Notching machine
A notch cutting machine (also called KSM or English CCC-machine) is a semi-automatic cutting machine that is used on motorways and federal highways to create predetermined breaking points on concrete protective walls . With the help of a small crane, it is placed on the top of the wall and can move independently from interface to interface. It was developed in 2003 by TfB Faber GmbH and has been in use across Europe since then. The KSM is equipped with a rapidly rotating diamond cutting disc and is controlled by means of a control panel.
development
The concept of a notch cutting machine had already been developed in 2002 after the inventor, Hans-Georg Faber, observed workers inserting predetermined breaking points in an in-situ concrete protective wall using conventional angle grinders . In the following year 2003, the first prototype of a KSM ("Maukä", from "Mauerkäfer") was developed and built.
With the Maukä, the first automated cutting machine for in-situ concrete protective walls was created. In contrast to the modern notch cutting machines , the prototype was powered by a 220 V flex motor and was completely electric (modern machines are both electric and electronic). The switching of the functions was done analog, using relays and static control cards.
function
technology
The KSM has a total of 6 electric motors that drive the various components of the machine. The following parts of the KSM are equipped with their own 24 V electric motor: chassis, feed, horizontal slide, clamping and the swivel drive. The cutting arm itself has a high-frequency motor with an output of 400 V / 400 Hz. This motor drives the diamond cutting disc attached to the lower end of the cutting arm using a V-belt. In addition, the notch cutting machine is equipped with a wet cutting device that binds the resulting fine dust through an automatic water supply, thus reducing the risk of damage to health. The KSM is equipped with a SIMATIC S7-1200 PLC ( programmable logic controller ).
Schematic representation
Working method
The machine is placed on the top of the wall and can move independently from interface to interface there. The machine is fixed at the interface by means of automatic clamping without damaging the fresh concrete. The cut is made from top to bottom so that the resulting joint is not soiled again. The same procedure is repeated on the back of the wall.
Sensors scan the wall profile and the cutting depth so that the same cutting quality is always achieved. The positive guidance and the constant speed of the cutting wheel create even joints (depth of cut, width of cut).
Occupational safety
The notch cutting machine was built according to the Machinery Directive 2006/42 / EC and has had an official CE mark since 2010 and is therefore approved for use throughout Europe.
The safety of the operator is ensured through various aspects. The KSM is connected to the control panel by a 6 m long control cable. This gives the machine operator sufficient distance from the fine dust and any fragments that may flake off the concrete. The automatic water supply to the wet cutting device binds the dust and thus represents additional work protection .
distribution
Since 2004, more than 2,000 km (approx. 360,000 joints) of concrete protection walls in Europe have been cut with the notch cutting machine. It is used in countries such as Belgium, Germany, England, France, the Netherlands, Russia and Slovakia.