SpaltFix K-710-a-Vario

Sawing unit: Extremely robustly built and easy to maintain – for maximum durability in tough everyday use

The SuperCut harvester saw unit is fitted to ensure maximum cutting performance, precise guidance and clean cuts. It is fitted with a powerful skew-axis motor, which ensures reliable driving power. The hydraulic blade clamping and chain tensioning are carried out automatically – but only when the protective cover is closed! An integrated hydraulic cylinder with a rack-and-pinion drive ensures a consistently smooth saw feed. The saw chain is continuously lubricated by a piston pump throughout the entire swivelling movement of the saw bar. This reduces wear and tear and extends the service life of the guide bar and chain. A generously sized chain oil reservoir allows for long running times without the need for constant topping up. The saw chain can be changed fast and tool-free. Once the chain has been removed, the guide bar can also be replaced without any difficulty. The drive sprocket can be easily replaced by loosening just one fixing bolt. The control system manages the sawing process automatically. The process can be started via the control panel, whilst the pressure and speed of the saw feed can be adjusted individually using two adjustment knobs. Machines with a drive of 22 or 30 kW are equipped with a System 100 saw unit fitted with a 0.404-inch saw chain. For greater cutting performance, machines with a 37 kW electric motor are equipped with the larger System 150 saw unit. A 3/4-inch saw chain ensures a longer service life.

Fully automatic sawing process with precise length measurement using CutControl

The desired cutting length, including the tolerance, can be easily set directly on the display. Once automatic mode has been activated – either by pressing a button on the control unit or using the radio remote control – the front feed automatically moves the trunk towards the saw unit. The CutControl function ensures a smooth, automatic process with no offcuts. During the feed rate to the sawing unit, sensors measure the trunk length. Based on the set length and tolerance, the system automatically divides the trunk into equal sections. If it is not possible to cut the wood into equal pieces, a scrap piece is first cut off and automatically discharged via the residual wood ejection. As soon as the trunk is in the cutting position, it is secured by the hold-down device and the wood support behind the saw unit is lowered to prevent the saw blade from becoming jammed during the cut. Swivelling a chip flap into position prevents sawdust from triggering the safety light curtain during the cutting process and interrupting automatic mode. The sawing process then begins and the trunk is cut by the sawing unit. To ensure optimum cutting performance at all times, the pressure and speed of the saw feed can be individually adjusted using two adjustment wheels in the operating area. Once sawing is complete, the wood support is raised again, the chip flap is swung back, and the ejector transfers the cut piece of timber to the AutoSplit’s buffer belt. The ejector then returns to its starting position, and the trunk is fed forward for the next cut. This automatic process is repeated until the trunk has been fully processed.

Everything under control: Reliable clamping and precise cutting thanks to the hold-down device

The solid, linearly guided hold-down device reliably secures the timber from above in the timber trough during the sawing process. This prevents the trunk from twisting or slipping. The hold-down device stands out thanks to its sturdy construction, featuring robust roller bearings and replaceable guide rails. The precise guidance ensures low-wear and smooth operation – even under heavy loads and continuous use. Before sawing begins, the hold-down device is lowered by a hydraulic cylinder until it rests against the trunk and secures it firmly in place. Robust serrations on the contact surfaces ensure extra grip and effectively prevent the wood from twisting or slipping. To save time, the hold-down device does not move to its uppermost end position before the feed rate for the next cut; instead, it opens only by the preset amount above the trunk, automatically detects its position via a non-contact sensor, and only returns to its uppermost end position once the trunk has been fully processed – this saves time and prevents collisions with subsequent logs.

Smart timber transfer

After sawing, the log section remains on the wood support. The wood holder fitted to the ejector reliably prevents the cut piece from tipping over and must be manually preset to the desired cut length. A measuring scale makes this adjustment easier, and a sensor protects the wood holder from damage if it is positioned incorrectly. A hydraulic cylinder moves the ejector back and forth. As a result, the piece of wood is either conveyed to the residual wood ejection chute or transferred to the buffer belt for further processing by the AutoSplit. In automatic mode, the ejection mechanism is controlled entirely by the control system. If necessary, it can also be operated manually using the push-buttons in the operating area. The ejector impresses with its sturdy construction, featuring robust roller bearings that are guided linearly along replaceable guide rails. The guide ensures low-wear, smooth operation – even under heavy loads resulting from continuous use.

