Paul Ernst - NEPTUN
NEPTUN The Modular Edge Treatment System
Deburring Technology With 100 % Flexibility • • • • •
Deburring Edge Rounding Oxide Removal Graining Washing and Drying
www.ernst-maschinen.de
NEPTUN Perfect deburring and finishing results. Operation in wet mode facilitates processing of any type of material in any sequence without risk of combustion. Produce clean, fully deburred parts safely. The modular concept lets you configure the machine according to your current requirements. And when they change you can react accordingly. Our Heavy Duty Processing Modules deliver deburring results setting today’s standard and guarantee longevity based on design excellence, quality components and workmanship.
www.ernst-maschinen.de
EN1000/102010
The Better Way to Finish Your Parts
NEPTUN
The Modules
Module
Deburring Drum
Module
Brush Rollers
Module
Rotor
Module
Grinding Belt
Module
Wash & Dry
Removes the burr without removing material form the surface
Break edges, round edges, oxide removal. Targeted results with corresponding choice of brush rollers
Provides maximum rounding of edges Consistent - both for heavy plate and thinner gauges Including upforms, PVC coated and galvanized parts
Creates a perfect surface finish after processing your edges
Clean parts thoroughly and dry both top and bottom
www.ernst-maschinen.de
Deburring
Edge breaking Edge rounding or removal of the oxide layer
Wash & Dry
Deburring
Extremely consistent and homogeneous edge rounding
Wash & Dry
Deburring
Edge rounding
Removal of the oxide layer
Wash & Dry
Deburring
Edge breaking Edge rounding or removal of the oxide layer
Surface finish
Wash & Dry
Deburring
Extremely consistent and homogeneous edge rounding
Surface finish
Wash & Dry
www.ernst-maschinen.de
EN1000/102010
Configuration Examples
Querbürsten Deburring Drum Module
Application Removal of Burr and Attached Dross (From Reflections and Piercing) Very flexible soft rubber foam deburring drum
Adapts to surface
Oscillating deburring drum
Creates consistent results
Mounted on an air cushion
Adapts to surface variations distortion and material variance are not a problem
Can be reinforced with a fiberglas sheet
Avoids cuts and tears in the abrasive when removing heavy burr
Simple rectangular abrasive sheets
Results in much lower abrasive consumables cost
Application of ScotchBrite TM
Allows processing of coated materials such as galvanized or PVC film as well as parts with upforms
Fast change over of abrasives
Increases throughput for your entire parts spectrum
www.ernst-maschinen.de
Module
Deburring Drum
Technical Data
Removal of material mainly around the contours
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
580 mm
Height
1650 mm
Power
12 kW
Amperage
24 A
Air Supply
6 bar
Air Consumption
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Removal of burr and Attached Dross
QuerbürsBrush Rollers ten Module
Application Breaking edges, rounding edges or removing oxide Large variety of results based on choice of brush rollers Counter - rotating pair of brush rollers
Give you consistent results on all edges
•
Stainless steel /steel wire - brush rollers
Eliminate sharp edges by forming edge
•
Fleece Rollers
Round edges uniformly and create a fine surface finish
•
Spring steel brush rollers
Remove laser oxide on the cutting surfaces in material up to 25mm thickness
•
Abrasive strip rollers
intense edge rounding
Pressure rollers independently suspended
Secure holding power regardless of material variance and distortion
Oscillating brush rollers
Lower abrasive consumption lower cost
Innovative design
Speeds up brush roller exchange - flexible in the application
www.ernst-maschinen.de
Module
Brush Rollers
Technical Data
Wire brushes
Spring steel brush rollers
Edge rounding
High Density Fleece Rollers
Abrasive strip rollers
Detail Spring steel wire
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
870 mm
Height
1650 mm
Power
12 kW
Amperage
24 A
Air Supply
6 bar
Air Consumption
80 Nl/min
Oxide layer removal www.ernst-maschinen.de
EN1000/102010
Application Breaking edges, rounding edges, removing oxide Multiple processes from greater tool variety
Querbürsten Rotor Module
Application Extreme edge rounding with very high consistency of all edges - for flat parts as well as parts with forms, also coated materials, i.e. galvanized or PVC
8 abrasive strip brush heads each 500 mm long
Very high processing speeds
Entire rotor unit spins itself
Very uniform and intense edge rounding on all inside and outside contours
Large brush diameter
Reliable high quality from long lasting tools
Rotation speeds on all axes controlled by variable frequency drives
Consistent results independent of the feed rate
www.ernst-maschinen.de
Module
Rotor
Technical Data
Application Intense and uniform rounding of all edges in any contour. For flat parts and parts with forms as well as any film coated and galvanized/aluminized parts
Rotation unit with 8 counter rotating brush rollers
... as well as heavy plate
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
2120 mm
Height
2130 mm
Power
20 kW
Amperage
40 A
Abrasive strip brush strip brush rollers
Top view Rotation unit
www.ernst-maschinen.de
EN1000/102010
Extreme edge rounding in thin gauge material...
