Table. Characteristics of some four-sided machines (characteristics - seller company, model, number of spindles, workpiece width, workpiece height, minimum workpiece length, spindle diameter, rotational speed, feed speed, loading table length, planer support, motor power 1 and 4 spindles, motor power 2 and 3 spindles, the presence of a molding support, possible positions of the molding support, the power of the engine of the molding support, the power of the feed motor, the power of the traverse lifting motor, the total power of the machine engines, the machine dimensions, the weight of the base machine; the manufacturing company is BZDS S23-4, Winner, Nortec, Gau Jing Machinery Industrial Co. Ltd GA-623H, Nortec, Machinery Industrial Co. Ltd GN-6S23, Griggio S.p.A. G 240/5, Griggio S.p.A. G 240/6, BZDS S25-5a Pro, SCM Group Superset NT Plus, High Point M-180, High Point MX-180/5, Ledinek Superles 4V-S150, REX Bigmaster 310-K, SCM Group Topset Master, REX Timbermaster Type U-41-K, MIDA Alfa-500)
Figure 1. Schemes of feeders
Figure 2. Scheme of the cardan drive of the rollers of the feed mechanism using worm gears
Figure 3. Variants of the location of the spindles in four-sided machines
See table and figures in
And the quality of the machined parts largely depends on how uniform this movement will be.
Feeders on quadrilateral machines
The feed mechanisms of four-sided machines are devices with a frictional connection between the workpiece and its feeders. The movement of workpieces occurs due to the adhesion of their surface to the moving working elements of the feed conveyor. In this case, resistance is overcome in the form of friction forces applied to them and longitudinal components of cutting forces.
In four-sided machines, concentrated feed mechanisms of three types were used and are used: caterpillar, roller-caterpillar, roller - and distributed - roller (Fig. 1).
Caterpillar feed mechanisms are distinguished by the reliable capture of workpieces advanced on the table, which eliminates their slippage, and the uniform distribution of vertical force, which reduces the straightening of warped workpieces. Such mechanisms are used to feed short workpieces (for example, in domestic machines of the PARK-8 and PARK-9 models, designed for processing parquet riveting) and in many modern four-sided machines based on double-sided planer-thickness planers - in the zone of planer support.
Roller-caterpillar mechanisms are also distinguished by reliable grip and high feed force of workpieces. They are mainly used in machine tools for processing heavy workpieces of large cross section, for example, wall beams.
Rollers, consisting of rollers (rollers are a pair of parallel drive shafts rotating towards each other), were originally used in four-sided machines. These mechanisms are characterized by a simple design, reliability and low sensitivity to different thicknesses of the advanced workpieces.
A common drawback of concentrated feed mechanisms of all three of these types is the advancement of short blanks end to end; with obliquely cut ends, workpieces can be extruded to the side and up, which leads to the need to increase the force of the upper and side clamps in the machine, leading to an increase in the required feed force.
Therefore, in the design of most four-sided machines manufactured today, a distributed feed mechanism is used in the form of a set of drive rollers located one behind the other along the entire length of the desktop.
First quadrilateral machine with such a distributed feed mechanism was introduced in 1960 by the German company Harbs, and today they are equipped with the vast majority of four-sided machines. The advantage of the roller mechanism is the possibility of feeding workpieces with an inter-end gap and processing only one workpiece, which, without being pushed by others following it, is freely guided by drive rollers through the entire machine. Moreover, when feeding workpieces end to end, the last loaded workpiece does not remain clamped in the machine.
The rollers of such a feed mechanism are mounted on a single beam on rocking arms and at the same time play the role of upper clamps. In older models of machine tools, these rollers were pressed against the workpieces by springs, and today pneumatic cylinders are used for this purpose. The lifting of the beam together with all the rollers and clamps for adjusting to the processing size is carried out using a motorized drive, which also allows you to get free access to the machine table and its spindles for their inspection and replacement of cutters.
The working surface of the feed rollers in the machines is corrugated. The drive rollers behind the finishing cutter are covered with a layer of wear-resistant plastic.
Feed drive on quadrilateral machines
Rice. 2. Scheme of the cardan drive of the rollers of the feed mechanism with
using worm gears:
1 - beam;
2 - swinging lever;
3 - feed roller;
4 - feed roller spindle;
5 - axis of rotation of the worm gears;
6 - worm gear;
7 - cardan shaft;
8 - desktop of the machine;
9 - guide ruler
Initially, the rotation drive of the rollers of such feed mechanisms was carried out from common shaft passing through the entire lifting beam, by means of bevel gears and chain drives.
