Skiver Cutting Unit TYRE 800 Truck

Industria Elettromeccanica Commerciale Italiana
Milanese S.r.l.
Via Muoni N16, 20064 Gorgonzola MILAN, ITALY
Tel: (+39) 02.951.5551 Fax: (+39) 02.951.5784
E-mail: iecim@iecim.191.it
SKIVER CUTTING UNIT
TYRE 800 TRUCK
SAFETY AT WORK AND FUNCTIONAL

DESCRIPTION MANUAL
SANTO ANDRE
Skiver Cutting Unit TYRE 800 Truck
Contents:
Page:
1.
GENERAL SAFETY ADVICE
1.1
Warnings and safety instructions Explanation of symbols
1.2
Intended use
1.2.1
Improper use
1.2.2
Inadmissible use
1.3
Safety at work advice
1.3.1
General instructions
1.3.2
Work carried out whilst the line is in operation
13
1.3.3
RESIDUAL RISK __________________________________________
14
1.4
List of most important safety signs
2.
FUNCTIONAL DESCRIPTION
18
2.1
SKIVER CUTTER
26
2.2
Dancer Roll
40
2.3
Tread Centering Unit
2.4
15
____________________
41
Pressing Roller
_____________________
42
2.5
Measuring Unit
_____________________
43
2.6
Pressing Fingers Group
____________________
44
3.
TABLES OF LUBRICANTS
___________________
45
4.
DRAWINGS LIST
______________________
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1.
GENERAL SAFETY ADVICE
1.1
Warnings and safety instructions Explanation of symbols

Important operating and safety instructions that are to be strictly observed to avoid
personal injury or damage to the machine are set off as follows:
NOTE This term is used to identify important information on the machine and its subassemblies as well as safety instructions and other
Note !
important information to be strictly observed to ensure correct and safe

use and operation to the machine.
ATTENTION Failure to observe safety instructions and procedures

(precautionary measures in accordance with the regulations for the
Attention !
prevention of accidents or as specified in these operating instructions)

preceded by the term Attention! may cause minor injury and/or
damage to the machine.
WARNING Failure to observe safety instructions and procedures
identified by the warning symbol may cause severe injury and/or
damage to the machine.
DANGER Failure to observe safety instructions and procedures
identified by the danger symbol will inevitably cause severe injury, fatal
accidents and/or severe damage to the machine.
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1.2
Intended use
The Skiver Cutting Unit TYRE 800 is designed for the cutting of un-vulcanized semifinished rubber products (treads).
1.2.1
Improper use
Any use of the Cutting Unit not in accordance with the definition in section 1.2
or with technical data specified in this manual or in other machine documentation
is improper. The user of the equipment is fully responsible for any damage to persons, to the machine or to the other equipment. The user is also responsible for
inadequate operating results arising from improper use of the equipment.
Failure to observe EU, UVV (Regulations for the prevention of accidents) regulations, occupational safety and disposal requirements or operating and safety
instructions is equally considered improper use.
1.2.2
Inadmissible use
Any use of the equipment not in accordance with the safety or operating instructions or with the intended use is inadmissible.
Note !
The manufacturer declines any responsibility for damage resulting from

use not in accordance with the operating instructions or from incorrect
use or operation of the machine.
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1.3
Safety at work advice
1.3.1
General instructions
Every person who is concerned with a operation of the machine must have read
and understood the operating instructions, or have been familiar with them in the
course of a training session.
Attention !
Safety, monitoring and guarding devices must neither be removed

nor their function in any way reduced or by-passed!
Note !
The safety instructions included in the individual sections of these

operating instructions warn against specific dangers and must be
strictly observed.
1.3.1.1
Safety equipment
Do not start the Skiver Cutting Unit if safety equipment is not in perfect working
order.
Do not change, disconnect or by-pass the safety equipment. The user of the
plant will be held fully responsible for damage arising from failure to observe
these instructions.
Detailed specifications must be provided for the following equipment where
included in the scope of supply (Product Liability Act; in the case of damage, any
proven manipulation of safety equipment will at least result in the user of the
plant being subject to secondary liability):
emergency switchgear
main switch, power switch
mode selector or repair switch
mechanical safety equipment, covers, protection hood, grids etc.
mechanical/electrical safety equipment, limit switches etc.
pneumatic safety equipment

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electrical safety equipment
danger and warning signs, type plate
additional safety equipment in accordance with local and internal regulations

and safety equipment to be provided and installed by the user prior to
commissioning
optional safety equipment, where necessary, which is available but not
included in the scope of supply.
1.3.1.2
Safety instructions concerning electrical equipment