Working Width
Querbürsten Grinding Belt Module
Application Surface finish – graining finish from a high end contact roller
Electronically controlled abrasive thickness adjustment
Fast setup
Belt centering control for dusty environment
Dependability
Option: frequency controlled RPM
Optimal surface finishing results
Option: switchable grinding direction
Your choice: smoother surface or higher material removal
Contact roller with customized rubber shore hardness
Perfection applied to each material and component
Wide variety of abrasives and gritsl
Individual surface pattern
Adjustable oscillation amplitude
Optimation of grain pattern
www.ernst-maschinen.de
Module
Grinding Belt
Technical Data
Grained stainless steel component
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
580 mm
Height
2130 mm
Power
20 kW
Amperage
40 A
Air Supply
6 bar
Air Consumption
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Surface finish - graining finish from a high end contact roller
Modul
Wash & Dry
Application Clean parts thoroughly and dry both top and bottom
Cleaning Nozzles with Rinsing Unit
Excellent Cleaning results with less laborious maintenance
Squeegee Rollers and Blower
Maximum Drying Performance, Minimum Energy Consumption
Integrated Compact Filter Unit
Full Accessibility with Compact Dimensions
www.ernst-maschinen.de
Module
Technical Data
Wash & Dry
Filter Unit
Cyclone Air / Water Separator
Arbeitsbreite
1500 mm
Materialstärke
0,8 – 100 mm
Breite
2704 mm
Länge
550 mm
Höhe
1650 mm
Leistung
5 kW
Stromaufnahme
10 A
Druckluftanschluss
6 bar
Druckluftverbrauch
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Clean parts thoroughly and dry both top and bottom
Accessory
Small Parts Template
Application Securely process small parts - any material and any geometry
Movable pins
Any geometry in small parts
Protruding pins
Reliably counter lateral processing forces
Variable pin Protrusion
Adjust pin height according to material thickness
Customized pin density
Template adapts ideally to your part size
www.ernst-maschinen.de
Accessory
Small Parts Template
Technical Data
Application Securely process small parts - any material and any geometry in any ERNST deburring system
Template with part after processing
Template with part before processing
500 mm
Length
500 mm
Thickness
ca. 20 mm
Pin Height
1 – 5 mm
Template after removal of part
www.ernst-maschinen.de
EN1000/102010
Template
Width
Querbürsten Options Futher
Machine Conveyors
Magnet for ferritic small parts (down to credit card size) Vacuum for small parts including stainless and aluminum alloys (down to post card size) Conveyor belt material according to application made from extremely wear resistant rubber.
Peripheral Equipment
Belt and roller conveyor tables Automatic gauge detection
Material
Abrasives and consumables available in a large selection
Service
Affordable maintenance contracts Competent advice and support Fast response times
Other than that ...
We also supply dry deburring/deslagging technology for customers who process single general types of materials
www.ernst-maschinen.de
www.hensel-web.de
3D-Illustration: cct:werbeagentur 2010
EN1000 102010
Perfect Finish – New Flexibility
Abweichungen durch Konstruktionsänderungen vorbehalten.
