Luxmaster KG 5000

LUXMASTER: THE TRENDSETTER IN GRANITE POLISHING

Granite polishing lines are the soundest investment for companies requiring high productivity, top quality and operational ease, whilst maintaining budget-friendly operating and maintenance costs.

Breton was the first company to develop machines for the continuous polishing of granite slabs, bringing about a radical change in the industry.

Today, thanks to the company’s unequalled long-term experience, factors such as automation, productivity, low operating costs and ease of use whit low maintenance have become the norm for Breton, all of which are skillfully implemented into the exemplary Luxmaster.

Luxmaster is a worldwide success with customer satisfaction unparalleled on the contemporary market and is built with the excellent quality Breton machines are known for.

Distinctive marks: RELIABILITY AND VALUE

Thanks to their inherent quality, the ability to remain high-performance machines throughout their service life and the readily available spare parts guaranteed by the company, Breton polishing machines are easy to sell on the second hand market and maintain a very high trade-in value even after several years (a fact not to be ignored when purchasing a new Luxmaster machine).

Honing-polishing units

Made of aluminium alloy, designed to be lightweight with increased stiffness.
The raising-lowering system is perfectly balanced through a pair of pistons with protected internal rods.
The heads rise and fall in a fraction of a second, maintaining optimal contact with the slab surface, so slab edges are perfectly polished and operating speed is maximized.
Every head has a pressure regulator that displays the operating pressure on an analogue display.
Each spindle is fitted with a protective front plastic housing that can easily be removed, making servicing the spindle body a simple task.

THE SPECIAL BRETON HEADS: Heads with 8 oscillating bricks

Luxmaster KG 5000 are usually equipped with the more productive Breton heads Mod. SG/8 with 8 oscillating bricks, 510 mm in diameter and oil bath lubricated.
Upon the customer’s request, it is however possible to mount also the traditional Breton heads Mod. SG/6 with 6 oscillating bricks, 460 mm in diameter and oil bath lubricated.
The SG/8 heads derive /8 against 126 bricks for a polisher with 21 heads holding 6 bricks each):
  • BETTER HONING thanks from the SG/6 head project, but have obviously been adapted to hold 8 bricks; they offer the following advantages;
  • HIGHER OUTPUT thanks to the greater number of operating bricks (152 bricks for a Luxmaster KG 5000 with 19 heads Mod. SGto the larger head diameter (510 mm for the SG/8 heads against 460 mm for the 6-brick heads) and heavier weight (140 kg for the SG/8 heads against 105 kg for the 6-brick heads) that gives them more “stability” when operating;
  • INSTALLED POWER REDUCTION 285 kW for a Luxmaster KG 5000 with 19 heads Mod. SG/8 against 315 kW for a polisher with 21 heads holding 6 bricks each).
Head lubrication
All the Breton heads operate in an oil-bath system, thus minimizing the wear of mechanical parts. Each rotating head contains the required amount of oil.

Beam

The arc-welded steel beam has a special box-type section design to reduce weight and increase stiffness.
The honing units are fixed to it and help increasing its flexural strength.
The spindle/beam assembly is thus extremely stiff and dynamic for fast acceleration/deceleration ramps.

Beam Drive
The beam is actuated by two rack and pinion systems driven by two gearmotors, which are fixed at each end of the beam and are mechanically synchronized.
The gearmotors are driven by two brushless motors controlled by special drives, which, besides enabling a sine-like beam movement, make it possible to keep the number of beam strokes constant even when slab width changes; this ensures better polishing quality and uniformity over the whole surface of the slab, edges included. This system is extremely reliable and time-tested, guaranteeing highly dynamic movements without putting stress on the mechanical components. The beam’s working speed reaches 70 m/min. Furthermore, when beam traversing slows, “energy recovery” drives transfer the energy generated by braking back to the grid, with consequent energy savings.

The load-bearing structure

The load-bearing structure is made of arc-welded steel anchored to the foundations without any deformable connecting elements. The bed on which the conveyor belt rides is a thick, milled monobloc to guarantee perfect planarity.
The bed sub-structure is designed to prevent process water pooling, which could damage the frame.
The conveyor belt is driven by a Brushless motor for the best speed control.

Beam sliding bridges

The beam ends are welded to two shoulders sliding on sturdy, cast-iron bridges, which house hardened, ground, oversized roller-races with large diameter roller bearings running in an oil bath, and an antimigration micro pinion. The transmission racks have angle cut teeth to guarantee precise pinion meshing.
The sliding components are protected by stainless steel labyrinth housings.

Slab profile and thickness detection

A photoelectric barrier reader detects the slab profile with 10x10 mm resolution while a sonar reader senses its thickness. This system allows to process even slabs with a polished surface (such as already polished or resin-treated slabs).
The system controlling the automatic head lifting- lowering, ensures the selfadjustment of the beam travel to the slab width and guarantees that the spindle front, anti-splash and sound-deadening barriers are positioned automatically to match the slab thickness.

