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Echidna NewsWhat was needed was a specially designed machine that would have a large metal blade.
A test with a small test unit confirmed that this kind of saw did indeed cut the slab, and that started off the project.
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A test with a small test unit confirmed that the metal saw did indeed cut the slab.
There were three main issues to be dealt with. Firstly, the blade needed to be lowered gently onto the slab so that the teeth were not torn off on impact. Secondly, the saw needed to be precisely aligned with any previous cuts. Thirdly, the whole unit needed to be absolutely steady and free of vibration.
The design of the machine commenced in August 2008 by Echidna's top engineer and designer, Dr George Fischer. George has a background in materials science, engineering and mining engineering and has been designing and developing a wide range of precision machinery for many years.
It was worth a try but unlikely to succeed. Although the saw did cut, the going was slow and, as predicted by the Echidna engineer on site at the test, a diamond saw was not the machine for the job.
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Test cut with D3 diamond saw
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What was needed was a specially designed saw that would have a large metal cutting blade.
The problem with this kind of blade, however, is that it is easy to break the tips off, it requires a very steady and constant feed rate and an excavator is not an instrument capable of meeting these requirements.
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The machine was completed by mid-November of 2008. When the client first saw it, shortly before it was commissioned, they were amazed that such a machine could have been produced in less than 2 years. It actually took 10 weeks from start of design to completion.
The finished machine is of a gantry type, weighing in at a little over 8 tonnes.
The saw blade is driven by two hydraulic motors, geared down by two Sumitomo CycloDrive speed reducers to give an output torque in excess of 40,000 Nm and an absolutely steady speed output of 8 rpm.
The motors were run from the hydraulics of the host 45t excavator.
The horizontal and vertical movement of the gantry are driven by another set of orbitl hydraulic motors that are driven from an auxiliary hydraulic system powered by a diesel motor.
The machine is put into position by the excavator and lowered to the ground. From there, the excavator operator can initiate the cut using a radio operated remote control unit from a distance up to 1 km.
As the excavator operator does not need to operate the saw during the cut, only one person is needed to operate the two machines.
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The project was completed in conjunction with civil engineering firm Select Civil Pty Ltd who supplied the excavators and operators.
The hydraulic components and remote control device were supplied by Southcott Pty Ltd.
The CycloDrive speed reducers were supplied by Sumitomo Drive Technologies in Sydney.
The design, frame construction and machine assembly and testing were done at Echidna's workshop.
Echidna uses Australian materials and workmanship whereever possible in all of its projects.