NEPTUN: The modular wet mode edge treatment system
Paul ERNST Maschinenfabrik GmbH Alte Meckesheimer Str. 74927 Eschelbronn Germany Telephone +49 6226 9504-0 E-Mail: [email protected] www.ernst-maschinen.de
Deburring Technology With 100 % Flexibility • • • • •
Deburring Edge Rounding Oxide Removal Graining Washing and Drying
www.ernst-maschinen.de
NEPTUN Perfect deburring and finishing results. Operation in wet mode facilitates processing of any type of material in any sequence without risk of combustion. Produce clean, fully deburred parts safely. The modular concept lets you configure the machine according to your current requirements. And when they change you can react accordingly. Our Heavy Duty Processing Modules deliver deburring results setting today’s standard and guarantee longevity based on design excellence, quality components and workmanship.
www.ernst-maschinen.de
EN1000/102010
The Better Way to Finish Your Parts
NEPTUN
The Modules
Module
Deburring Drum
Module
Brush Rollers
Module
Rotor
Module
Grinding Belt
Module
Wash & Dry
Removes the burr without removing material form the surface
Break edges, round edges, oxide removal. Targeted results with corresponding choice of brush rollers
Provides maximum rounding of edges Consistent - both for heavy plate and thinner gauges Including upforms, PVC coated and galvanized parts
Creates a perfect surface finish after processing your edges
Clean parts thoroughly and dry both top and bottom
www.ernst-maschinen.de
Deburring
Edge breaking Edge rounding or removal of the oxide layer
Wash & Dry
Deburring
Extremely consistent and homogeneous edge rounding
Wash & Dry
Deburring
Edge rounding
Removal of the oxide layer
Wash & Dry
Deburring
Edge breaking Edge rounding or removal of the oxide layer
Surface finish
Wash & Dry
Deburring
Extremely consistent and homogeneous edge rounding
Surface finish
Wash & Dry
www.ernst-maschinen.de
EN1000/102010
Configuration Examples
Querbürsten Deburring Drum Module
Application Removal of Burr and Attached Dross (From Reflections and Piercing) Very flexible soft rubber foam deburring drum
Adapts to surface
Oscillating deburring drum
Creates consistent results
Mounted on an air cushion
Adapts to surface variations distortion and material variance are not a problem
Can be reinforced with a fiberglas sheet
Avoids cuts and tears in the abrasive when removing heavy burr
Simple rectangular abrasive sheets
Results in much lower abrasive consumables cost
Application of ScotchBrite TM
Allows processing of coated materials such as galvanized or PVC film as well as parts with upforms
Fast change over of abrasives
Increases throughput for your entire parts spectrum
www.ernst-maschinen.de
Module
Deburring Drum
Technical Data
Removal of material mainly around the contours
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
580 mm
Height
1650 mm
Power
12 kW
Amperage
24 A
Air Supply
6 bar
Air Consumption
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Removal of burr and Attached Dross
QuerbürsBrush Rollers ten Module
Application Breaking edges, rounding edges or removing oxide Large variety of results based on choice of brush rollers Counter - rotating pair of brush rollers
Give you consistent results on all edges
•
Stainless steel /steel wire - brush rollers
Eliminate sharp edges by forming edge
•
Fleece Rollers
Round edges uniformly and create a fine surface finish
•
Spring steel brush rollers
Remove laser oxide on the cutting surfaces in material up to 25mm thickness
•
Abrasive strip rollers
intense edge rounding
Pressure rollers independently suspended
Secure holding power regardless of material variance and distortion
Oscillating brush rollers
Lower abrasive consumption lower cost
Innovative design
Speeds up brush roller exchange - flexible in the application
www.ernst-maschinen.de
Module
Brush Rollers
Technical Data
Wire brushes
Spring steel brush rollers
Edge rounding
High Density Fleece Rollers
Abrasive strip rollers
Detail Spring steel wire
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
870 mm
Height
1650 mm
Power
12 kW
Amperage
24 A
Air Supply
6 bar
Air Consumption
80 Nl/min
Oxide layer removal www.ernst-maschinen.de
EN1000/102010
Application Breaking edges, rounding edges, removing oxide Multiple processes from greater tool variety
Querbürsten Rotor Module
Application Extreme edge rounding with very high consistency of all edges - for flat parts as well as parts with forms, also coated materials, i.e. galvanized or PVC
8 abrasive strip brush heads each 500 mm long
Very high processing speeds
Entire rotor unit spins itself
Very uniform and intense edge rounding on all inside and outside contours
Large brush diameter
Reliable high quality from long lasting tools
Rotation speeds on all axes controlled by variable frequency drives
Consistent results independent of the feed rate
www.ernst-maschinen.de
Module
Rotor
Technical Data
Application Intense and uniform rounding of all edges in any contour. For flat parts and parts with forms as well as any film coated and galvanized/aluminized parts
Rotation unit with 8 counter rotating brush rollers
... as well as heavy plate
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
2120 mm
Height
2130 mm
Power
20 kW
Amperage
40 A
Abrasive strip brush strip brush rollers
Top view Rotation unit
www.ernst-maschinen.de
EN1000/102010
Extreme edge rounding in thin gauge material...
