PILATUS- ROLLER TURNING MACHINE - pilatus-ag.ch

PILATUS- ROLLER TURNING MACHINE
SWISS QUALITY
1007e1

PILATUS
M a s c h i n e n b a u A G
A revolutionary invention
roller turning machine
Roller turning mills crush loamy earth mixed with stones between two rolls rotating against each
other. The rolls are made of chilled cast iron or chrome steel. A rough material result from the
grinding process and at the end of a long production chain bricks, tiles and other such products
are obtained. During the grinding process the rolls are worn out irregularly. In the past, these
rolls were ground back into on approximately cylindrical shape from time to time using very
simple grinding devices. This no precisely, extremely dust- and time intensive way of grinding
(8 to 10 hours per roll) however, did not lead to a satisfactory result.
The company PILATUS Maschinenbau AG saw this problem and in the seventies developed
the idea not to process the rolls by grinding but by turning in the dry system procedure.
Subsequently PILATUS constructed the first special machine to work the rolls by turning
automatically, precisely and in short time.
The so-called "roller turning machine" was a revolutionary invention for the brick and tile
industry of that time. It brought a decisive improvement of the working conditions worldwide and
at the same time an acceleration of the production cycle.
Up to now more than 2500 PILATUS roller turning machines are in action worldwide. PILATUS
roller turning machines can be combined with roller mills of all makes and are available for all
roller widths.
Thanks to long experience in the machining of rolls on the roller mill, PILATUS has an
enormous professional knowledge, which continually flows into the technical development of
new roller turning machines.

PILATUS
M a s c h i n e n b a u A G
The development
roller turning machine
1978 PILATUS Maschinenbau AG develops the first roller turning machine on the world
market.
The ability to machine the rolls cylindrically directly and exactly on the roller mill is responsible
for a fast and relevant change in the brick and tile industry. The change from the dust intensive,
time-consuming and inexact grinding device to the clean, fast and precise roller turning
machines sets ideal conditions for the production of an optimal end-product and for the
acceleration of the production cycle.
1989 The first roller-turning machine with two turning tools for significantly reduced
turning time.
The experience of the first years lead to the special development of the roller turning machine
with two turning tools (TWIN system). Together with the reduced turning times, the TWIN
system is suitable for the application where the lateral space situation is limited.
1994 The roller turning machines with the anti-vibration system (VIBRA/P) for better
protection and ease of operation.
With the development of the anti-vibration system (VIBRA/P) the user is for the first time given
the guarantee to leave the roller turning machine permanently on the roller mill without any
damage. The up till now valid recommendation of the manufacturer to remove the roller-turning
machine from the roller mill after each turning operation is no more necessary. The antivibration
system, which is integrated into the basement of the roller-turning machine neutralises
all shaking during the grinding process.
1997 Fundamental change on the roller turning machine concept for faster cutting
speed.
Thanks to the change of the guide-way geometry the power function between the guide-way
and the carriage is considerably improved.
Higher cutting thrusts are significantly better received, and it is possible to drive with an up to
40 % faster cutting speed. Electro technical improvements lead to a complete feed drive
renewal. The unit, motor and electronic control equipment, sets new standards in the rollerturning
machine driving quality.
2000 A new machine bed allowing higher precision and expanded life.
The newly developed machine bed with over dimensioned ribs and solid wall strengths stands
for a up till now unreached consistency, which plays an important role during the turning
process.
2006 The new control system with even greater reliability and simpler usage.
The control system is special for its simple usage, its variable rotation speed, its compact way
of construction, as well as its minimal current consumption. It may be added to all PILATUS
roller turning machines as well as machines of other makes.

Advantages
PILATUS
M a s c h i n e n b a u A G
General:
Swiss quality product
market leading with more than 25 years of experience
world-wide more than 3000 machines in service
suitable to roller mills of all makes
2 years of guarantee
high performance and long life
easy to service
excellent product assistance
Cast iron bed / carriage
supersized wall thickness
strong ribbing
adjustable wearout bars
big and annealed slideways
Greasing
simple central lubrication with high performance
long-term lubrication of the gearing mechanism
Drive:
central drive on the carriage
motor and controller plug connection
short circuit prooved
mechanical overload cut off
electromechanic limit switches
infinitely variable
roller turning machine

The types
PILATUS
M a s c h i n e n b a u A G
roller turning machine
The types are different in the construction height, one type has a flat, and the other type has a
high machine bed. To make the right choice of the machine bed the fitting dimensions of the
different roller mill types must be considered.
The WDM-GL roller turning machine
(with a high bed)
The WDM/P-GL roller turning machine
(with a low bed)

PILATUS
M a s c h i n e n b a u A G
The turning systems
roller turning machine
The SINGLE-POINT roller turning machine
while turning with one cutting tool, with minimal
material removal.
Ideal for roller widths up to 2000 mm.
The machining time of a roller width of 1000 mm
is approx. 30 min.
The TWIN roller turning machine
while turning with two cutting tools, with
minimal material removal.
Ideal for roller width from 1200 mm on,
but also suitable for smaller roller widths.
This system has been developed to
minimise the cutting time, i.e. the
production breakdown. The machining
time of a roller width of 1000 mm is
approx. 15 min.