For detailed information, please refer to the vendor documentation supplied for
electrical equipment.
The machines have to be connected in accordance with the following standards
and regulations: EN 60204-1, EN 292, EN 563, EN 50082, UVV 1.0 (VBG 1),
UVV 7.0 (VBG 4), UVV 10.0 (VBG 5) or any other standard and regulation
notified in the electical equipment supply.
The control system must only be used by trained personnel and checked at
intervals.
As specified in UVV 7.0, section 2, para. 3, repair and maintence work is

only to be carried out by a trained electrician after the mains voltage has
been switched off.
1.3.1.3
Fire protection
Fire fighting and fire protection must involve all personnel employed at the
production site.
Employers and managers are required to:
take all technical and organizational mesures that are necessary to prevent
fires;
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provide all necessary fire fighting equipment and arrange for their personnel
to be trained in the use of such equipment;

inform all personnel of the fire hazards involved and provide instructions on
how to avoid such hazards.

In-plant occupational safety experts and safety officers are required to
support the employer and employees in implementation of the above
measures.
Staff members are required to observe all fire prevention instructions and
to conduct themselves in such a way as to help implement of all measures
for the prevention of fires and explosions.
1.3.1.4
Labour protection
Country of origin: European Union (EU).
The equipment complies with the following regulations and directives:
Machinery Directive 98/37/EG
Electromagnetic compatibility directive 89/336/EEC
Low Voltage Directive 73/23/CEE 93/68/EEC
Simple Pressure Vessels Directive 97/23/EC
The following harmonized standards apply in particular:
Safety of Machinery IECT/TS 62046
Safety Distances ISO 13857:2008
Electrical Equipment of Machinery EN 60204 - 1
The regulations governing labour protection and the prevention of accidents in

force at the installation site or at the users facilities and all measures specified
in these operating instructions must be observed during the transport, installation
and operation of the machine. The user of equipment is fully responsible for any
failure to observe these regulations.
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1.3.1.5
Fundamental safety information

General observations:
The Cutting Machine has been designed and built according to the state of art
(see IECT/TS 62046 ). It is safe if employed in accordance with its intended use
and provided that the agreed technical data and operating conditions are
observed.
WARNING!
The machine may cause danger to life, personal injury or damage
to the machine and other equipment if installation, operation and
maintenanance are not carried out by suitably qualified personnel
or if the machine is not employed for its inteded use or used in an
improper manner!
Unspecified risks of personal injury and damage to the equipment may be

caused within the installation area of the machine and by the material to be
processed. Such risks are beyond the manufacturers responsibility and cannot
be excluded even when the machine is operated in a proper manner. The user
of the machine is required to take all necessary measures to prevent injury or
damage resulting from such risks.
1.3.1.6
Users responsibility
In case of damage, the user of the plant is fully responsible for the safe
execution of any work carried out on the TYRE 800 machine by the users
personnel authorized by user to perform such work.
Safety measures to be taken by the user:
Immediate action is required in case of danger.
The machine must be checked to make sure it is safe and fully operative.
Damage and faults must be eliminated immediately.
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The users operators and maintenance personnel and any third parties
instructed to carry out work on the machine must be informed about the
risks involved.
The user must provide recommended / prescribed personal safety

equipment and make sure it is used.
Work on the machine must be carried out by qualified personnel only.
Spheres of responsibility for the operation and maintenance of the machine

must be clearly specified.
The regulations for the prevention of accidents and the Material Safety
Data Sheet must be available to the personnel.
1.3.1.7
Waste must be disposed of in the correct manner.
Operators duties
Every person who is concerned with the operation of the machine must have
read and understood the operating instructions before the first commissioning
of the machine!
Before taking up work on the machine, all operators must inform themselves about the following factors:
potential risks / residual risks at the machine
personal safety equipment
danger zones at the machine and at the workplace during operation
risks caused by emissions
external risks (at the place of installation)
safety equipment
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mode of operation and controls of the machine, in particular emergency

switches
controls and emergency stop switches, as well as escape route have to be

accessible at all times.
fire extinguishers.
Always use the recommended / prescribed personal protection equipment,

such as heat-resistant gloves (protection against risk of burns in case of contact
with hot surfaces), safety goggles, ear protection etc.
Operators must respect the following rules:
The machine must only be switched on by authorized personnel.
The machine must only be switched on when danger to persons is excluded

