Effi cient Milling and Granulating of Road Pavements. The World of Wirtgen Cold Milling Machines

Transcription

1 Effi cient Milling and Granulating of Road Pavements The World of Wirtgen Cold Milling Machines

2 Contents

3 Introduction 4-5 History 6-7 Small milling machines in detail 8-11 Large milling machines in detail Leadership in technology Product portfolio Manufacturing technology Reliable customer service In operation around the globe Environmental sustainability // 3

4 INTRODUCTION Cutting-edge technology for better roads

5 Wirtgen is setting the pace in road rehabilitation International traffic volumes are steadily increasing. As a result, road systems are required to cope with ever higher demands. The state-of-the-art milling technology meets all requirements in terms of the economically efficient and environmentally friendly rehabilitation of roads. Our inspired concept to rehabilitate damaged road pavements quickly and efficiently with the innovative milling process heralded the era of the cold milling technology. Since that time, Wirtgen has been considered the world market leader in this multi-faceted segment. Fascinated by the infinite possibilities it offers, we are pressing ahead with the continuous development of this method, ensuring that our innovative solutions will continue to vitalize the road network in the future. Cold milling has gained acceptance worldwide, and it is unrivalled when it comes to economic efficiency and environmental sustainability. 4 // 5

6 HISTORY From milling contractor to world market leader Innovative milestones 1971 The powerful, technically mature cold milling machines of today need some two minutes to fill a 30-tonne truck with granulated asphalt material. They have come a long way and Wirtgen has played a vital role in their breathtaking development. In 1971, Wirtgen built the first of a total of 100 hot milling machines for the contracting fleet it owned at that time. The technological leap from hot milling to cold milling was sparked in 1979 by the use of carbide tools commonly used in the mining industry. From the first cornerstone development of the cold milling technology for road construction to date, we have paved the road to success of this technology with numerous, innovative milestones. Today, the name Wirtgen is distinctively and inextricably tied to tried-and-tested cold milling technology of superior quality. The prototype of a hot milling machine is successfully milling off damaged asphalt layers Like all small milling machines of the first generation, the 500 C offers a milling depth of up to 100 mm The first replaceable toolholder system increases the economic efficiency of the cold milling machines The VCS extraction system reduces dust emissions during operation The SF 2500 is equipped with large gas tanks increasing the machine s productivity The 2000 VC is the first front-loader, making a deep and lasting impact on site logistics The W 2000 large milling machine sets a new standard in operation and performance The proprietary LEVEL PRO automatic levelling system increases both precision and operator comfort.

7 1979 The 3800 C, a cold milling machine of the first generation, is a rear loader with hydraulic milling drum drive The range of applications is broadened considerably by the DC model range, which offers working depths of up to 300 mm The flexibility of the machines is enhanced by the FCS quickchange system for milling drums A dual-engine concept is implemented in the W 210 for the first time to reduce operating costs. 6 // 7

8 SMALL MILLING MACHINES IN DETAIL Specialists for the more delicate jobs

9 Cutting the corner with small milling machines Not only large-scale construction projects but also and in particular rehabilitation jobs carried out on a smaller scale play a vital role in the structural maintenance of road networks. Small milling machines are the ideal candidates for this type of job. Their compact design and extremely small milling radius enable them to work with maximum precision even in extremely confined conditions. These highly manoeuvrable machines play their many economical advantages in particular when carrying out partial repairs, milling tie-ins, removing road markings, milling around road fixtures or constructing trenches for supply lines. Their repertoire also includes the efficient milling of larger surfaces. Working in tandem, large milling machines the specialists for removing surfaces on a large scale and small milling machines are a perfect team. 8 // 9

10 SMALL MILLING MACHINES IN DETAIL Operating principle and components Working effi ciently with small milling machines LOADING CONVEYOR Slewing and height-adjustable conveyor for continuous loading of the milled material Small milling machines are usually equipped with wheels, their milling drum being arranged at the rear of the machine. A one-stage conveyor accepts the asphalt material granulated by the rotating milling drum, discharging it directly onto waiting trucks. This is why small milling machines are also called rear loaders. Depending on job site conditions, the milled material can also be deposited in a windrow next to the machine via the slewing conveyor, or can be left in the milled cut after the conveyor has been removed. CONVEYOR BELT SPEED Variable conveying speed for efficient loading of trucks HEIGHT ADJUSTMENT Hydraulic height adjustment of the two rear wheel units for precise adjustment of the milling depth The manoeuvrable small milling machines mill off road pavements at working widths ranging from 35 cm to 1.3 m. In addition, their all-wheel drive, compact dimensions, front wheels with large steering angles, and fold-in right-hand rear wheel enable efficient milling along obstacles or in restricted space conditions. MILLING DRUM DRIVE Highly efficient mechanical milling drum drive RIGHT-HAND REAR WHEEL Fold-in right-hand rear wheel for milling flush to kerb or along obstacles MILLING DRUM Milling drums offering different widths and variable tool spacings for a wide range of applications