Selective discharge of wood offcuts

If the trunk cannot be cut into sections of exactly the same length, a scrap piece is sawn off during the first cut and is channelled directly by the ejector via the chute with a plastic curtain into the residual wood ejection chute. Part of the wood chip discharge chute can be folded down to allow easy access to the platform when carrying out chainsaw maintenance. The damper position is monitored by a safety limit switch. If the slide is folded down, the safety circuit is broken and it is not possible to operate the machine, as the safety clearances from the saw unit are not guaranteed.

Adjustable wood support

To prevent the saw blade from jamming when sawing curved trunks, the movable wood support to the right of the cutting range is automatically lowered by a hydraulic cylinder before sawing begins. Once the sawing process is complete, the wood support is automatically raised to allow the cut section to be transported out by the ejector and to prevent the remaining trunk from tipping over at the feed rate. The height of the wood support can be adjusted in three stages tool-free, using set pins. To prevent chips from accumulating under the saw unit, a chip chute with side panels directs the chips away.

Efficient hydraulic technology for maximum performance

A wide range of solenoid valves, in combination with the control system, enables the machine to operate fully automatically, thereby ensuring reliable operation. Sequence control valves ensure that the defined processes on the machine run automatically and in the correct order – without the need for additional control systems. The hydraulicly pilot-operated saw valve precisely controls the sawing process and ensures fast, smooth cutting movements whilst maximising process reliability. Two pressure filters and a return filter – each equipped with a contamination indicator – reliably protect the entire system from contamination. A large hydraulic tank with a high oil capacity and a standard oil cooler ensure that the oil temperature remains low. This reduces wear on the hydraulic components and extends their service life – ideal for professional use. To make set-up easy, the hydraulic components of the front feed can be connected to the saw unit fast and easily via hydraulic couplings. To facilitate maintenance work, all hydraulic components are labelled and clearly documented in the hydraulic diagram and the spare parts list. Labelled test ports on each hydraulic circuit enable fast and straightforward system diagnostics – thereby ensuring maximum availability with minimal downtime.

Everything under control and at a glance – right at the control panel

The arrangement of all the controls in the operating area is ergonomic and clear. It features a 7-inch touchscreen display and buttons for: - Drive Start/Stop, - Automatic Start/Stop, - Safety circuit. In addition, there are 12 buttons available for manually controlling the control system for all functions of the front feed and saw unit. In addition, a holder for the wireless remote control is fitted. The control panel features a pushbutton for the electric drive’s emergency stop function and three adjustment knobs, which can be used to set the pressure and speed of the saw feed, as well as the reduced feed speed for the front feed. A measurement port for the saw feed pressure is fitted directly to the control panel, making it easy to monitor.

This keeps the machine cool: Oil cooler for a longer service life and less wear and tear

An oil cooler designed for continuous operation (recommended for operating times of 4 hours or more, or when operating at temperatures above 30 °C). This reduces wear and tear, thereby ensuring a longer service life for the hydraulic components. Cooling only takes place when necessary – ensuring maximum service life and minimum running costs thanks to intelligent thermostat control.

Intelligent control system with touchscreen and IIoT connection

The electronic control system continuously records sensor and input values ( .g. positions, temperatures, pressures, switch states), processes them in accordance with a pre-programmed sequence and then controls the outputs accordingly. It is positioned at an ergonomic height above the control panel, allowing for a comfortable control system. A 7-inch touchscreen clearly displays all the information relating to the various functions and the safety circuit. The display can be shown in various languages. The desired cut length, including the tolerance, can be set easily directly on the display. The control system processes and monitors a wide range of real-time data, such as the position of the front feed unit, the position of the hold-down device, the hydraulic pressure and the oil temperature. At the same time, it monitors the safety circuit of the protective covers. Operational data is digitally recorded via the IIoT connection and can be analysed. Operating hours and the number of cuts are recorded and displayed as daily and total counters. Particularly handy: The daily counters can be reset at any time. A wide range of operational data, such as the number of logs, running metres, residual wood ejection and other key figures, is recorded and clearly presented in the ‘Analysis’ section. Individual user settings can be configured directly within the system, and the section length is displayed for both the actual and target values. Even special operating modes such as ‘Sawing Only’ (OnlyCut) can be activated directly via the touchscreen. If an error occurs, a message with the relevant text appears on the display (e.g. ‘Machine cover has been opened!’). All messages are stored in an error log. Software updates can be carried out by the customer either via a memory card or – once enabled on the control system – via remote maintenance, provided there is a stable internet connection.

