saw blade is closely associated with (among other things) its individual level of self-equilibrating stress. The stress placed on the tool shifts the existing natural frequencies upward. This is a desired effect, since a greater gap between the natural frequency and the application frequency makes for quieter and smoother operation. In this regard, it is important for the manufacturers of circular-saw blades to know the correlation between the range of tension in the saw blade, the distribution of tension in the roller groove and the operation performance. In order to live up to these standards in practical application, circular-saw blades must be set to a certain level of initial tension. This particular level of initial tension is broken down by the saw leveller into the ranges fi rm, medium and slack. A blade which is only slightly pre-straightened is referred to by the pre-straightening level fi rm ; a blade set to a high level of pre-straighten is referred to by the pre-straightening level slack. The determining factor in the prestraightening level is the intended application of the saw blade. Circular-saw blades set to the prestraightening level slack can be subjected to higher stress levels. By way of straight rolling that is to say, by way of the ring-shaped application of a roller groove on the surface of a saw blade the above pre-straightening levels are generated. The correlation between rolling conditions and the pre-straightening level was analysed. For the straight rolling machines which one encounters in practical application, the rollers are continuously powered and pressed onto the tool with the previously-set force by the saw leveller after fl ipping a switch. For one-time rolling, at the end of the roller groove (this depends on the operator s reaction speed), there is a more or less extended zone of a seam. In this section of the roller groove, the rolling process has already taken place twice - however, in an uncontrolled manner. We have had the process and the effects of straight rolling analysed. To the greatest possible extent, the results of this analysis have been applied to our new design.

MR 4 TEST PLATFORMS Types 1-5 The test platforms MR 4 - Types 1 to 5 are conducive to the verification of the results of rolling and levelling work performed on saw blades and circular knives.

Extensions with a motorised actuator, vibration-gauging equipment ort he setup of a unit for testing the blade thickness and conicity as well as generally documenting the gauged data are available.

7 MR 4 TEST PLATFORMS Types 1-5 The test platforms MR 4 - Types 1 to 5 are conducive to the verification of the results of rolling and levelling work performed on saw blades and circular knives. The five different types comprise the most commonly used design forms in practical application. The testing blocks are made of a sufficiently-dimensioned aluminium profile. Extensions with a motorised actuator, vibration-gauging equipment ort he setup of a unit for testing the blade thickness and conicity as well as generally documenting the gauged data are available. These auxiliary parts render further final testing unnecessary. This results in shorter processing and testing intervals. MR 4 - Type 1 The blade acceptor is positioned in front of the table. Fixation is performed via a pneumaticallyactivated pile nail positioned in the hollow shaft. [ 1 ]. The opposing cap [ 2 ] is equipped with a rotary handle to enable the turning of the blade to a position in front of the counter. Each of the two horizontallypositioned deflectors - [ 3 ] and [ 4 ] is designed as a pneumatic cylinder which affects the blade directly and which can each be activated individually. The stroke gauging [ 5 ] takes place at a 90-degree angle by way of a counter (conventional mode) or a gauging scanner (documentation made).

MR 4 - Type 2 The blade acceptor is positioned in front of the table as in TYPE 1.

Both deflectors - [ 3 ] und [ 4 ] are horizontally positioned as in TYPE 1.

MR 4 TEST PLATFORMS MR 4 - Type 3 The image on the left illustrates merely the basic principle which corresponds to that of TYPE 2.

8 MR 4 - Type 2 The blade acceptor is positioned in front of the table as in TYPE 1. Since the blade fixation occurs in this case via a pneumatic counter-pressure spindle [ 6 ], an opposing table [ 7 ] must absorb these forces. Both deflectors - [ 3 ] und [ 4 ] are horizontally positioned as in TYPE 1. The gauging of the stroke [ 5 ] occurs analogous to TYPE 1, in a 90-degree angle. MR 4 TEST PLATFORMS MR 4 - Type 3 The image on the left illustrates merely the basic principle which corresponds to that of TYPE 2. here, the blade acceptor was positioned between two tables. The blade fixation occurs via a pneumatic counter-pressure spindle. Since the two vertical deflectors [ 7 ] und[ 8 ] both of which are pneumatic cylinders as in TYPE 1 are positioned vertically, a particularly high level of stability must be emphasised here. The stroke gauging occurs in the same manner as in TYPE 1 and TYPE 2.

Only a single deflector is built vertically into the stand (180 degrees). This deflector is activated via a pneumatic cylinder. It is a separates component which pivots outward when in use.

9 MR 4 MR 4 - Type 4 In TYPE 4, the blades can be inserted into the stand from both sides. Here, too, the blade fixation occurs via a counter-pressure spindle, which even in the pressure state can be easily turned via a large hand-wheel. Only a single deflector is built vertically into the stand (180 degrees). This deflector is activated via a pneumatic cylinder. It is a separates component which pivots outward when in use. It is length-adjustable and then remains constant; this eliminates the drawbacks of a direct-action cylinder. A deflection in a 90 angle is likewise possible. This component was subsequently attached and is designed on one side as a folding table. Here, the stroke gauging occurs in the same manner as in TYPE 1. TEST PLATFORMS MR 4 - Type 5 The testing platform MR 4 TYP5 corresponds with regard to its functions and structure to TYPE 4 and to the testing table MR 5. The image on the left shows the testing platform with all auxiliary parts for gauging the blade thickness, the conicity and the stroke as well as the concentricity of the soldered teeth. For this test, the circular blade is held between two straightening caps. First, the blade is tested and levelled, as always. After that, the results can be verified and documented at the same tension level. All values determined in this process will be documented and are precisely reproducible, as necessary. MR 4 - Test Platforms In their basic form, all testing platforms consist of a stable aluminium-profile system. This makes them expandable at any time, and important auxiliary devices such as the pneumatic cylinder or the deflector can be positioned inside in an accessible spot. A steel plate on which one or both spindles is assembled serves as a table. For the Type 4 (currently dimensioned for mm blades), the spindles are positioned exactly opposite each other due to their construction method. The fixed side is the side on which the blade is attached with custom-designed retainers. The straightening flanges are equipped with a so-called fourpoint keyhole system for even interlocking, and can be designed according to the individual customer s specifications with regard to their diameters. The slack side is formed by a rotor-spindle combination. The rotor presses the corresponding straightening flange onto the circular blade. The centre axis can be rotated via a large handwheel; this action enables the blade test. The counter and the acceptor for a sound-image transmitter are positioned on the fixed side behind the blade, in a stable linear configuration. An additional deflector can be integrated in the basic profile. This component must also be attached subsequently. The adjustable deflector is positioned on the fixed side, at a 100-degree angle to the counter. Subject to design changes. We reserve all rights to all MR 4 types.

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