11 OPERATOR S PLATFORM Ergonomically designed operator s platform for non-tiring, productive working SOUNDPROOFING Effective engine soundproofing for low noise emission levels ENGINE Powerful diesel engine for high milling performance WHEELS 3 or 4 wheels with large steering angles at the front for small turning radii ALL-WHEEL DRIVE Permanent all-wheel drive for reliable traction 10 // 11

12 LARGE MILLING MACHINES IN DETAIL Maximum power for large surfaces

13 High daily production rates guaranteed Large milling machines offer decisive advantages when it comes to large-scale rehabilitation projects: superior area performance, fast completion of construction projects and minimum disruptions to traffic are all marks in favour of the use of these high-performance machines. Their central field of application is the removal of road pavements at full depth on motorways, federal roads or airports. Under ideal conditions, the largest cold milling machine model the W 250i is capable of removing up to 1,200 tonnes per hour of asphalt material, equalling the loading capacity of 60 trucks. Large milling machines equipped with fine milling drums are also eminently suitable for the production of specified surface textures. These applications include levelling of irregularities on large, continuous traffic surfaces, fine milling of surfaces prior to applying a new, thin pavement layer, or restoring the skid resistance of road pavements. 12 // 13

14 LARGE MILLING MACHINES IN DETAIL Operating principle and components High-performance rehabilitation of roads DUAL OPERATOR S PLATFORM Spacious, ergonomically designed operator s platform with two identical workplaces for non-tiring, productive working Large milling machines are mostly designed with crawler tracks, a milling drum arranged in the central part of the machine and a forward-loading conveyor system and are called front loaders. Loading the milled material towards the front offers many benefits: the machine operator has a direct view of the loading operation and can ensure optimum loading of trucks. The slewing, height-adjustable discharge conveyor enables flexible and cost-effective loading. Front loading also permits trucks to change on the fly quickly, ensuring that the milling operation can continue non-stop. In addition, front loading allows trucks to easily pull in and out of the flowing traffic. SOUNDPROOFING Effective engine soundproofing for low environmental emission levels ENGINE / DUAL ENGINE Economical, powerful engine for high milling performance The high-performance machines meet the requirements placed on them thanks to their high engine power. A smooth flow of traffic is ensured in most projects as vehicles can drive past the job site on adjacent lanes. TRACK UNITS Hydraulically steerable and heightadjustable track units for precise adjustment of the milling depth and precise machine manoeuvring

15 CONVEYOR BELT SPEED Continuously adjustable conveying speed to alter the discharge pattern and ensure that trucks are loaded to full capacity DISCHARGE CONVEYOR Discharge conveyor for continuous loading of the granulated material onto trucks VACUUM CUTTING SYSTEM Vacuum cutting system for extracting fine material particles in the area of the milling drum housing PRIMARY CONVEYOR Primary conveyor of the two-stage conveyor system to accept the granulated material from the milling chamber CUTTING TOOLS Optimized arrangement of toolholders, equipped with point-attack cutting tools, and edge segments for high milling performance MILLING DRUM Milling drums offering widths of up to 4.4 m and variable tool spacings for a wide range of applications 14 // 15

16 LEADERSHIP IN TECHNOLOGY Core expertise in cutting technology Milled surfaces made to measure Whether milling drum, toolholder system or point-attack cutting tool: Wirtgen is the leader in cutting technology and is pressing ahead with the continuous further development of this key area. A cold milling machine s core element is the milling drum, which rotates against the direction of travel and is equipped with point-attack cutting tools. During milling, the cutting tools remove the pavement, granulating it into small-sized, reusable material. The operation produces an even surface with excellent bonding properties and accurate milling edges. The texture of the milled surface is determined by the tool spacing. The patented Flexible Cutter System (FCS) is unique worldwide, enabling the quick and simple exchange of milling drums of different working widths or tool spacings. Our tried-and-tested quick-change toolholder systems are yet another successful proprietary development. They reduce idle times and increase the service life of milling drums.

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18 LEADERSHIP IN TECHNOLOGY Powerful material loading system Flexibility comes as a standard feature The conveyor systems of cold milling machines from Wirtgen are distinctive for their wide conveyor belts with high ribs, large slewing angles to both sides and variable conveyor belt speed. The conveyor of rear loaders or small milling machines can be attached or removed quickly by means of a quick-release coupling. Choosing from several conveyor options of different lengths enables flexible adjustment of the machine to any given job condition and space requirement. The conveyor system of front loaders or large milling machines is comprised of a primary and a high-capacity discharge conveyor. It is tailored to high performance and permits flexible adjustment to conditions prevailing on the job site. The conveyor system makes an easy job of loading trucks even in narrow bends or when negotiating obstacles.

