Autoclaved Aerated Concrete AAC horizontal cutting machine / AAC Block Cutting

JQF-4B autoclave aerated concrete cutter is a product of JQF-4 series, develop from moving cutting to constant power cutting, the cutter set is composed of four systems: longitudinal (horizontal) cutter, traverse cutter, cutting car  and rails. 
 

1. Cutting mode: 

After the poured blocks are turned over for ninety degrees in the air, hoisted to the cutting car and stripped off the mould frame, then the cutting car carried it to the longitudinal cutter and the traverse cutter position, and the longitudinal cutter and the traverse cutter will cut them on six sides. First of all, the longitudinal cutter cut the block longitudinally and horizontally on four sides. When this operation is completed, the cutting car will carry the block stay under the traverse cutter position, so that the block is cut vertically on the remaining two sides by the traverse cutter. After cutting is finished, the block will also carried by the cutting car to the position under semi-finished hoisting tool , then the semi-finished hoisting tool will hoisted the block to the steaming and curing wheelbarrow. Then the car will go back quickly ,carry the block for the next cutting mould. Cutting cycle is less than seven minutes.
 

2. Function of each system

a) Longitudinal cutter : Its function is to cut the block on the car on four sides (the two lateral sides and the top and bottom surfaces). After cutting, the block will have a size of 600 mm wide and 1200 mm high. At the same time, horizontal cutting will be performed according to the specifications of the product (height or width). In addition, necessary keyways will be milled on both ends of the block.
b) Traverse cutter : Its function is to cut the block on two ends so that the block after cutting will be the require length. At the same time, vertical cutting (from tom to bottom) will be performed in the middle of the block according to the specifications and the thickness of the product.
c) The cutting car is a special carrier for carrying the blocks to the cutting position.
d) The rails are special tracks for the cutting car.
 

3. Major technical specifications

a) Longitudinal cutter:
    i.Maximum overall dimensions: 
      6028 mm (long) × 2870 mm (wide) × 2550 mm (high without any load)
    ii.Mass: 3957 kg
    iii.Diameters of the cutting wires:
       Horizontal cutting: φ0.5 mm
       Longitudinal cutting: φ0.8 mm
b) Traverse cutter: 
    Maximum overall dimensions:
    5100 mm (long) × 2830 mm (wide) × 3525 mm (high )
   i. Mass: 6727kg
   ii. Speed reducer for vertical cutting: 
     Type: SKZN34C20T2,    Quantity: 1
     Form of assembly: b03
    Drive ratio: i=20
    Motor:
   Type: DEJ112MH-4G,    Quantity: 1
   Power: 4 kW    Speed: 1420 rpm
   Time needed for moving up and down: single way upward: 73 s, downward; 48.5 s
 iii. Speed reducer for the drive:
     Type: SKZH64C22.4i13 (R1)    Quantity: left and right side one apiece
     Drive ratio: 22.4
iv. Cutting swing (traverse cutting)
    Stepless speed reducer: 
    Type: MBW-40Y-3W1,    Quantity: 1
    Scope of speed regulation: 200 – 1000 rpm
    Motor: Y2-100L1-4    Quantity: 1
    Power: 3 kw    Speed: 1430 rpm
v. Amplitude of swing: 7.5 mm
vi. Diameter of the cutting wire: φ0.8 mm
 

c)Cutting car

i. Maximum overall dimensions:
 3720mm(long)×1650mm(wide)×753mm(high)
ii. Mass: 660kg
iii. Speed reducer for the move:
Type: BWN13-43-4    Cycloidal pinwheel speed reducer
Motor:   Retropack
Power: 4 kw

4. Structure: 

The main parts in the longitudinal cutter, traverse cutter and cutting car are all made of square or rectangular steel tubes. They feature high rigidity, long service lives, simple structure, easy installation and convenient adjustment.
a) The longitudinal cutter includes the following parts: portal frame, cross beam, vertical beam, cutting shaft, washing tank, longitudinal cutting wires, horizontal cutting wire, wire tensioning devices, etc.
b) The traverse cutter includes the following parts: portal frame, traverse cutting frame, bottom beam, guide shaft (its guide sleeve is a specially made lubricated bearing that needs no further lubrication), dual swinging devices for traverse cutting, drive unit for vertical cutting (up and down movement driven by sprocket and chain) and cutting wire.
c) The cutting car includes the following parts: bodywork, cutting frame, wheel and moving device. Its movement driven by speed reducer, use chain for the traction.
 

5. Operation

a) The cutting wires on the longitudinal cutter are stretched tight by the tensioning device so as to eliminate any possible slack. The front and rear cutting wires or cutting knives are positioned on either side. The front cutting wire serves to cut off the surplus material from the block while the rear cutting wire serves for trimming so that the accuracy of the 600 mm wide block can be maintained.
Horizontal cutting falls into five grades. The cutting wire cuts into the block at a tilted angle of 39°48’. The first advantage of such an arrangement is to allow the block to sink down horizontally in a stable way after the cutting and prevent any possible cracks on the block. Its second advantage is to prevent the block from collapse after the cutting is finished.
Each set of wires are provided with accurate scale positioning to guarantee good accuracy of the product.

b) When the block stop at the traverse cutting pisition, the traverse cutting begin cutting, its cutting process as follows: Vertical and traverse cutting will be done synchronously. Vertical cutting, driven by the SKZN34C20T2 speed reducer, will move from top to bottom. The speed reducer of the drive unit will drive the sprocket into operation so that the cutting frame moves up and down to complete the movement of vertical cutting. 
Traverse cutting is driven by the MBW-40Y-3W1 speed reducer. The swinging device composed of an eccentric unit drives the cutting wire to make a reciprocal motion to complete the movement of vertical cutting. The cutting wires on both ends will cut the block to a require length. In the middle the block will be cut according to product specifications.
Each set of cutting wires are tensioned by leaf springs and their accuracy is marked by measuring scales.
The cutting time fro each mould (up and down) is 121.5 seconds.

c) The cutting car is a special carrier of carrying the blocks for cutting. Its come-and-go movements driven by speed reducer,. When the sprocket wheel running, the chain moving, so the car moving.
 

6. Assembly:

Based on a frame structure, big parts like the longitudinal cutter ,the traverse cutter and cutting car are already assembled and tested before they are delivered ex works. What needs to be assembled on site just includes a small number of loose parts that have to be taken down due to shipping reasons.
a) Longitudinal cutter
Install the cutting wire, switch on the gas line. 
b) Traverse cutter
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