Working Width
Querbürsten Grinding Belt Module
Application Surface finish – graining finish from a high end contact roller
Electronically controlled abrasive thickness adjustment
Fast setup
Belt centering control for dusty environment
Dependability
Option: frequency controlled RPM
Optimal surface finishing results
Option: switchable grinding direction
Your choice: smoother surface or higher material removal
Contact roller with customized rubber shore hardness
Perfection applied to each material and component
Wide variety of abrasives and gritsl
Individual surface pattern
Adjustable oscillation amplitude
Optimation of grain pattern
www.ernst-maschinen.de
Module
Grinding Belt
Technical Data
Grained stainless steel component
Working Width
1500 mm
Material Thickness
0,8 – 100 mm
Width
2704 mm
Depth
580 mm
Height
2130 mm
Power
20 kW
Amperage
40 A
Air Supply
6 bar
Air Consumption
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Surface finish - graining finish from a high end contact roller
Modul
Wash & Dry
Application Clean parts thoroughly and dry both top and bottom
Cleaning Nozzles with Rinsing Unit
Excellent Cleaning results with less laborious maintenance
Squeegee Rollers and Blower
Maximum Drying Performance, Minimum Energy Consumption
Integrated Compact Filter Unit
Full Accessibility with Compact Dimensions
www.ernst-maschinen.de
Module
Technical Data
Wash & Dry
Filter Unit
Cyclone Air / Water Separator
Arbeitsbreite
1500 mm
Materialstärke
0,8 – 100 mm
Breite
2704 mm
Länge
550 mm
Höhe
1650 mm
Leistung
5 kW
Stromaufnahme
10 A
Druckluftanschluss
6 bar
Druckluftverbrauch
5 Nl/min
www.ernst-maschinen.de
EN1000/102010
Application Clean parts thoroughly and dry both top and bottom
Accessory
Small Parts Template
Application Securely process small parts - any material and any geometry
Movable pins
Any geometry in small parts
Protruding pins
Reliably counter lateral processing forces
Variable pin Protrusion
Adjust pin height according to material thickness
Customized pin density
Template adapts ideally to your part size
www.ernst-maschinen.de
Accessory
Small Parts Template
Technical Data
Application Securely process small parts - any material and any geometry in any ERNST deburring system
Template with part after processing
Template with part before processing
500 mm
Length
500 mm
Thickness
ca. 20 mm
Pin Height
1 – 5 mm
Template after removal of part
www.ernst-maschinen.de
EN1000/102010
Template
Width
Querbürsten Options Futher
Machine Conveyors
Magnet for ferritic small parts (down to credit card size) Vacuum for small parts including stainless and aluminum alloys (down to post card size) Conveyor belt material according to application made from extremely wear resistant rubber.
Peripheral Equipment
Belt and roller conveyor tables Automatic gauge detection
Material
Abrasives and consumables available in a large selection
Service
Affordable maintenance contracts Competent advice and support Fast response times
Other than that ...
We also supply dry deburring/deslagging technology for customers who process single general types of materials
www.ernst-maschinen.de
www.hensel-web.de
3D-Illustration: cct:werbeagentur 2010
EN1000 102010
Perfect Finish – New Flexibility
Abweichungen durch Konstruktionsänderungen vorbehalten.
NEPTUN: The modular wet mode edge treatment system
Paul ERNST Maschinenfabrik GmbH Alte Meckesheimer Str. 74927 Eschelbronn Germany Telephone +49 6226 9504-0 E-Mail: [email protected] www.ernst-maschinen.de