(after machine switch off) and provided that faults have been rectified and
maintenance work has been completed.
The machine must be checked for external damage once a day or once per
shift. Any faults identified during these checks must be reported immediately
to the person / office appointed by the user of the machine.
In case of malfunctions, the machine must be switched off immediately.
Maintenance or repair work must only be carried out when the machine is
switched off and secured in such a way that it cannot be switched on by
unauthorized persons.
Any work carried out on the machine must be performed in proper manner
and observing all relevant safety regulations. Any tool or equipment used must
be in perfect working order.
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Work on the electrical equipment must only be carried out by a qualified

electrician.
Warning signs, pictographs and type plates must be kept legible at all times.
No unauthorized modifications or changes have to be carried out on the

machine. Safety equipment must not be modified, switched off or by-passed.
1.3.1.8
The place of installation must be kept clean and clear at all times.
Personnel qualification
Qualified personnel must be familiar with installation, connection, operation and
maintenance of rubber processing machinery and must have acquired such
knowledge and expertise in the course of technical training sessions.
The term qualified personnel refers to:
qualified mechanical engineers and technicians or personnel that must

have acquired special knowledge and expertise in this field in the course of an
in-house training sessions;
qualified electrical engineers and technicians or personnel that must have

acquired special knowledge and expertise in this field in the course of inhouse training sessions. Such personnel must meet the requirements of EN
60204 and any other standard, law or regulation in force at the installation site
and must be authorized to switch on/off, connect or ground electric circuits,
units and systems in accordance with safety standards.
The required qualification includes:
familiarity with the contents of these operating instructions and with machine,
its mode of operation, control system and equipment;
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completed training in the installation and operation of rubber processing

machinery and in the use and maintenance of labour protection and safety
equipment;
completed first aid course.
It is entirely the users responsibility to ensure that its staff members possess the
qualifications specified above, that they are trained on the machine and familiar
with all potential risks involved in the use of the machine.
Staff that have not completed the training specified above may only carry out
work on machine if supervised by experienced qualified personnel.
1.3.1.9
Potential risks and residual dangers

The following safety advice given in accordance with the requirements of the
Product Liability Act warns against danger zones and potential risk and residual
dangers. This safety advice must be observed in order to ensure safe operation
and maintenance of the machine
WARNING!
Failure to observe the warnings and instructions may cause danger
to life, personal injury and / or damage to the machine and other
equipment. The user is fully responsible for any failure to comply
with such warnings and instructions.
The warnings and instructions given below cannot provide exhaustive

information on all measures to be taken to ensure safe operation and maintenance of the machine.
These warnings and instructions do not relive the user of the plant of its obligation to initiate, implement and supervise additional safety and health protection measures required by special conditions for the installation and connection
of the machine and by special material properties.
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1.3.2
Work carried out whilst the machine is in operation:
The machine must only be operated by suitably trained personnel!
Access to the Cutting Machine is only allowed to the operating personnel.
Attention !
Work on the machine must only be carried out after the main
switch has been set to OFF (electrical equipment switched off and
pneumatic system depressurized).
This is of major importance when the protection hoods have to be
opened to allow maintenance work to be carried out!
The main switch must be locked in such a way that it cannot be

set to ON.
Work on the electric control system must only be carried out by suitably
qualified personnel!
The operation and maintenance instructions must be strictly observed.
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1.3.3
RESIDUAL RISK
Attention !
After the voluntary or unvoluntary stop of the machine the

blade continous to rotate per inertia.
DO NOT do a maintance work in the blade area until the FULL
STOP of the blade rotation!
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1.4
List of most important safety signs

I.E.C.I.M uses on its machines and in its operating instructions warning,
prohibiting and order signs according to EN 61310-1 / ICE 1310-1.
Added to these signs are safety signs that have proved useful in practice.
Warning signs (black and yellow)
DANGER
RISK OF ELECTRIC CURRENT
MACHINE IN OPERATION
RISK OF HAND INJURY
STUMBLING-BLOCK
BEWARE OF TRANSPORTATION VEHICLES
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Prohibition signs (red and white)
DONT TOUCH
NO SMOKING, MATCHES OR OPEN LIGHTS
NO TRESPASSING
TRANSPORTATION VEHICLES PROHIBITED
WATER MAY NOT BE USED TO EXTINGUISH

FIRE
Signs in case of fire-extinguishing (red and white)

ROUTE INDICATOR
( mostly in combination with other signs )
FIRE EXTINGUISHER
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Order signs (blue and white)