Water system

Water is supplied to the heads by a common, large diameter PVC pipe that is securely fixed behind the spindles and connected to the spindle units by flexible, rubber hoses.
A revolutionary system diverts water outside the spindle casing in the event of overflowing or clogging of the ducts, thus preventing excess water from coming into contact with the internal components of the spindle.

Automatic centralized lubrication system (optional)

A centralized system, mainly consisting of a grease reservoir, a pump with double micrometer filtration system, sequential distributors and pipes for high-pressure, guarantees the automatic lubrication of either the spindle units or the other moving parts of the machine. The system is warned about possible malfunctions by pressure sensors that easily pinpoint where the circuit is clogged.

Brushless motorization of the beam and the belt

The mechanically synchronized gantry system responsible for moving the beam ensures that it always traverses in a perfectly orthogonal direction, preventing any sideways displacement in the event of system faults.
The two digitally-controlled brushless synchronous motors provide constant torque, both during maximum speed traverse and, more importantly, during reduced speed traverse at the time of reversal of the direction of movement on the slab.
Unlike systems that still today use inverter driven asynchronous motors, with brushless motors the deceleration/acceleration ramps are controlled perfectly, making the Luxmaster KG the polishing machine with the best potential to guarantee a perfectly uniform polished slab surface.
Another benefit of this modern system is that it makes it possible to recover the kinetic energy released during braking and return it to the power feeding network. Therefore, apart from delivering better performance, the machine is also more efficient.
Also the conveyor belt is driven by a brushless motor to guarantee constant torque regardless of the feed speed and the weight of the slabs being processed, a condition that cannot be achieved with the use of inverter driven asynchronous motors.

Automatic control of abrasives wear

This system is designed to continuously monitor the abrasive wear of each single head through video advice notes and warning signals before tools are completely worn out.
It also guarantees minimal lifting of the heads on slab infeed/ outfeed, and subsequent rapid head descent, thus ensuring better polishing of the edges and a higher operating speed.

Accident-prevention guards

A pressure regulator is installed on each single spindle in a high, ergonomic and safe position.
Pressure is displayed on an analogue pressure gauge (on request, optional manual selectors for lifting/ lowering each single head can be supplied).
The front, sliding accident-prevention panels have a sandwich-like structure made of ABS.
Sound-deadening splash guards with a stainless steel sandwich-type structure are installed on the beam, in front of the heads, “level” with the slab. Their vertical positioning is automatically controlled to match the slab thickness and they lift each time the abrasive bricks need replacing.

With the Luxmaster Tango, Breton moves the benchmark a step further

Luxmaster Tango radically solves the polishing shade problem along the edges of the slabs, thanks to the clever spindle assembly oscillating system, whose swinging motion, interpolated with that of the beam, follows curved work paths that may be configured as desired depending on the material to be machined.
The result is a consistent quality finish on the whole slab surface, both for polishing and honing.
Management and programming
A colour touch-screen and advanced, user-friendly software are used to manage the main processing functions, which include:
  • option to store (and recall) different work programs for the types of material;
  • conveyor speed and synchronism of the whole line, including loaders and connection roller conveyors;
  • beam movement (speed, customized programming of the acceleration and deceleration ramps);
  • anti-skid conveyor back-slipping correction on badly-sawn or curved slabs, for single slabs and packs of slabs;
  • continuous, automatic monitoring of abrasive brick wear for each single head, with video advice notes and warning signals before the tool is completely worn out;
  • option of disabling all, some, or just one slab, or even a portion of a slab (head, end, corner) that’s being processed.
Statistics
The PC is used to gather and process statistical data on production and consumption, such as:
  • production statistics (square metres produced per partial batch, per job order, per shift, progressive or total quantities)
  • tool wear statistics (square metres produced with the operating tool, square metres produced with the last replaced tool, etc.);
  • figures on machine availability (time: machine turned on, machine operating, machine in alarm state, etc.) alarm statistics;
  • maintenance scheduling with video alarm when preventive maintenance intervals are expired.
Remote diagnosis
The standard Luxmaster model comes with an advanced software solution for remote assistance (Internet connection with Breton required) for the remote trouble-shooting of any possible technical failure: a time and cost-saving solution, since technical service on the spot is no longer required.

Breton GREEN POWER: energy saving with the LUXMASTER

The Luxmaster has been designed to save energy. Two machine functions save a considerable amount of energy:
  1. through special drives, the “Energy Recovery” function transfers electrical energy generated during braking when the beam slows down, to the electrical grid, saving energy as a consequence;
  2. the “Stop & Go” function stops all the motors and utilities automatically once the machine no longer contains unpolished slabs and the belt conveyor has stopped moving. This minimizes energy consumption when the machine isn’t working. Once a new, unpolished slab has been fed into the machine and the conveyor belt has started, the software starts all the motors and utilities again automatically.

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