Porcelain stoneware
GHIBLI AUTOMATIC DRY-SQUARING MACHINE Automatic dry-grinding complete lines for the finishing process on porcelain stoneware tiles and large slabs
Porcelain stoneware
GHIBLI TECNEMA BRETON GROUP THE FUTURE STARTS TODAY Breton bolsters its presence in the ceramic segment by acquiring Tecnema Technology Srl’s majority share, a company established almost 30 years ago achieving success on product innovation. As an example, Tecnema was the first company to strongly believe in the benefits of dry squaring, which is now being used by more and more companies. Tecnema and Breton’s current challenge is to become a leader also in the ceramic end-of-line stage, taking advantage of the synergies between the two companies and their ability to innovate. The needs of ceramic companies all over the world are rapidly evolving, driven by the spread of new production systems that can create large ceramic slabs. Technological change brings the chance to implement more streamlined and performant solutions that can mitigate the workforce’s involvement while qualifying it at a higher level. With the new Ghibli automatic dry-squaring machine, the Tecnema Breton Group taps into change and forestalls the competition by offering the ceramic industry an automatic and technologically advanced product that can meet the needs of tomorrow, today.
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Tecnema BRETON Group - AUTOMATIC dry-squaring machine
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GHIBLI
GHIBLI The best or nothing! Maranello’s bright RED heart beats in this squaring machine Uncompromising design, mechanics and electronics
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
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GHIBLI
Grinding spindles HSC (High Speed Cutting) technology In the HSC version, the Ghibli squaring machine is equipped with particularly reliable and performant gauging spindles that are the result of years of research and experiments and whose mechanical engineering is worthy of Maranello’s greatest motoring traditions. All the spindles are inverter-driven and - through the precision-fitting of the bearings and careful dynamic balancing - can rotate at 4,900 rpm and drive the diamond grinders at extreme peripheral speeds, up to 75 m/s. Rotating at almost twice the speed of the market standard, each diamond grain removes lesser material per revolution, thus generating thinner powder. This reduces stresses on the material and on the grain, which is subject to lower breaking and rounding actions and cuts more effectively and efficiently. The tool/material thermal exchange is also improved, increasing performance by 35% with the same energy consumption; this means higher removal and higher feeding speeds. It should be noted that HSC spindles are not subject to overheating and work at very low temperatures (35°÷40 °C in ≈ 30 °C environments) and need no cooling system. The inverter allows adjusting the high rotational speed to adapt it to the type of material and tool and optimize the cutting action even more. Moreover, the high rotational speeds increase the tool’s flywheel effect, therefore the machine’s sensitivity to temporary overloads caused by oversized material is lower. As such, the Ghibli squaring machine in the HSC version stands out for its notably higher removal rate and feed speed and its lower energy consumption and tool wear. Just like the GHIBLI wind in the desert, the high-speed tools of the Tecnema Breton Group squaring machine generate impressive powder whirls that are extracted by the dedicated system.
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
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GHIBLI
Bevelling spindles A 3-kW spindle is fitted on each side and can be tilted to machine a small lower bevel or alternatively positioned horizontally to be used as a finishing gauging spindle fitted with a resin tool. Finally, a 1.5-kW floating spindle is used to carry out the upper bevel.
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
GHIBLI
Tiles/slabs are fed forward by two electronically synchronized powered units equipped with brushless motors, to ensure that any situation is managed in the best possible way; the two lines are therefore perfectly synchronized and allow swift and easy belt replacement. The applicable speed range varies from 0 to above 34 meters per minute, which suits any processing need.
Powder extraction manifold
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The input to each module is equipped with two sensors that detect possible tiles having an “irregular perimeter�, caused for example by broken corners on the tile itself. Another pair of sensors redundantly detects tile positioning defects during the machine feeding phase, which could cause collisions with machine components. In both cases, the line automatically stops and alerts the operator.
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
Precision mechanics working properly is key to the good result of the squaring operation and to extend the life of the tools. It centers the tile so as to equally distribute on each side the amount of material to be removed. As such, the Ghibli can remove even minimal amounts of material from each side.
