Individual machines and complete systems for refractory ceramics, technical ceramics, sanitary ceramics and catalysts
This machines can process different kinds of bricks on 1,2,3 or 4 sides. Brick shapes like arch, wedge, straights, skew and other shapes.
This processed brick shapes are used in converters, electrical furnaces, degusser a.s.o.
Important for the choice of a manually or automatically operation is the production level. The high precision in all systems is always the same.
The different processing of sliding plates are grinding, boring and special needs. The concepts depends on the production flow.
The normal grinding process of the sliding gate plates is a to grind four plates in one step in a reversable machine. The used clamping system is for all different plates. On that account the machine set-up time is very short. The flatness of the surface is market leading.
The kiln car grinding machine is build for all different sizes of kiln cars. The kiln car moves in a automatically process into the machine. The machine starts with cleaning the surface. The surface is brushed and sucked off automatically. A scanning system moves over the surface and determines the highest and the lowest point. If the measured value exceeds the admissible tolerance, the grinding aggregate moves to the corresponding position and grinds over the surface.
After grinding the machine moves to the basic position, the clamping and arresting are released ant the kiln car can move outward.
Machines for 2-, 4- and 6- side processing of insulating bricks in passage operation. Additional the machine is equipped with tilting- and rotating devices for processing the bricks in any position. The processing is done dry, the abrasive grit will being exhausted.
Refractory products for the glass industry are machined in a variety of ways, with processes performed on anything from one-sided and two-sided to fully automated six-sided grinding machines. Sawing and drilling can be performed in addition to grinding.
Here too, Wassmer offers all the machinery required to handle these materials. Again, the production quantity is crucial to determining the design of the system.
With manually operated machines, the operator inspects the parts with measuring tools and enters the wear of the tools manually on the computer. In systems with higher production capacities, the parts are measured in fully automatic processes before and after machining and the tools are adjusted automatically for the wear. When the maximum service life has been reached, the operator is alerted to this on the screen.
The automatic systems handle the quality checks, so there is minimal requirement for personnel.
With a new patented concept in processing fused cast or pressed materials for glass melting tank we are able to remove unevenness up to 5mm on fused and up to 10mm on pressed blocks in roughly 3-4 min. After the roughing the blocks remaining oversize of about +- 0,5mm will be finished with a finer grid.
We offer special concepts for the machining of moulded bricks in low volumes and/or the machining of special formats with routing, boring, countersinking, etc.
Product-specific versions of the STS-03B allow individual formats to be sawn manually. For larger quantities, continuous systems that perform several operations in succession are available.
CNC machining centres are used for more complicated parts. These currently work with up to 12 axes.
A system for the complete machining of cathodes consists of several machines linked by conveyor and handling units. In these systems cathodes are machined on all six sides in a fully automatic process and the grooves for the power supply and the notches are milled on the outer sides. Special parts such as side blocks are machined on the integrated CNC saw. Additional installations include measuring units, weighing and control stations, various quality checks and other product-specific requirements of the customer.
The system is operated by one person.
The aluminium electrolytic cells are lined with the cathodes and side blocks (amorphous, graphitic, graphitized).
Graphite electrodes and pins for the production of electric steel are applied in electric arc furnaces.
The mechanical process begins when the electrodes are cleaned or trimmed. Before impregnation and/or graphitizing, the electrode is freed from baking residues on the circumference and its faces.
Graphitization is followed by the actual finishing process. This machining is performed on a system with several stations. The number of stations is determined both by the desired production capacity and by the requirements on quality and material testing. The largest fully-automated system comprises ten stations.
The pin machining system also consists of several stations. The pin rod is first sawn to length. This is followed by the various machining stages: centering, rough turning, thread machining, polishing, groove milling, drilling. After these steps comes the quality inspection. How the machining phases are split will depend on the required production capacity and specific customer requirements for measuring and testing.
Other projects in this sector can be designed and built according to specific customer requirements.
The fully automatic systems are run by one operator.
The laboratory machine has been developed to produce a wide variety of test pieces. In this version the parts are machined on three different stations: drilling, sawing, grinding. The stations are operated independently of each other.
