LUXMASTER KFT 5000 Marble Polishing Systems

Luxmaster KFT 5000- High production line for polishing marble slabs

LUXMASTER: THE TRENDSETTER IN MARBLE POLISHING

Marble 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 marble 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.

Breton special plates with 10 abrasive bricks

For high efficiency, each spindle is equipped with a specifically engineered, Breton abrasive brick holding plate with a diameter of 560mm that holds 10 abrasive bricks, which ensures an extremely high marble polishing capacity and work stability for perfect and uniform polishing even up to the edges of the material.

The special Breton plates have an exclusive one-way shock-absorbing system ensuring correct flexibility as well as homogeneous and optimal working pressure.

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.
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 KFT 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.

Slab cleaning

A rubber wiper fixed at the machine outlet removes water from the slab surface.

A pneumatically controlled spindle, integral with the beam and holding an optional brush, cleans the slabs once they are polished.

The spindle is raised and lowered automatically each time a slab passes.

Accident-prevention, sounddeadening 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 and sounddeadening panels have a sandwich-like structure made of ABS and polyurethane.

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.