Automated precision milling of ultra-flat industrial floors

GREATER FLATNESS, LESS DOWNTIME

Even minor floor irregularities can slow down automated intralogistics systems. Conventional floor grinding and milling methods, however, only reproduce existing deviations. The laser-controlled, high-performance floor milling machine LASER CAMEL from the Dr. Schulze Group, headquartered in Wilnsdorf, takes a different approach: It actively mills industrial floors to a new reference level – with flatness of up to ±1 mm over a length of 50 meters.

In logistics and production halls high-precision industrial floors are a key requirement for the safe and efficient operation of automated intralogistics systems. The quality and accuracy of the floor increase the speed and operational precision of the automation systems used, while simultaneously minimizing maintenance and downtime. Even minor unevenness can lead to vibrations, increased wear, misalignment or reduced performance of these systems.

High-precision industrial floors with stringent requirements for flatness and long-term stability can be produced in new buildings either using laser-guided floor pavers or by applying of special self-leveling screeds. For existing hall floors, these methods are either not applicable or involve high costs and lengthy downtime.

Therefore, when reworking older floors or newly constructed surfaces that have deviated from the required tolerances during the concrete curing process, only mechanical processing by grinding or milling is feasible. However, traditional grinding and milling methods are increasingly reaching their limits, as they typically follow the existing floor profile and reproduce the existing unevenness. Against this backdrop, sensor- and laser-controlled milling concepts are gaining importance, as they specifically create an independent reference level with tight tolerances. This is where the new technology, which the Dr. Schulze Group is launching on the European market this year, comes in.

Machine concept: Leading instead of following

The centerpiece of the new precision milling process is the high-performance LASER CAMEL floor milling machine with an active guidance system, that controls the milling process depending on the substrate. While conventional machines reproduce unevenness by removing the same layer thickness everywhere, the LASER CAMEL uses precise laser control systems and intelligent sensors, which not only continuously and automatically adjust the milling depth but also control the milling machine’s travel path with an accuracy of 3 mm – crucial for processing of VNA floors.

The machine orients itself to the reference plane defined by the laser transmitter and mills the floor to this predetermined level. Local bumps, depressions or waves therefore do not affect the resulting flatness of the floor. This principle makes it possible to produce even large industrial floors with consistent flatness values, even if the existing surface exhibits significant variations.

Furthermore, LASER CAMEL features an integrated system for controlled milling head tilt. This allows ramps, slopes and transition areas of narrow aisle surfaces to be machined with a uniform milling depth and inclination. The machine automatically maintains the preset tilt angle without the need for manual adjustments. This enables LASER CAMEL to flexibly adapt to virtually all geometric requirements of industrial floor surfaces.

An additional operating mode allows the machine to be used quickly and effectively for conventional surface preparation and for exposing aggregates (for example, in the production of terrazzo), even without laser control. In this mode, the machine removes most irregularities and creates a fine, uniform surface structure as a basis for further processing.

Productivity and cost-efficiency

The LASER CAMEL is built as a fully gear-driven milling machine. The elimination of belt drives reduces maintenance and increases operational reliability, especially under high continuous loads. Its robust construction withstands even high-strength concrete surfaces and continuous industrial use.

Another feature of the machine is its finely adjustable milling depth. The working depth can be set in very small increments of 0.25 mm, with a maximum milling depth of 25 mm per pass. The machined surface acquires a fine milled texture, which can be completely removed with a single subsequent grinding pass using #40 diamond grit.

The LASER CAMEL doesn’t follow the existing standard, it creates a new reference level.

A key argument for using the LASER CAMEL is its high productivity. With an average milling depth of 5 mm, the machine can achieve a daily output of 350 to 400 m² (based on 8 hours of operation) – a significant increase in efficiency compared to conventional methods.
Such enormous productivity with the LASER CAMEL results from:

▪ Higher material removal rate due to a milling depth of up to 25 mm per pass,
▪ Reduced personnel requirements due to automated control,
▪ Low subsequent floor processing demand due to fine surface structure,
▪ Minimal dust disposal efforts due to dry milling,
▪ Compact dimensions and low weight (approx. 1,200 kg) of the machine, which simplifies its transport and the setup of the construction site.

Especially in the case of large-area industrial floors and the processing of narrow aisle floors, these factors have a positive effect on the overall costs and scheduling.
During the development of the LASER CAMEL, care was taken to ensure that the floors processed with this machine meet the criteria of internationally recognized standards for industrial floors, including EN 15620 (EU), DIN 15185 (DE / VDMA), ACI F-min (USA), TR34 (UK).

Further system components

For even more effective operation, LASER CAMEL is complemented by other machines from Dr. Schulze’s product portfolio. For example, WOLF MAX – a self-propelled, high-performance dust extraction system for dust-intensive floor preparation – can be directly combined with the laser-guided LASER CAMEL. With its continuously adjustable airflow of up to 1,620 m³/h, high-performance filtration (8 antistatic filters) and automatic filter cleaning, WOLF MAX ensures continuously dust-free operation of the entire machine package. A frequency-controlled suction turbine, integrated feed drive, wireless remote control and a battery for off-grid transport make WOLF MAX efficient and practical for demanding construction site environments. Both machines can easily be operated simultaneously by a single person.
For post-processing of the surfaces milled with the LASER CAMEL, the company offers various grinding machines depending on the application. For example, narrow aisles can be post-processed in a single grinding pass using the DBS-820 class grinding machines with a working width of 780 mm, while the gear-driven ride-on grinding machine DBS-1520-8H, with its grinding width of 1,520 mm, is suitable for producing large-area, ultra-flat industrial floors.

Conclusion

The machine package presented by the Dr. Schulze Group, centered around the high-performance automatic milling machine LASER CAMEL, represents a technological paradigm shift in the production of ultra-flat industrial floors. Through the combination of intelligent laser guidance, comprehensive sensor technology and precise depth control, the floor is actively milled to a new reference level. The result is reproducible flatness, high efficiency and reduced costs and processing times compared to conventional methods.
According to the manufacturer, the LASER CAMEL can achieve flatness levels of up to ±1 mm over a length of 50 meters in automatic operation – a value that significantly exceeds the capabilities of conventional methods. This makes the LASER CAMEL particularly suitable for projects with high demands on floor precision and execution efficiency.