But in 1970, the German company Gubisch developed a four-sided longitudinal milling machine
Maud. GN14, which was the first to use the cardan drive of the feed rollers, which is used today in the designs of almost all similar machines. In such a drive, each of the feed rollers is connected through a cardan drive to the output shaft of its worm gearbox, and the worms of all these gearboxes located on the same axis are connected by couplings and rotate simultaneously by one drive (Fig. 2), which is also mounted on the beam and rises with it .
As such a drive for rotating the rollers, electric motors with variators of various designs were initially used, which provided stepless control of the feed rate. In modern machines, instead of variators, frequency regulation of the rotation speed of the electric motor of the feed mechanism using electronic converters is used.
Calipers on quadrilateral machines
Any four-sided machine is equipped with at least four calipers: horizontal (bottom and top) and vertical (left and right). In this case, the left calipers can be tilted. In the so-called moulders, an additional universal support is used - moulder.
For the purpose of unification, each equipment manufacturer tries to make all these calipers the same. However, their design is significantly affected by the need for tuning movements. So, for the lower and right-handed spindles, radial adjustment is required, and its value is minimal, since it is necessary only to regulate the allowance removed by the cutter installed on them. At the same time, all left and upper spindles, when adjusted to the size of the workpiece to be machined, must be displaced within a significant range. All spindles generally also have axial movement to adjust the position of the profile cutters.
Depending on the design developed by the machine tool manufacturer, either the motor shaft (motor-spindles) or a shaft mounted in bearings and driven by an electric motor through a belt drive serves as a spindle. In the most simple and cheap machines, one electric motor can rotate two vertical spindles simultaneously.
To transfer the rotation of the electric motor to the spindle in older models, v-belts, and in modern ones - thin synthetic ones.
The accuracy and rigidity of spindles is largely determined by the bearings in which they are mounted. Many manufacturers use conventional bearings to reduce the cost of their machines, while expensive and high-quality ones use high-precision bearings.
It is believed that the use of machines with motor-spindles is ineffective, since when replacing bearings in them, the rotor may be out of balance, which can lead to a decrease in the quality of processing. In addition, in belt-driven calipers, the belt serves as a damper, which prevents the engine from being overloaded; its replacement in case of failure will cost less than replacing the motor spindle.
To carry out adjustment movements, the calipers are mounted on dovetail guides or on parallel rolling pins. The movement of the calipers along them is carried out by means of a pair of "screw - nut", rotated manually, with position control along the ruler with a vernier scale, or, in machines equipped with electronic system control, controlled by her servomotors.
Mauling support of a four-sided machine
This name arose from the concept of "moulding" - a profile drawn on the edge of the workpiece. Armin Berner designed his first molding machine in Germany in 1920. And in 1954, the German company Weinig announced the receipt of a patent for a multi-purpose four-sided machine with a moulder that can be moved to various positions.
Such a support, depending on the version and model of the four-sided machine, can only work with respect to the workpiece from below, below and left, below and above, below and right, as well as below, above, left, right, or tilt at any angle.
Choice technological possibilities of this support depends on the cross-sectional profiles of the parts produced by the enterprise.
Mauling calipers at domestic enterprises, in most cases, as a rule, are used to select a longitudinal recess on the underside of a machined part, for example, a casing, or for longitudinal cutting of milled blanks into narrow parts.
There is one more nuance: when choosing a machine, many manufacturers do not even think about the required power of this spindle, which leads to errors in the processing of parts. So, for simplicity of calculations, it is considered that when cutting with saws, one cut requires engine power at the rate of 1 kW per 1 cm of workpiece thickness. That is, if a workpiece with a thickness of 40 mm is cut into three parts (with two saws) using a molding spindle, then its engine power must be at least 8 kW.
Power of other spindles on quadrilateral machines
If we carry out a simple analysis commercial offers on four-sided machines transferred by our machine tool trading companies to their potential buyers, it turns out that the drive power of the spindles in this equipment is for some reason very often the same.
At the same time, the first feed cutter in the machine, which creates the basis for further processing of the part, removes a rather small allowance from the workpiece, and the required drive power is lower than the sellers offer. The power of the electric motor of the right cutter can also be insufficient, since it removes the allowance on the edge of the workpiece, which is always obviously narrower than the largest width of the face.