Smart drive solution with a 22 or 30 kW electric motor – powerful and energy-efficient

Look after yourself and your environment: The electric motor runs more quietly and can be powered by electricity from renewable sources. These solutions help to reduce air pollution and do not produce any harmful exhaust fumes in your working environment. This drive system, featuring a powerful 22 kW electric motor and a grey cast iron pump, is the ideal solution for demanding applications where reliability and energy efficiency are key. The automatic star-delta start with rotation field detection and phase inverter ensures safety and gentle start-up. The system is easily switched on and off using buttons in the operating area. The emergency stop function takes the safety-critical electrical systems out of operation. When used in conjunction with an AutoSplit 700, both machines are connected using the connecting cables supplied as standard. If the emergency stop function is activated on either of the two machines, both machines are automatically shut down – ensuring maximum safety. Machines fitted with a 22 kW electric motor are equipped with the System 100 saw unit, which uses a 0.404-inch saw chain. The version with a 30 kW electric motor offers around 25 % more cutting power thanks to a more powerful drive motor and a larger hydraulic pump. Here, too, the System 100 saw unit is used with a 0.404-inch saw chain. Machines fitted with a 37 kW electric motor are equipped with the larger System 150 saw unit, which delivers 25 % more cutting performance. The robust 3/4-inch saw chain reduces wear and ensures a significantly longer service life.

Powerful log feed

The solid feed unit operates precisely and with minimal wear in replaceable guide rails fitted with high-quality roller bearings – ensuring stable and smooth movement across the feed trough. The drive is reliably provided by a powerful hydraulic motor in combination with a roller chain, spur gear and rack – ensuring a powerful feed rate. The feed plate is mounted on a rotatable bearing and is swung upwards by a hydraulic cylinder for the return stroke, ensuring a fast and smooth operation. The safety valve ensures that the feed plate is held securely in position during the feed movement. Two non-contact sensors monitor the swivel positions of the feed plate. This ensures a smooth sequence of movements, which elevates the operational safety and reliability of the system. The feed rate initially takes place at high speed and is automatically reduced just before the saw position is reached to ensure precise positioning. The reduced feed rate can be adjusted manually using a control dial on the control panel. Thanks to a sophisticated hydraulic system, the reversing speed is particularly high, meaning that such an empty run can be completed fast. Both the travel distance and the speed of the reduced feed rate up to the cutting position can be adjusted individually, allowing them to be optimally tailored to the specific conditions. For measuring log length, an integrated rotary encoder enables the feed unit to be positioned precisely and ensures a consistent cut length. Whilst the feed unit is in motion, a solid energy chain ensures the safe and controlled routing of all hydraulic and electrical cables. Using the chain supplied, which includes a block strip hook, a trunk can be pulled back through the feed trough using the feed unit. The central lubrication rail on the feed unit enables simple and efficient lubrication of all relevant components. Lubrication can be carried out fast and conveniently via the easily accessible maintenance hatch – this reduces maintenance requirements and ensures long-term, reliable operation.

Lifting arms with damping and lifting functions

When the feed unit is in its home position (at the rear), the two lifting arms, which are recessed flush with the feed trough, are raised synchronously by two hydraulic cylinders and a flow divider. During the subsequent transfer of a trunk, the raised lifting arms act as shock absorbers, preventing the trunk from striking the trough directly and significantly reducing the mechanical stress on the system. Before the log feed starts, the lifting arms are automatically lowered so that they are flush with the surface. Two non-contact sensors monitor the position of the arms when they are lowered, in order to reliably prevent any malfunction during the log feed. The lifting height of the lifting arms for the damping function can be adjusted individually via the control system’s display. An additional function of the lifting arms enables trunks to be safely lifted out of the feed trough following a misfeed – for example, if, during manual feeding using a cross conveyor, two trunks accidentally fall into the feed trough at the same time. This avoids the need for manual intervention.