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20 LEADERSHIP IN TECHNOLOGY Perfect operation and control

21 High productivity in focus Our perfectly engineered operating and visibility concept paired with state-of-the-art control technology is a decisive factor in ensuring relaxed, productive working. The ergonomically designed operator s platform enables intuitive operation, high operator comfort and perfect visibility. Support of the machine operator in his highly responsible job by providing increased operator comfort without impairing the milling quality that was our goal when developing the innovative machine management system WIDRIVE. WIDRIVE combines the different functions of a cold milling machine into one unit. It carries out functions that greatly facilitate work for the operator. It is not surprising, therefore, that top production rates are the order of the day. The state-ofthe-art automatic levelling system LEVEL PRO PLUS is also part of the WIDRIVE system. Its clear-cut and intuitive handling permits superior, high-quality milling results. 20 // 21

22 PRODUCT PORTFOLIO The world s biggest fl eet of cold milling machines Numerous equipment features Wirtgen offers by far the broadest portfolio of cold milling machines worldwide. The standard milling widths range from 30 cm to 2.2 m and can be extended to an impressive 4.4 m. The choice of machines ranges from the exceptionally small W 350 E an electrical cold milling machine designed for indoor use all the way to the W 250i which completes large projects on motorways or airports in record time. Our delivery range caters to all needs. It offers made-to-measure, technically superior solutions for all customer requirements. Conveyor length, milling drum width, tool spacing, integrated dust extraction, track or wheel units to name just a few options. Customers can generally choose from a multitude of equipment options for their cold milling machine in order to achieve maximum performance rates even when having to deal with complex site conditions.

23 W 350 E W 35 DC W 50 W 50 Ri W 60 Ri W 100 W 100i W 100 H W 130 H W 100 F W 100 Fi W 120 F W 120 Fi W 130 F W 130 Fi W 150 W 150i W 1900 W 2000 W 200 W 200i W 200 H W 200 Hi W 210 W 210i W 220 W 250i 22 // 23

24 MANUFACTURING TECHNOLOGY High quality guaranteed

25 Expertise in manufacturing At our main production plant in Windhagen, the machines are built for a long life, safe operation and extreme toughness. Our high-quality manufacturing processes are characterized by state-of-the-art production technology, outstanding core competencies and experienced staff. This unparalleled wealth of expertise is our recipe of success for ensuring the production of durable, robust quality equipment. Both small milling machines and large milling machines are assembled in a cyclic process. Optimized assembly lines guarantee consistently high quality and short lead times. 24 // 25

26 RELIABLE CUSTOMER SERVICE Full customer service around the globe Effi cient after-sales service Complying with our entirely customer-oriented company philosophy, we have created a close-meshed, global service infrastructure. Around 60 sales and service companies and an extensive network of dealers are reliable local partners of our customers in all parts of the world. Our subsidiaries support customers around the globe with spare parts and dependable customer services. Our highly qualified and fully equipped service engineers are on site quickly to provide active support, Large inventories of stocked parts ensure that our tried-and-tested original spare parts are available in sufficient quantities as and when needed.

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28 IN OPERATION AROUND THE GLOBE On the road of success in over 100 countries around the world Cold milling is state-of-the-art technology around the globe The path to global success of the cold milling technology began in Germany and quickly spread across Europe to overseas and the Far East. Today, cold milling is an internationally accepted construction method. Innovative small and large milling machines are maintaining the lead in over 100 countries when it comes to the powerful rehabilitation of motorways, federal roads, airports or industrial sites. Today, Wirtgen is the world market leader in cold milling.

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30 ENVIRONMENTAL SUSTAINABILITY Environmentally friendly machine technology Signifi cant reduction of emissions Wirtgen is very strongly committed to actively protecting the environment and saving natural resources. The reclaimed asphalt is valuable recycling material that is fully reused for the production of asphalt mixes. Large milling machines featuring the dual-engine concept enable the second engine to be switched off in accordance with the job at hand to save diesel fuel and reduce exhaust emissions. And last but not least, it goes without saying that our fuel-efficient diesel engines comply with current international exhaust emission standards. The WIDRIVE machine management system, which greatly improves operator comfort, offers numerous automated features to ensure a fuel-efficient and low-emission milling process. Our effective VCS vacuum cutting system for large milling machines reduces dust emissions and improves the air quality in the area of the milling drum housing. Effective soundproofing and anti-vibration mounting of the engine ensure low noise and vibration levels. State-of-the-art engine technology reduces exhaust and noise emissions reduces exhaust and noise emissions WIDRIVE machine management system and noise emissions engine support

31 reduces vibration Anti-vibration Vacuum Cutting System reduces dust emissions reduces noise emissions Soundproofing 30 // 31

32 Illustrations and texts are non-binding and may include customized fi ttings. Subject to technical changes. Performance data depend on operational conditions. No EN-09/14 by Wirtgen GmbH Printed in Germany Wirtgen GmbH Reinhard-Wirtgen-Str Windhagen Germany Phone: +49 (0) / Fax: +49 (0) / Internet: info@wirtgen.com