PILATUS
M a s c h i n e n b a u A G
roller turning machine
Construction and method of construction
1. Prism- flat guideway
2. Motor
3. Operating light
4. Feed speed
5. Control system
6. Left/right switch
7. Centralized lubricating system
8. Scraper
9. V-Ledge
10. Handwheel
11. Machine bed
12. Stop switch
13. Handwheel
14. Cross slide
15. Advance feed control lever
16. Wing nut
17. Worm gearing
18. Lifting cog
19. Gear rack
Slide
The slide is guided on the machine bed (11) by a vee- and a flat guide (1).
The guides are lubricated by the central lubrication system (7).
To protect against wear to the guide surfaces and scrapers (8) remove adhering chips and dirt before
processing.
Infeed
The infeed to the slide is moved lengthwise by means of a rack and pinion drive (19). The power for this is
fed in by a handwheel (10) or an infeed motor (2) via cogwheels and a worm drive (17).
By displacing the cog wheels (drive wheels) or the dog clutch, the infeed can be connected to operate
manually or under power.
After setting the lever switch (15) to "manual operation" the slide can be moved lengthwise by operating the
handwheel (10).
After setting the lever switch (15) to "power drive" the slide can be moved lenghtwise by means of the infeed
motor (2).
The lenghtwise travel of the slide is limited by the limit stop switch(12) and the lifting cog (18).
Infeed motor
The infeed motor (2) is fitted to a splined shaft, making it simple and rapid to remove. It is held in position by
a wing nut (16).
Control-system
The control system (5) is easy to remove. It is plugged into the cross slide and is connected to the mains
supply and the infeed motor by means of a rapid-release connection with stop switches (12).
The operating light (3) shows when the machine is ready for use.
The toggle switch (6) is used to set the rotational direction of the motor.
The control knob (4) is turned to set the infeed speed.
Cross slide
The cross slide (14) is held in a swallow-tail guide. Its play is set by means of a V-ledge (9).
Moving the cutter tool can be done by means of a threaded spindle and a handwheel (13.) There is a scaled
ring by the handwheel (13) with a vernier scale. The cut can be read exactly by means of the scale marks.

Machine bed
PILATUS
M a s c h i n e n b a u A G
The most important requirement for a precise and ideal roller gap.
roller turning machine
The PILATUS- machine bed The conventional machine bed
Only PILATUS specially designed roller Conventional proprietary roller turning
turning machine bench has the capacity machine benches are faulty to the point to
indefinitely contend with the high- of allowing major deviations.
stress demands of roller mill operation.

Substruction
PILATUS
M a s c h i n e n b a u A G
Construction of turning machine on retro- fitting.
roller turning machine
For all rolling mills, the cutting heights can be adjusted with base plates, segments and
consoles.
Construction with consoles and segments

PILATUS
M a s c h i n e n b a u A G
Vibra/P- System
roller turning machine
Strong roller mill shaking and percussions during the grinding process, without any effective
protection, lead to damage to the roller turning machine. The anti-vibration system VIBRA/P
offers the necessary safe protection.
The Anti-Vibration System (VIBRA/P)
Thanks to the integration of the VIBRA/P system vibration
damages are excluded. With it the roller-turning machine
can also be left on the roller mill during the grinding
process without any damage. The anti-vibration system is
integrated into the base of the roller-turning machine (see
picture on the left).

PILATUS
M a s c h i n e n b a u A G
Complete revision
Work of revision:
- visual damage examination
- disassemblage of the machine
- cleaning of the machine components
- to hob, harden and grind the machine bed guideways
- to hob and fit the guide-ways of the plain turning
slide
- to hob and grind the guide of the cross slide
- to fit the new play differential gib of the cross slide
- replacement of the key screw joints
- to wash the oil channels
- to clean and control the drive mechanism
- to replace damaged bearings and gear wheels in
the drive mechanism
- to replace the pinion shaft to gear rack in case of
wear
- to grease the drive mechanism
- to remill, possibly replace the grinding sockets
- partial replacement of the screw set
- replacement of the spindle with nut, of the plain
turning slide
roller turning machine
- replacement of the missing handwheels and
cranks
- replacement of the oil scraper
- replacement of the control device by the new type
60
- replacement of the feed gear motor by the new
type 60
- replacement of the limit switch installation
- replacement of the pressure plate
- replacement of the stop units and rails
- new varnish color of the complete machine
- assemblage
- setting work of the play differential gib and of the
grinding sockets
- rust protection
- function control

References:
A small selection of our customer stem.
Germany Denmark
Händle GmbH
DE-75417 Mühlacker
BMS GmbH – Kema Görlitz
DE-02826 Görlitz
FAM
Magdeburger Förderanlagen
und Baumaschinen GmbH
DE-39112 Magdeburg
Janinhoff GmbH & Co KG.
DE-48163 Münster
AKA-Keraba
DE-31226 Peine
WIENERBERGER GmbH & Co.
DE-30637 Hannover
Skamol A/S
DK-7884 Fur
Vedstaarup Teglværk A/S
DK-5610 Assens
France
KORAMIC S.A.
FR-25170 Lantenne-Vertière
LAFARGE COUVERTURE
FR-75013 Paris
Imerys TC
FR-31773 Colomiers
Italy
STIV s.n.c.
IT-53048 Sinalunga (Siena)
Marocco Japan
Briqueterie Bati Chaouia S.A
Ma-Berrechid
Makino
JP-479 Tokoname
Saudi Arabia Belgium
Al Khayyat Red Buricks Mfg.
SA-Jeddah 21471
ROLLER TURNING MACHINES
BRIQUETERIE DE
PLOEGSTEERT s.a.
BE-7783 Ploegsteert