Robust frame construction – stable and durable

The solid, fully bolted frame is designed to withstand the heaviest loads when processing heavy trunks and ensures maximum stability, durability and sturdiness – even under the toughest operating conditions. Height-adjustable feet also allow the unit to be adapted to the local conditions and reliably compensate for any unevenness in the floor. The high-quality powder coating provides the frame with long-lasting protection against corrosion and mechanical stress. Furthermore, the design is prepared for the positive-lock connection of optional feed systems, such as cross conveyors or AutoFeed, so that the workflow can be easily expanded and automated as required. The front feed is supplied as a fully pre-assembled unit. Before commissioning, all that remains is to secure the feet and connect the hydraulic and electrical plug connections.

Good visibility with maximum protection

The feed trough and the feed unit have doors with an extra-wide width and mesh covering that make them easily accessible for maintenance work or any necessary interventions. Thanks to gas spring assistance, these can be opened tool-free and remain securely in the open position. They are equipped with safety limit switches which interrupt the safety circuit, thereby ensuring maximum protection during operation and maintenance.

Spring-loaded feed belt with metal strips for a long service life

The feed belt is the central component of the AutoSplit and ensures the synchronised transport of the timber sections through the splitting channel until they are transferred to an optional conveyor belt. A sensor above the buffer belt detects whether there is any timber on it. If wood is detected, the system measures the diameter of the trunk to calculate its volume and starts the automatic splitting process. If no wood is detected, the AutoSplit’s automatic mode stops to prevent idling and unnecessary energy consumption. Robust metal strips are bolted to the upper side of the hydraulically driven conveyor belt with a mechanical link, spaced closely together. This significantly reduces wear on the conveyor belt, as these protect the belt from mechanical stress during wood feed and the splitting process. The frame of the feed belt is spring-loaded to effectively compensate for the movement of the timber during the splitting process. This protects the knife guides, the conveyor belt and the feed frame, reduces the splitting force required and thus extends the service life of the entire system. A sensor ensures maximum operational safety by detecting the maximum spring travel and, in such cases, stopping the splitting process to prevent damage to the machine. The control system can be used to specify how the system should respond in the event of this error: Either an error message is displayed, or automatic mode continues without interruption. In this case, the logs that have not been completely split (large pieces of wood) remain in the production flow. Alternatively, automatic mode is deactivated – in which case manual intervention is required: Using two buttons on the control system, the position of the piece of wood can be adjusted manually via the feed belt. A new splitting process can then be initiated manually by actuating two further buttons. This process can be repeated as often as you like.

Continuous wood feed

The buffer belt with a length of 2 metres serves as the buffer storage for pieces of wood that have previously been sawn by the PowerCut. This ensures that the AutoSplit remains continuously utilised – even when there is no steady supply of material during the log feeding process. The hydraulically driven conveyor belt with a mechanical link is controlled in synchronisation with the AutoSplit’s feed belt. This ensures that the pieces of wood are fed into the splitting area at regular intervals and with precision, thereby ensuring a smooth workflow. Side guide rails prevent the pieces of wood from twisting or toppling over. One of the guide walls can be adjusted tool-free to ensure optimum centring and adaptation to different log lengths. High-quality protective covers ensure maximum operational safety and prevent unauthorised access. The buffer belt is rotatable on the AutoSplit; on the opposite side, a connecting bracket ensures a stable support and a positive-lock connection to the PowerCut 700. For installation or maintenance work, the belt can be raised and lowered effortlessly using a hand-operated cable winch.

Intelligent control system with touchscreen and IIoT connection

The electronic control system continuously records sensor and input values ( .g. positions, temperatures, pressures, switch states), processes them in accordance with a pre-programmed sequence and then controls the outputs accordingly. It is positioned at an ergonomic operating height above the feed area, allowing for comfortable operation. The protective rain cover also ensures reliable operation in all weathers. A 7-inch touchscreen clearly displays all the information relating to the various functions and the safety circuit. The integrated control system processes and monitors a wide range of real-time data, such as the position of the splitting blade, the wood diameter, the hydraulic pressure and the oil temperature. At the same time, it monitors the safety circuit of the protective covers and controls the central lubrication system. Operational data can be digitally recorded and analysed via an IIoT connection. Thanks to intelligent functions such as OptiSplit, VolumeControl, and counters for splitting cycles and performance data (e. e.g. daily and total counters for cubic metres, loose cubic metres or solid cubic meters), the entire timber processing process can be efficiently monitored and documented. Particularly handy: The daily counters can be reset at any time, individual user parameters can be set directly within the system, and the wood feed rate is displayed as both the actual and target values. Even special operating modes such as ‘Sawing Only’ (OnlyCut), reduced lift or idle runs can be activated directly via the touchscreen. A software update can be carried out by the customer either via a memory card or, once authorised, via remote maintenance on the control system, provided there is a stable internet connection.