GENERAL SIGN
( mostly in combination with other signs )
SAFETY BOOTS COMPULSORY
EYE PROTECTION COMPULSORY
EAR PROTECTION COMPULSORY
SAFETY GLOVES COMPULSORY
SAFETY HELMET COMPULSORY
SAFETY SUIT COMPULSORY
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2.
FUNCTIONAL DESCRIPTION
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General Assembly drawing PK/SA2.M.01
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The function of this Skiver Cutting Unit is cutting of tread in start/stop mode.
EXTRUSION LINE DATA

Mechanical speed
[m/min.]
3,0 to 30
Production speed
[m/min.]
14,0 to 27,0
Working width
[mm]
800
Operator side
Left to flow direction
LENGTH TOLERANCE OF THE CUT

Accuracy of tread cut length
[mm]
+/- 4,0
Mechanical length tolerance w/o material
[mm]
+/- 0,5
CUTTING ANGLE
Cutting angle, side view / to the surface
[deg]
17,5 to 32,5
Cutting angle, top view / to flow direction
[deg]
90
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OPERATING CONDITIONS
LOCATION
Santo Andr - BRAZIL
POWER SUPPLY
VOLTAGE
3 X 440 V AC, + / - 10%

60 Hz, + / - 2%
CONTROL VOLTAGE
110 V AC, + / - 10%

60 Hz, + / - 2%
24 V DC (solenoids, limit switches, sensors, etc.)
AMBIENT
TEMPERATURE
Geared motors: from 15C to 45C

Electric equipment: from 15C to 40C
HUMIDITY STRESS
MAX. 60% relative humidity
COMPRESSED AIR
6 bar
AMBIENT AIR
Free from harmful influences
OPERATING HOURS
24 h / day
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After passing through the cooling process, treads are cut to the correct length on
the Skiver Cutting Unit which alternates between Stop/Go operations.
During the cutting process rubber profiles form a loop which is scanned with a
Dancer Roll and used for control and regulation purposes, such as for the
calculation of the starting speed.
A programmable logic control system regulates the process and the positioning of
the profiles to accord with the pre-selected length of the cut.
Profiles in-feed is via specially designed drive (with brushless motor) with the
capacity to accelerate the product rapidly.
During the cutting rubber profiles are held in position on a cutting bar arranged on a
level with a conveyor, by means of pneumatically controlled hold-down clamps
(Pressing Fingers).
The cut is carried out by a rotating circular knife lubricated by a very fine water
spray.
The advance / return transversing travel of the cutter ball-bearing supported
carriage is by means of an AC brushless motor.
The travel of the knife carriage is adjustable within limits.
After the completed cut, the rubber profiles are transported on a friction roller
conveyor which is driven by its own geared motor.
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SKIVER CUTTING UNIT TYRE 800 TRUCK
Rubber profiles length
[mm]
from 2300 to 3350
Rubber profiles maximum thickness
[mm]
60
Cutting angle, top view / to flow direction
[deg]
90
Cutting angle, side view / to the surface
[deg]
Rubber profiles maximum width
[mm]
550
Cutting disc diameter
[mm]
500
[nCUTS /min.]
20
Number of cuts
Cutting discs cooling and cut lubrication
Material temperature after cutting
Noise level
from 17,5 to 32,5
H2O spray
[C]
from 30 to 50C
< 80 Db
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TREAD MAIN GEOMETRY, TOLERANCES AND COMPOUND CHARACTERISTICS
TREAD
min. [mm]
MAX. [mm]
Length
2300
3350
LT (total width)
200
550
LS (shoulder width)
160
450
EM (thickness)
16
60
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SKIVER CUTTING UNIT is composed of:
Skiver Cutter 800 Truck

Dancer Roll
Tread Centering Unit
Pressing Roller
Measuring Unit
Pressing Fingers Group
25
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2.1
SKIVER CUTTER Dwg.s PK/SA2.M.100A, PK/SA2.M.100B, PK/SA2.M.100C
26
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27
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TECHNICAL FEATURES:
Belt Type: AMMERAAL type ULTRASYNC T10 590 FG, code UC5900,
Colour BLUE, Width = 850 mm, Development = 7760 mm.
Conveyors Motor: Brushless ALLAN-BRADLEY type MPM-B1302T, P = 1,65 kW,

Output shaft 24X50 mm.
Conveyors Gearbox: SEW EURODRIVE type KH57/R/TAQA115/3,

Red. ratio: 1/15,22, Output shaft: hollow 40 mm
Mounting position: M1A.
Carriage translation Motor: Brushless ALLAN-BRADLEY type MPM-B1304M,

