Roller Grinding Technology

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2 welcome We are providing solutions now which make a real improvement to our customers workflow and reduce running costs immediately. This investment in new technology and plant through our turnkey approach is reflected directly in their bottom line and our success Carl Slingsby Managing Director Optimus... a total commitment to effective solutions.002

3 Optimus The Optimus Approach Knowledge, experience and expertise Welcome to Optimus Wizard, the roller grinding solution which offers excellent quality and value with a compact footprint A Different Approach Optimus has been developed for the specific requirements of rubber roller manufacturing. Historically, this is an industry where new technology and mechanical developments do not occur very often, and a market which relies on legacy machinery. Optimus is designed to improve roller quality, increase consistency, develop efficiencies and extend productivity on the shop floor. To achieve this we have utilised the latest technology combined with the best of traditional engineering. In return this provides the roller manufacturer with a real alternative - a Grinder which is easy to use for all employees and can contribute to your bottom line from day one. Budgets, levels of quality, style and types of rollers will be different for every roller manufacturer and we understand this situation intimately having been manufacturers and service agents to the industry for many years. The Optimus range recognises this requirement for flexibility and is therefore split into three distinct model groups, Wizard, Latitude & Ultra. Wizard Range The Wizard range featured in this brochure is designed to offer excellent value for money. An entry level model is available for basic parallel grinding, through to a highly sophisticated profile grinder. Installing a Wizard component will allow your business to maximize its existing technology across the full range of complex roller shapes. The Wizard range is designed to be retro fitted to almost any type of centre lathe or grinder. Wizard 1 is a basic but robust parallel grinder. Wizard 2 has extended features such as Touch Screen programming for profiled rollers. The Wizards can be powered by either 7.5kw, 11kw or 18kw motors. This flexibility is enhanced further as the motors can be specified with an infinitely variable inverter drive. Grinding wheel speeds can be achieved from 500 to 5800 rpm in one rev increments. Fine tuning of the wheel speed can contribute to the speed and quality of the finished product. All Wizard models and options are easy to use and the compact design is unlikely to affect your normal turning operations when not in use. On completion of the build, each Wizard completes many hours of testing before shipping. You can be confident that you will receive your British engineered Wizard in the best possible condition and benefit from the most reliable products available on the market today..003

4 benefits Optimus Benefits Thinking beyond the box Having worked in the roller industry for many years both as a manufacturer of rollers and as a service agent, Rollertech understand the pressures that affect your business - reliance on highly skilled staff, energy consumption, factory floor space and the increasing need for more efficiency in a cost conscious commercial environment. We have taken those needs as a start point and developed key aspects of our roller grinding solutions to answer them, providing you with a direct boost to your bottom line. Our aim is to combine the very best of old and new... traditional engineering and tooling quality along with the latest thinking on electronics and control systems Quality engineering with high technology - modern, fit for purpose and robust solutions. Intuitive control system - requires less training and more easily deployed to staff. Digital screens on most models. Improved ease of use - over competitor equipment. Efficient, ergonomically designed plant - providing improved comfort, access and control. Compact footprint - less real estate lost on the factory floor. Multi-feature machines - mean more efficiency and lower plant levels. Compact headstock - with improved ease of use. Integrated electrics in build - less setup time with plug and play. Andrew Fairbank Operations Manager Flexible range - machines available for simple through to complex grinding applications. One piece lift, transport and installation - less cost and down time..004

5 Wizard Optimus Wizard Model shown Wizard kw PLC Controlled Multi Profiled Grinder.005

6 Wizard 1 Optimus Wizard 1 Parallel Grinder The Wizard 1 can regenerate and old lathe into a modern, efficient grinder The Wizard 1 is a specially designed grinding attachment that can be retro-fitted to any type of centre lathe for parallel grinding. Although this is an entry level machine in terms of cost, it benefits from the latest CAD system and years of engineering experience. It is lightweight and robust which provides enhanced performance and greater rigidity, with less stress on the lathe slide way system. The standard model has a 7.5kw special high torque, two pole 2800 rpm motor. This can be increased to 11kw and both sizes can be specified with an infinitely variable inverter drive. For a business that needs the flexibility to grind rollers of differing diameters, this variable speed option allows the operator to adjust the grinding wheel speed from 500 to 5800rpm, selectable in one revolution increments. The Wizard 1 can regenerate an old lathe into a modern, efficient grinder. The reliability, high quality and simplicity it provides are key benefits. You can be confident that an investment in any model from the Wizard range will improve your workflow and profitability from the very first roller..006

7 Wizard 2 Optimus Wizard 2 PLC Controlled Multi Profile Grinder The Wizard 2 can allow companies to enter new markets or enhance their competitive edge in an existing market This Wizard 2 grinder builds on the advantages and features of the entry level Wizard 1. It is capable of grinding the most complex of roller profiles with ease, providing added confidence for the machine operator. This is achieved in part through our advanced software engineering on the Omron PLC, combined with an intuitive 8.5 Touch Screen panel from which the operator can control it. The motor options range through 7.5kw, 11kw and up to 18.5kw. The latter sized motor provides the Wizard 2 with flexibility for those customers who wish to utilize large grinding wheels. Features include CNC linear bearing slideway technology for the wheel head travel, in addition to a high precision recirculating ballscrew drive from a servo motor - this technology ensures that the Wizard 2 delivers micron accuracy. The Wizard 2 can allow companies to enter new markets or enhance their competitive edge in an existing market. You can be confident that this investment will improve your workflow, and profitability from the very first roller..007