The most powerful of all the above should be the drive of the upper horizontal cutter, which removes the increased allowance, which includes all inaccuracies in the dimensions of the workpiece in thickness and width. Experience has shown that the power of its engine should be at least 11 kW. Moreover, this may not be enough if processing of deep profiles is supposed.
The lack of power of at least one, any, spindle leads to the need to reduce the feed rate, which reduces the productivity of the machine.
The composition and arrangement of the spindles of quadrilateral machines
On fig. 3 shows some of the options mutual arrangement of spindles in four-sided machines. Manufacturers must select them in advance, before purchasing the machine, based on the required profile of the workpiece.
So, with the arrangement of spindles shown in Fig. 3.1, it is possible to process parts with a rectangular profile or shallow profiling on four sides. The composition of the spindles shown in fig. 3.2, makes it possible to mill a deep profile on the bottom face of the part, and the spindle configuration shown in fig. 3.3, - on the right (by filing) edge.
If the composition of the machine units corresponds to that presented on
rice. 3.4, with the help of a molding support placed in various positions, it is possible to make deep profiles on all surfaces of the part and to carry out its longitudinal cutting.
Additional lower spindle, as in the diagram shown in fig. 3.5, makes it possible, for example, when jointing using a comb work table, to level the surface of the lower face of the part and mill a profile on it using a moulder spindle.
To select a deep profile along the left edge and other surfaces of the part, additional vertical and molding spindles are used (diagram 3.6).
The location of the spindles, corresponding to scheme 3.7, allows you to get U-shaped profiles, and shown in diagram 3.8 - H-shaped.
The layout of the spindles, shown in fig. 3.9, makes it possible to mill K-section profiles, and the diagram shown in fig. 3.10, - even more complex, with additional longitudinal grooves.
On machines in which the spindles are arranged in accordance with the diagrams in Fig. 3.11 and 3.12, it is possible to obtain X-shaped profiles.
The spindles can be sequentially arranged in another order, for example, in such a way that allows you to distribute the allowance removed during the formation of the profile, two or even three cutters. In addition, some profiles cannot be obtained without tilting at least one spindle.
Therefore, the leading machine tool builders, by order of a particular consumer, can manufacture four-sided machines that have ten or more spindles. Today, machines with non-standard spindle arrangements are often found in the market for refurbished, used equipment.
Noise from quadrilateral machines
In many countries, the maximum permissible noise level in the workplace is set at 85 decibels (dB). Where the noise level exceeds this value, protective measures must be applied. In fact, 85 dB is the maximum noise level that a person can be exposed to for eight hours without hearing loss. An increase in this noise level by 3 dB corresponds to a doubling of the exposure intensity and a halving of the allowable sound exposure time. At 88 dB, the allowable exposure time is four hours, at 91 dB, two hours, and so on. This means that 110 dB noise can only be tolerated by the ear for a few minutes.
But it is precisely this level of noise that is typical for all working four-sided machines. And even the presence of noise-absorbing covers on the equipment, as a rule, open at the back of the machine and having a decorative rather than protective purpose, does not help to reduce it. Therefore, such machines in production should be placed in a special soundproof cabin (Fig. 4), and machine operators while working in without fail must wear antiphons.
Four-sided machines are one of the main types of equipment in any woodworking enterprise, and from their right choice often depends not only on the quality of products, but also on the productivity of the enterprise. This means that when choosing a machine, one should pay attention not only to its price, but also to carefully study the design of such equipment and the proposals of potential suppliers, in particular, comparing them with the needs of the enterprise, and only then make the final decision on the purchase.
Andrey MOROZOV,
company "Media Technologies"
commissioned by LesPromInform magazine
Product size quickly adjustable according to special rulers by moving the right and upper spindles (the left and lower spindles are adjusted in a small range to compensate for tool wear)
Innings blanks occurs through a powerful gearbox with the help of two pairs of upper and lower, corrugated, spaced from each other ripples. This solution makes it possible to increase the reliability and accuracy of feeding workpieces. good quality and high humidity (unlike the ryabukhs located nearby).
Quadruple machine "START 5x210" completed stepless feed rate adjustment system, allowing you to optimally adapt to the available material for work.
Precise workpiece position in two planes is provided by special support plates running almost the entire length of the desktop and paired spring-loaded rollers. The clamping force of each roller is independently adjustable over a wide range. The pair design of the rollers allows you to evenly distribute the clamping force.
Precise grinding of work rolls quadrilateral machine "START 5x210" guarantee the complete absence of end and radial runout of the tool.
High spindle speed(4500 rpm) allows you to achieve a high quality finish surface. Optionally, it is possible to install one or two upper spindles with a rotation speed of 6000 rpm.