P = 2,2 kW, Output shaft 24X50 mm.
Cutting blades Motor: WEG type W22, Cast iron frame IE3, P = 3 kW,
Frame type L100L, IP55.
All components of the Cutting Machine: supporting structure, tanks, etc. are made of
stainless steel.
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Attention!
ADJUSTING CUTTING ANGLE
In order to cut various types of product profiles, we can change a cutting angle
within range from 17,5 to 32,5.
30
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31
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Note!
Instructions for adjustment of the cutting blades angle
Tools: Wrench 36 mm (for M24 bolt)
Be sure that the cutting blade is in UPPER (No-Cutting) position and that
Transversal Carriage is in RIGHT (out-off center) position.
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Loose Nr 2 screws M24.
33
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Turn a Screw Jacks lever until you reach desired cutting angle.
Lock Nr 2 screws M24.
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Verify that the knifes edge is penetrating between two cutting bars as shown in
the picture.
Perform a cutting probe.
If necessary adjust positions of two cutting bars.
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KNIFE DISMOUNTING AND SHARPENING

After some period of time a disc blades edge will become dull and the edge is to be
re-sharpened.
First, dismount lower water jet and lower blade protection cover.
Loose Nr 3 M8 screws and with attention dismount a blade.
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Attention!
During operations of blades dismounting / mounting wear safety

anti-cut gloves.
ADJUSTMENTS OF THE BLADES POSITION
For the best cutting result the blades edge during cutting must be always in
position shown in the picture.
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We can adjust that position moving forward / backward blades carriage starting
position.
Loose Nr 8 M10 screws shown in the picture above.
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Put a blade in best cutting position with loosing / closing nuts.
Lock all nuts and bolts.
If necessary adjust a position of two cutting bars.
Perform a cutting probe.
If necessary repeat all operations until you find a perfect cut.
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2.2
DANCER ROLL Dwg. PK/SA2.M.600
40
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2.3
TREAD CENTERING UNIT Dwg. PK/SA2.M.400
41
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2.4
PRESSING ROLLER Dwg. PK/SA2.M.300
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2.5
MEASURING UNIT Dwg. PK/SA2.M.500
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2.6
PRESSING FINGERS GROUP PK/SA2.M.200
The function of this pneumatically driven group is to hold down a product during
cutting.
Because profiles to cut are not flat, it is composed of 44 pressing springed fingers
which follow products profiles.
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3.
TABLES OF LUBRICANTS
45
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LUBRICATION
Components
Lubrication
system
Lubricant
type
Producer
Instruction
Geared
Motors
SEW
EURODRIVE
Permanent
lubrication
with
synthetic oil
See
producers
manual
See
producers
manual
See
producers
manual
Grease
Bearing
supports
Greasing
Sliding
guides
Greasing
Air treatment
systems
To fill up every
ESSO
BEACON EP2
four months
Grease
Filling up
To grease every
ESSO
BEACON EP2
four months
Oil
TERESSO
320
To control weekly
ESSO
oil level
Grease
Chains and
gears
Greasing
Lubricators
Greasing
To grease every
ESSO
BEACON EP2
four months
Grease
To fill up every
ESSO
BEACON EP2
four months
46
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47
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48
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49
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Transversal Carriages Runner Blocks are lubricated from central lubrication unit.
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4.
DRAWINGS LIST
ITEM DESCRIPTION
DRAWING
SKIVER CUTTING UNIT

2.1
PK/SA2.M.01
NOTE
General Assembly
SKIVER CUTTER
PK/SA2.M.100A
Assembly
SKIVER CUTTER
PK/SA2.M.100B
Assembly
SKIVER CUTTER
PK/SA2.M.100C
Cutting Carriage
2.2
DANCER ROLL
PK/SA2.M.600
Assembly
2.3
TREAD CENTERING UNIT
PK/SA2.M.400
Assembly
2.4
PRESSING ROLLER
PK/SA2.M.300
Assembly
2.5
MEASURING UNIT
PK/SA2.M.500
Assembly
2.6
PRESSING FINGERS GROUP
PK/SA2.M.200
Assembly
Copyright
All rights reserved. No part of this manual may be reproduced or transmitted in any form
or by any means, electronic or mechanical, including photocopying, recording, or any
information storage and retrieval system, without our explicit permission.
Industria Elettromeccanica Commerciale Italiana Milanese S.r.l.

Via Muoni N16, 20064 Gorgonzola MILAN, ITALY
Tel: (+39) 02.951.5551 Fax: (+39) 02.951.5784
E-mail: iecim@iecim.191.it
51

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