The machining of very thin and sensitive ceramic parts presents enormous challenges to the machining system. High-grade guide elements and spindle bearing arrangements specially designed for this task guarantee splinter-free saw cuts and high sawing precision.
The product range extends from the simple, manually operated machine to the fully automated system.
Ceramics / building materials / facades / brick slips
Machines and systems for processing, transport and handling. The offer includes all processing such as sawing, grinding and drilling as individual machines or as an overall project in one system: loading and unloading, palletizing, sorting and formatting, quality controls, break detection, robotics, product tracking and labeling, safety technology, grinding dust disposal, water treatment and accessories.
As a specialist and market leader in grinding technology for ordinary and fine ceramics, the Wassmer Group constantly takes on new challenges. The enormous technical bandwidth for cement-bound building materials in the brick industry and in the refractory industry delivers numerous synergy effects, particularly when it comes to machining technology, feed and transport systems, tools and grinding dust disposal. Wassmer’s surface grinding machine sets new standards in the machining of lining bricks. The first grinders with 700mm diameter tools were put on the market back in the 1990s. At first they had a single-stage operation, but this could be expanded to two-stage operation, i.e. with four tools in total. Even then Wassmer was already producing modular systems to meet the growing requirements of the products. Developments in the last few years have seen demand for systems with three-stage operation, i.e. six tools in total. Tool diameters have increased to 1100mm, delivering longer service lives and availability. With several monitoring functions, the user-friendly control system ensures that the complete system operates smoothly and reliably.
This system was designed for a specific product idea. As they pass through, the bricks are ground plane parallel on the bearing surfaces and two grooves are made. On the second machine one long side is then ground. These facing bricks are laid seamlessly without the use of mortar or adhesive. The wall takes on a new appearance and can be dismantled again at any time.
The bricks are deposited either manually or automatically in a row on the conveyor belt in front of the machine. They are aligned automatically and clamped firmly during the sawing process by a pressure unit acting from above. The first quarter brick is sawn to size with two saws from above and below. It then slides onto a discharge conveyor that transports it back to the operator. Next, the brick is automatically aligned to the opposite side against a stop while a second quarter brick is sawn to size and likewise returned to the operator. The system has a high feed rate because the cutting is divided between two units and the bricks are guided and clamped securely during the sawing process. This also ensures that the saw blades have a longer service life.
The system is integrated into the existing production line and is configured for multi-shift operation. The facade slab is centered, guided at an angle to the sawing units by means of a cam conveyor chain and clamped firmly during the sawing process by two pressure units acting from above. The length is calibrated and sawn from above and below. A variety of special cuts can be performed on this system, including mitres and rabbets. The special cooling water guide system and a robust saw blade mount ensure high feed speeds and long service life.
The roofing tile grinder machines the green roofing tiles on the face prior to the upright firing process in a U-cassette. Existing H-cassettes can be machined to allow reuse if the form of the roofing tile is changed.
The transport, handling and machining of aerated concrete blocks presents a particular challenge to the stability and robustness of the system. The considerable weights of the “wet” blocks demand a solid structure with dynamic drives if a reliable process is to be achieved. The system (illustrated) comprises units for the complete unloading from and subsequent stacking onto the grilles, the entire reforming and regrouping units for the various formats and the pallet feed. A gripping aid milling facility is also integrated.
The bricks are ground in layers as they pass through the system. In the first step the complete layer is ground in one or two stages, depending on the amount to be removed and the desired feed speed. The layer is then turned 180 degrees and ground on the underneath.
Gable, stop and offset bricks are sawn on the passage saw. The machine is equipped with a vertical and a horizontal sawing unit. The bricks pass through the machine, ensuring a high throughput in a short space of time.
The vitrified clay pipes are ground circular on the end faces at two stations in the system. The pipes are taken from the customer’s conveyor, measured and transferred to two machining stations. After the grinding process the ground diameter of the two pipes is measured automatically at the exit measuring station. Automatic adjustments are also made for the wear on the diamond tools.