Four-sided planer "START 5x210" equipped protection system from ejection of the workpiece.
The machine is designed in such a way that it provides convenient access to all important components of the machine, while having the necessary rigidity, eliminating vibration during operation.
Working surface The table is made of extra strong steel, which increases its service life, and is additionally ground to minimize feed resistance and increase machining accuracy.
Work surface life is at least 10-15 years old however, if necessary, this part can be replaced separately from the rest of the equipment. Interchangeable table top makes the service life of the machine practically unlimited, unlike analogues, where the frame of the machine and its working surface form a single whole.
The control of the electrical systems of the machine is carried out on an independent mobile console.
The machine can be equipped with a special reception desk, with precise height adjustment. Properly chosen height of the receiving table will avoid "cutting" at the end of the workpiece.
Compact dimensions and low weight of the machine make it quite mobile and easy to install.
The most simplified, but well-thought-out design ensures its high reliability.
Used for the production of various construction and finishing materials as well as furniture. Many of the most important goals can be achieved with this reliable equipment. Setting up the tool is a feasible task for those who learn the basic principles from the presented article.
The central part of the machine is a cast planer table, which is mounted on a stable tripod. This design eliminates vibration. The planer table also includes a bottom cutter and 2 side cutters. The top cutter and rollers are fixed on a tripod. They move on massive bars. 4 cutters are powered by separate motors.
Machine setup steps
Preparation for work begins with the adjustment of the planer table. This prevents unwanted mechanical impact on the workpiece. Only correct installation equipment guarantees high quality processing.
Table setting
The gap remaining between the part and the table should be no more than 0.127 mm in length. If the back of the platform is set too low, the workpiece will begin to rise off the bed. For this reason, the edge will be processed with more curvature than required, and an incorrect cut will be formed.
In the tuned machine, discrepancies at the joints of the indicated parts are excluded. Otherwise, they will be visible.
When set correctly, the clamping bar creates pressure, due to which the cutting occurs with some effort. If pressure is not felt, the end of the workpiece will not be finished properly.
Feed setting
In order for the supply of any elements to be smooth, ensuring the continuity of the workflow, it is necessary to fine-tune the position of the lower rollers. They should be aligned with the upper cutting head. The leading feeder must be located above the second.
Placement of both rollers at correct setting corresponds to a direct tangent to the comb part of the lower rollers. The imaginary line is directed towards the cutting head.
At the same time, the bed crossing must be fixed only in front of the upper head.
Adjustment before working with short workpieces
Often there are situations when it is not possible to hold the closely stacked workpiece. In this case, feeding through an automatic feeder is used, which can work with arbitrary lengths. This principle is due to the fact that it is almost impossible to ensure the movement of the workpiece at the required speed manually.
If it takes 2-3 seconds to stop, the cutting edges of the rotating heads can instantly become dull.
The main indicators of any woodworking production are high-quality work and productivity. To fulfill these conditions, you must have the appropriate equipment. One such equipment is a four-sided woodworking machine.
Design and scope
Relatively recently, in the production of wood processing, designs have appeared that combine several operations. Processing of wooden products in this case occurs from four sides at once. This equipment is most often used for milling and jointing.
The woodworking machine consists of:
- spindle section;
- part feed unit;
- equipment parameter control systems.
On the one hand, there can be several processing heads, which makes it possible to reduce the cost of manufactured products and reduce the time for performing a certain operation.
The four-sided machine is designed to perform the following operations:
- Milling. On the working heads of the equipment, instead of planing shafts, disk cutters are installed, which makes it possible to do longitudinal milling. To carry out processing with finger cutters, it is necessary to periodically stop the parts, however, this is not provided for by the design;
- Planing and jointing. This can be done using shafts with blades of a certain configuration mounted on them. The design of the machine makes it possible to perform both finishing and roughing;
- Reiming and profiling.
Most often, such models are used to create lumber with a flat surface or profile. All work can be done in one pass.
With the help of four-sided machines, you can make products such as:
Classification and differences of machines
All four-sided woodworking machines can be divided into:
- thickness planer;
- longitudinal milling.
Longitudinal milling machine used for cutting along the length of the material to the desired size. This woodworking equipment can perform profiling of any complexity. The lower shaft of the knife, taking into account the thickness of the planed wood, moves along with the table top in a vertical direction.
Planer used to cut a part to a specified thickness simultaneously from two sides. It is initially planer, but has an additional profiling function. Such a machine can produce shallow profiling with a simple small bar lock design.