VARIO splitting system

The perfect interplay between the feed belt and the X-splitting blade ensures a consistent, high-quality cut – even with large wood diameters. The pieces of wood are fed past the knife in a synchronised manner by the feed belt and are split by the knife. Splitting the logs several times with the X-knife produces the square-section logs characteristic of the VARIO system, whilst maintaining a consistently high standard of quality. The log edge length can be adjusted continuously from 5 to 15 cm via the control system’s display – for maximum flexibility and ease of use.

POSCH splitting blades: durable & low-wear

The X-shaped knife is encased in a robust wooden mounting plate and guided linearly by roller bearings. Two hydraulic cylinders apply pressure to them against the wood before the splitting process, thereby securing them in place. The knife then passes through the slits in the wooden support plate and performs splitting on the wood. In addition, plastic guides ensure that the wooden support plate is guided precisely along the knife and prevent dirt from getting behind the plate. The splitting blade is made of high-quality, wear-resistant steel, which guarantees a long service life. A sophisticated design reduces the splitting force required: Thanks to its double-edged blade and slim design, the knife cuts effortlessly through the wood, ensuring faster, more efficient splitting. The extremely long, replaceable brass guides significantly reduce wear on the replaceable guide rail. Instead of regular, manual lubrication intervals, the automatic central lubrication system carries out this task for the splitting blade fully automatically – reliably as and when required and whilst the machine is in operation. The lubrication interval is adjustable. This allows the lubrication to be optimally adapted to the operating conditions, which increases efficiency and reduces maintenance costs. The hoses of the central lubrication system for the gap blade guide are routed through a maintenance-free energy chain. This reduces the risk of a hose rupture and wear and tear by ensuring controlled movement. This not only reduces downtime, but also extends the service life of all moving components. Thanks to the precise metering, only as much lubricant is applied as is actually required – this saves resources, protects the environment and reduces operating costs. A user-friendly indicator on the control display provides reliable information as soon as the lubricating grease needs to be topped up.

OptiSplit: Automatic splitting stroke optimisation

The splitting performance is improved because the stroke of the splitting blade is automatically adjusted to the length of the material being split, thereby reducing idle travel. The wooden support plate, which is guided linearly by rollers, surrounds the x-shaped splitting blade and moves in sync with it towards the trunk. The timber-holding plate exerts pressure on the timber against the rear wall of the machine frame and secures it in place, whilst the splitting blade continues to move through the slots in the timber-holding plate and splits the timber. As the splitting blade moves back, it retracts into the wood-holding plate and pulls it with it. However, only until the wood is no longer held in place. Once this has happened, the knife stops and the wood is cleared for the next feed rate. With wood that is easy to split, such as fresh beech, a full splitting stroke is not necessary. The stroke can be adjusted accordingly via the control system: The knife returns to its starting position even before it has completely penetrated the piece of wood, which speeds up the process and saves valuable time.

Less maintenance – longer service life

The integrated electric central lubrication system performs automatic and even supply of grease to the five lubrication points on the splitting blade guides. This significantly reduces maintenance requirements, prevents the unit from running dry and extends the service life of the moving components. At the same time, downtime is minimised – ensuring reliable operation and maximum productivity. The hoses running from the central lubrication system to the gap blade guide are routed through a maintenance-free energy chain. This reduces the risk of a hose rupture and wear and tear by ensuring controlled movement. The lubrication interval can be adjusted individually directly via the central lubrication pump’s control system.

OnlyCut function

Would you like to cut the trunk into short pieces without causing splitting – for example, to make kindling or for some other purpose? To do this, simply activate the OnlyCut function via the display. In this mode, all sawn log sections are discharged via the residual wood ejection without going through the splitting process, rather than being transferred to the AutoSplit’s buffer belt.