SpaltFix S-500 Vario Plus

After the optional longitudinal conveyors, four ball-bearing-mounted feed rollers – which are fitted within the saw frame – ensure a reliable feed rate for the trunk until it reaches the wood stop. The well-designed construction of the machine frame makes it easier to feed the trunks into the feed area. Thanks to the inclined feed rollers with their diagonally arranged, blade-shaped guides, the trunk is automatically guided towards the rear wall of the cutting range as it is fed at a high feed rate. This ensures that the timber is always in the optimum position so that the machine’s maximum cutting diameter can be fully utilised. The robust rollers are connected by durable roller chains – integrated chain tensioners perform automatic tension maintenance, eliminating the need for manual retensioning. A powerful hydraulic motor drives the system, whilst solid bearings ensure low-wear, low-maintenance continuous operation. A metal panel between the rollers prevents short trunks from falling through and largely prevents debris from getting under the machine. A deflector plate ensures that any bark debris is channelled away in a controlled manner, whilst protecting the hydraulic components underneath from contamination. To prevent damage caused by the log feed, a built-in hydraulic valve ensures that the feed rollers are only activated once the saw blade is in its starting position.

The following components are clearly arranged on the control panel: - 1 joystick for controlling the saw, the wood flap and the feed mechanism, and a push-button for activating the cutting stop; - control levers for operating the manipulator and the cross conveyor; - a switch for the optional lighting; - two electric push-buttons for switching the electric drive on and off; - an emergency stop button. Beneath the control panel is a height- and angle-adjustable footrest which, in the context of its application with a standing aid, ensures a particularly comfortable and ergonomic working posture – even during long periods of use.

The patent-pending system enables an exceptional cutting diameter of up to 490 mm – using a saw blade with a diameter of just 1100 mm, thereby offering the ideal combination of efficiency and power. For maximum cycle performance, the saw feed is optimised as standard for a cutting diameter of 450 mm. If necessary, the operator can immediately activate the cutting reserve using the joysticks, thereby utilising the full cutting diameter of 490 mm. At the same time, the system elevates process reliability: In the case of trunks at the diameter limit, the operator is alerted to the fact that the cutting reserve must be specifically activated. This enables him to see straight away that the trunk to be processed is at the diameter limit.

The integrated SawControl function uses a sensor fitted directly to the saw shaft to monitor the saw blade’s speed in real time and automatically controls the feed rate. If the speed falls below the set limit whilst sawing, the saw feed is automatically interrupted. At the same time, the saw blade is pulled back slightly by return springs – this allows the speed to increase fast again, and the sawing process continues automatically. This reliably prevents the saw from being overloaded, ensures safe operation and extends the machine’s service life.

Two gripping arms hold the trunk securely in place before and during the sawing process. Both gripper arms are rotatable and are located within the feed area. Before the sawing process begins, they are automatically controlled by a hydraulic cylinder. The front hold-down device presses the trunk against the rear wall of the cutting range with even pressure, pushing it as far as possible. The second hold-down device, which extends from the rear panel, then closes and secures the trunk firmly – even if it is not fully flush against the rear panel. This reduces movement of the trunks during the cutting process. Robust ridges on the contact surface provide additional grip and reliably prevent the wood from twisting or slipping. The result: No slippage, fewer jams, no dead travel, significantly shorter cutting times – and thus full utilisation of the maximum cutting diameter.

After sawing, the piece of wood initially remains on the wood flap. When the joystick is actuated, the hydraulic wood flap folds down and transfers the log in a controlled manner onto the buffer belt of the optional AutoSplit.

The adjustable longitudinal stop ensures that the trunks are all the same length – without having to keep checking the measurement marks. In conjunction with the hydraulic clearance mechanism, the stop is automatically moved away from the trunk before the cut begins, to prevent the saw or the timber from becoming jammed. The stop can be easily accessed from the operator’s station by opening the protective cover tool-free. It can be adjusted tool-free in a matter of seconds in 1-cm increments from 12 to 50 cm. This means that the desired cutting length can be adjusted flexibly at any time. For offcuts that are too short to reach the stop, there are clearly visible length markings on the rear panel to the left of the saw blade. This means that even the final section can be aligned manually with ease and precision, or cut to the required length.

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.

The AutoSplit’s fully automatic splitting function is activated at the touch of a button: The wood is fed in at regular intervals via the feed belt and then split using the X-knife. A built-in sensor on the buffer belt continuously monitors the wood supply. If there is no wood on the conveyor belt, the AutoSplit’s automatic system stops, thereby preventing unnecessary energy consumption and the machine running empty, which results in a more consistent quality of firewood. Automatic mode starts automatically as soon as new wood is fed into the machine. An optional conveyor belt, which is connected to the machine’s hydraulic system, is automatically started and stopped by the splitting function. This prevents a blockage in the transfer area between the splitter and the conveyor belt. Whilst AutoSplit handles the entire splitting process automatically and reliably, the operator can concentrate fully on feeding the material onto the buffer belt.

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.

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. At the same time, kindling can be produced efficiently from logs with a log diameter of up to 35 cm. The v-shaped arrangement of the lower cutting edges on the X knife is specially optimised for kindling production, ensuring optimal splitting results. The log edge length can be adjusted continuously from 2 to 20 cm via the control system’s display – for maximum flexibility and ease of use.

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.

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.

Should the log section not be split – for example, for further processing elsewhere? The OnlyCut function can be activated via a simple setting on the display. In this process, all log sections are passed through AutoSplit without being subjected to splitting.

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.