Processing wood on four sides at the same time helps save time and increase productivity. That is why in the construction and furniture sectors, four-sided machines are the optimal equipment.
Main selection criteria
Considering that a machine for complex woodworking is expensive equipment, it is important to consider when choosing it specifications and all the nuances of the design. Equipment performance depends on:
- speeds and systems of giving of a bar;
- degree of processing and dimensions.
Choosing the optimal machine model you should pay attention to:
In order to precisely position the workpieces relative to the machining center, a system of sensors is required. In addition, when analyzing the model, one should take into account the cost of components, the degree of remoteness of the manufacturer's service centers and the terms of the warranty.
The design of the machine units
To understand the principle of operation of the equipment, it is necessary to consider design features of the machine, which includes many nodes.
In some models of equipment, a joyter, a hydraulic spindle and a number of working tools are included. Such devices sharpen knives directly during processing of the product.
Buying a machine
Longitudinal milling machine can be purchased at construction specialized stores, but it is better to buy it directly from the manufacturer (if we are talking about domestic manufacturers). Equipment can be rented or purchased by installments.
Before you buy the equipment, you need to pay attention to the following main points:
- performance;
- accuracy;
- operational reliability;
- service availability;
- equipment price.
If a four-sided woodworking machine will be an addition to an already running line, it is important to consider its dimensions. At the time of purchase, it is necessary to take into account the technical parameters and the combination of various processing options, the weight of the equipment and the speed of work.
Some companies providing such equipment are still little known. The price of their products relatively low, but the quality is adequate. For example, the German brand Beaver. The cost of their products is low due to the fact that the production is located in Taiwan and China. But parts of the assembly are made in Germany.
When choosing equipment, you should not consider cheap Chinese-made models. It should be borne in mind that it will be very difficult to find spare parts for them.
Service maintenance
Any machine tends to break down over time, the constituent parts wear out. In order to have fewer interruptions in work for such reasons, it is advisable to choose the equipment that is most durable and wear resistant.
In addition to productivity, it is important that the machine is as safe as possible. Therefore, the presence of limit switches, electric brakes and a metal protective casing with sound insulation is provided.
Processing on the machine of products should be as accurate and high-quality as possible. For these purposes, it is important that the device has static and dynamic balancing of all fixings of parts.
When operating the equipment, it is necessary to adhere to the rules specified in the instructions for it. It is impossible to process workpieces that are larger in size than those stipulated by the rules. It is essential to carry out preventive and repair work to keep the equipment in working order.
It is very important to set up the machine correctly., taking into account not only its dimensions and weight, but also the dimensions of wooden blanks. The operator should not face the difficulties associated with the supply of material.
Pros and cons of equipment
One of the most positive qualities of four-sided machines is high productivity. To achieve optimal results, the design must be equipped with a program numerical control unit. Then the influence human factor will be minimal.
The conditions for the correct compilation of the program must be met, and an accurate measurement of the workpiece being processed must be made. In the optimal configuration, the equipment is designed for processing cylindrical workpieces and rectangular timber. Jointing and milling of sheet materials can be performed on both sides. Features of the operation of machines of this type are the following factors:
The main disadvantages of four-sided woodworking machines are the high cost and complexity of setup. However, in a production line, these indicators are not significant.
Maintenance of four-sided machines with manual feeding and sorting of material, as well as acceptance of machined parts, is a labor-intensive process with low labor productivity. To eliminate certain difficulties for four-sided machines, a conveyor line has been developed that automatically feeds and receives blanks.
Two mechanized blocks are installed on the sides of a working machine - a feeder and a receiver. In total, the service line consists of four modules, which provide not only uninterrupted supply of workpieces, but also the possibility of their troubleshooting due to the formation of buffers caused by a lower speed of the conveyor. A longitudinal conveyor with a ejector and a transverse conveyor with a device for feeding blanks for four-sided machines are located on one side, and a receiving device and a sorting conveyor ensure the receipt of processed materials from the other side of the machine. The main application of the feeding and receiving system was found in large-scale enterprises and in workshops for the production of molded and joinery products, as well as glued construction beams and panels. Perfectly is suitable for processing of large-sized molded details.
Lines for supplying workpieces to four-sided machines
Device automated production lines for the production of furniture or standard housing construction, they need to mechanize the supply and receipt of materials for four-sided machines. Experienced specialists of our company will help you not only to purchase this conveyor equipment, but also to find the right place for it in the woodworking shop.