GHIBLI
Centring unit and squaring unit
An optical device on the output of the two modules automatically detects the work size of tiles and, should it be out-of-tolerance due to tool wear, all the gauging spindles will be repositioned to achieve the required size and improve the firstchoice yield, provided the machine is equipped with the proper extra device. The squaring device inserts the tile in the second operating unit so that the working line of the last two sides is orthogonal to the one processed by the first unit. At times, a worn conveying belt and/or an outof-tolerance tile or a worn grinder that was not repositioned may cause an imperfect positioning between the processed sides. The automatic correction system patented by the Tecnema Breton Group allows changing the position of the pushers without having to stop the machine: diagonal corrections, in automatic mode. Even when changing format, the squaring units always maintain the best possible tile/slab pushing position. Both devices may feed the relevant operating units at no less than 60 workpieces per minute.
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Motorized positioning of the grinding spindles (optional) Each spindle is positioned by the brushless motor installed in it - which ensures the required accuracy is achieved - and can be managed from the control panel (so as to avoid the need for the operator to move between spindles to carry out the required adjustments with the centesimal gauge, based on each motor’s input current).
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
Automatic grinding spindle positioning and tool wear recovery device Managing the operation of a squaring line, even if equipped with precise centring and squaring mechanisms and motorized spindle positioning, requires great commitment anyway, as at least forty tools have to be sequentially repositioned on a frequent basis. Correctly adjusting the position of each spindle improves finished product quality, almost zeroes second-choice percentage and diminishes both tool and electric energy costs. Tecnema has patented a fully automatic technology that can precisely adjust the position of all machine millers in a few minutes, by using laser to measure the absolute position of each tool
GHIBLI
(optional)
Different “recipes” for different materials may be set and stored; if this is the case, stopping the machine for only 10 minutes allows perfectly adjusting it for the format/product change, as the centring device and the squaring device will be simultaneously adjusted at the same time Once the positioning scale of the tools fitted on the spindles has been programmed, a laser device measures the actual thickness of each tool and performs positioning according to the newly selected “recipe”. Then, should the gauge placed on a module output detect the need for a minor realignment of the worn tools, Ghibli performs it automatically without stopping the machine. The line may be emptied once or twice a day; the actual tool measurement is taken in 5 minutes, after which the spindles are repositioned according to the original recipe in order to always work in optimal conditions This accessory is also very beneficial for the safety of the operators, as they no longer have to frequently check tool “sparking” or engage in other operations that may jeopardize their safety.
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THE VALUE CIRCUIT Driven by Innovation The Tecnema Breton Group is always in pole position in the innovation race. Cutting-edge innovative solutions developed with our core values in mind, to ensure our customers enjoy the best performances.
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RESEARCH
5
00.01.20
PERFORMANCE
00.01.80
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SAFETY
00.01.00
2
SERVICE 00.00.70
1
QUALITY
00.00.30
Tecnema BRETON Group - AUTOMATIC dry-squaring machine
Models and technical features
UM
GHIBLI
GHIBLI
12 X 18
20 X 40
Machines mass of the two modules
Kg
88.000 + 94.000
92.000 + 98.000
min / max format first module
mm
200 - 1200
300 - 2000
min / max format second module
mm
200 - 1800
600 - 4000
Tipo/Type
Belt rotator
Belt rotator and slab clamps
Adoptable calibrating spindles
Nr
10+10
10+10
Spindles for lower chamfer (possibility to set them horizontally and use them as calibrating spindles)
Nr
1+1
1+1
Spindles for upper chamfer
Nr
1+1
1+1
Tool diameter
mm
250 - 300
250 - 300
Spindle rotation speed (without inverter)
rpm
2850
2850
Spindle rotation speed - HSC version (with inverter)
rpm
4900
4900
Adoptable tool tip speed
m/s
26 - 76
26 - 76
Power of calibrating spindle for lower chamfer
kw
5,5
5,5
Lower chamfering spindle power
kw
3
3
Upper chamfering spindle power
kw
1,5
1,5
m/min
0 - 39
0 - 39
Size of touch screen installed on each unit
Inch
2/15"
2/15"
Average level of equivalent sound pressure
db(A)
85
85
90° rotating unit - type
Belt advanced speed
GHIBLI
GHIBLI
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printed in italy by Laboratorio Grafico BST
“Innovation distinguishes between a leader and a follower” Steve Jobs
TECNEMA BRETON GROUP S.r.l. Via Abetone Inferiore, 44 - 41053 MARANELLO (Modena) ITALY www.tecnema.it Tel. +39 0536 94 24 33 Fax +39 0536 9424 49 - Skype tecnema e-mail: info@tecnema.it
Tecnema Breton Group reserves the right to improve the productsspecifications and design, even during the execution of contracts. Therefore, every figure supplied, has to be regarded as an indicative and approximate figure.
rev 01 - 09/2018 - ENG
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