8 Wizard 2 Optimus Wizard 2 PLC Controlled Multi Profile Grinder Wizard 2 Control Screens Main control screen Cambered Roll Inverted Cambered Roll Manual MDI Jog Control Machine Setup Parallel Roll Multi Cambered Roll Inverted Multi Cambered Roll.008

9 technical Technical Specifications Wizard Range SPECIFICATION WIZARD 1 WIZARD 2 7.5kw (10hp) 25amps 2 pole 2800rpm fixed speed Option Option 7.5kw (10hp) 25amps 2 pole 5800rpm variable speed Option Option 11.0kw (15hp) 30amps 2 pole 2800rpm fixed speed Option Option 11.0kw (15hp) 30amps 2 pole 5800rpm variable speed Option Option 18.5kw (23hp) 32amps 4 pole 1440rpm variable speed - Option IP rating of IP55 on all motors Standard Standard Electrical panel and isolator Standard Standard Start / Stop push buttons on an operator station Standard Standard SPECIFICATION WIZARD 1 WIZARD colour TFT touch screen - Standard Omron PLC complete with all roller profiles pre programmed - Standard Graphical representations of all profiles for ease of use - Standard Bed error compensation programme included in software - Standard Precision ground ballscrew for enhanced accuracy - Standard BSEN electrical principles Standard Standard Wheel hub designed for 305mm (12 ) bore - Option Wheel hub designed for 127mm (5 ) bore Standard Option Wheel guarding Standard Standard Integrated 160mm (6 ) extraction port Standard Standard Operator instruction manual Standard Standard Electrical schematic drawings Standard Standard 380 / 415 V AC 50/60Hz Option Option Tungsten Carbide grinding wheel max dims. 350 x 60 x 127 (13.75 x 2.4 x 5 ) Dual or Single Grit Resin bonded grinding wheel max dims. 350 x 60 x 127 (13.75 x 2.4 x 5 ) Resin bonded grinding wheel max dims. 660 x 75 x 305 (26 x 3 x 12 ) Option Option Option Option - Option CE compliant Standard Standard CNC linear bearing slideway technology - Standard Wheelhead travel with micron accuracy - Standard AC servo motor with integrated encoder for X axis - Standard 1m (39.4 ) Z axis measuring scale - Standard Additional 1m (39.4 ) Z axis measuring scale - Option Automated wheel balancing system for 305mm (12 ) hub - Option Installation and commissioning Option Option.009

10 Optimus Machine Technical Drawings Wizard 1 7.5/11kw motor with ø rpm Please note: these drawings are provided for illustration purposes only. Detailed elements may be changed without notice by Rollertech..010

11 Optimus Machine Technical Drawings Wizard kw motor with ø660 1,000rpm Please note: these drawings are provided for illustration purposes only. Detailed elements may be changed without notice by Rollertech..011

12 Optimus Machine Technical Drawings Wizard 2 7.5/11kw motor with ø350 5,800rpm Please note: these drawings are provided for illustration purposes only. Detailed elements may be changed without notice by Rollertech..012

13 lathe layout Customer Machine Layout Please print this page, fill in the information panel and fax back to Rollertech.013

14 contact Contact Information Rollertech UK Limited Unit 8 Willows Business Park Shelley, Huddersfield HD8 8LU, England Telephone. +44 (0) Facsimile. +44 (0) info@rollertech.co.uk Rollertech Pedigree Company History: Established 1999 Location: UK, Europe Outlook: Global customer base and outlook The key advantage that Rollertech brings to customers is that we understand the roller grinding industry intimately. Created in 1999, our objective today is to provide innovative roller manufacturing solutions for new, existing and future rubber manufacturers. Initially, Rollertech ran alongside our successful rolller manufacturing company for 10 years until Tyke Rollers closed in The unique Tyke Open Door policy allowed visitors a great opportunity to see the realisation of new ideas and technology working in a commercial environment. This collaborative atmosphere, in addition to our existing industry experience, created the foundations of the solutions we are proud to offer today including the very successful Three Roller Builder. Our current milestones include having the three roll builder working on every continent and a provision for full or part Turn Key factory projects and installations in future. With this significant experience and development approach Rollertech have the expertise and experience to advise customers on each individual process within the manufacture of rubber rollers. With our close support the significant machinery investment you make in your business can then operate to its maximum potential..014

15 IMPORTANT NOTICE: Rollertech Limited is constantly seeking ways to improve the specification, design and production of its products and alterations will take place periodically. While every effort is made to produce up-to-date literature, this brochure should not be regarded as an infallible guide to current specifications, nor does it constitute an offer for sale of any particular piece of equipment. The contents of this brochure represent the company s business as a whole. Text and photographs may relate to specifications not available for sale on some derivatives. Performance results may vary depending on the specification of the particular equipment and factory conditions. Published figures should be used for comparison purposes only and verification should be sought directly from Rollertech. Limited by any express or implied undertaking or representation. V.2 May 2010 Rollertech