Schwing Introduces MDS 5034 Mobile Diamond Wire Saw for Mining Applications

Schwing has developed the MDS 5034, a mobile diamond wire saw designed to streamline the on-site cutting of large natural-stone blocks. Its reliability is supported by the use of plain bearings and energy chains made from high-performance polymers provided by igus.

In typical quarry operations, dust fills the air as heavy machinery maneuvers through the site, with temperatures often exceeding 30°C. After explosives are carefully placed and detonated along a rock face, massive boulders are released and fall to the quarry floor. At this stage, the MDS 5034 — mounted on a Manitou telescopic handler — is deployed and remotely adjusted for the required cut. Its pivoting range of 66° allows precise positioning. A water jet is used to suppress dust, while the diamond wire cuts at speeds between 20 and 40 metres per second. The machine can handle stone blocks up to five metres in width and cut to depths of 3.4 metres, achieving a cutting speed of around 10 cm per minute, depending on the material. Once the task is complete, the saw folds into a compact shape for easy transport on a standard low-loader, which can be moved without special permits due to its sub-three-metre width.

Given the challenging conditions and forces at play — up to 2.5 times gravity — as well as limited cleaning options due to scarce water resources, Schwing selected igus plain bearings and energy chains for the MDS. These components, made from tribologically optimized plastics, are engineered to handle heavy loads while remaining resistant to wear and dirt accumulation.

Expanding into New Markets

The MDS 5034 represents Schwing’s strategic move into a new application area beyond its core expertise in concrete pumps. The concept was introduced by Markus Hatzer, an Innovation Assistant and Application Engineer with extensive experience in the natural-stone industry. His initial idea for a mobile stone saw dates back to 2006, with the first patents registered in 2012. After constructing a large prototype featuring 20 rollers — later refined to just seven — Hatzer presented his concept to Schwing. The company’s R&D team collaborated with him to develop the final product. Currently, a dedicated team of ten works on the MDS, which marks Schwing’s foray into the natural-stone processing sector.

Contributing to Sustainable Stone Processing

Drawing from his background in the stone industry, Hatzer understood the significant resources involved in blasting and processing stone. Conventionally, quarried stone is transported hundreds of kilometres for processing, only to be discarded if defects such as cracks or discoloration are discovered. Blasting also leads to material losses of up to 20 cm. Furthermore, lubricants from conventional machinery can contaminate the stone, making it unusable.

To mitigate these issues, Schwing incorporated igus iglidur Q2 cylindrical plain bearings in the MDS 5034’s joints. These bearings are designed for high-load pivoting applications and are noted for their resistance to edge pressure, shocks, and impact — making them well-suited to quarry conditions.

Overcoming Initial Doubts about Polymers

While igus has collaborated with Schwing since the project’s early stages, the idea of using plastic bearings initially met with skepticism. Development Engineer Daniel Kriegl was accustomed to using brass components for such demanding loads. Confidence in the use of igus bearings was bolstered by a case study from an Austrian excavator manufacturer. Through collaboration with igus Technical Sales Consultant Fabian Legner, Schwing became convinced of the performance capabilities of the polymer bearings. In practice, the dampening properties of iglidur Q2 bearings proved beneficial for the MDS, which operates with limited impact load during its extension and retraction cycles.

Maintenance-Free, Clean Operation

A key advantage for Schwing is the self-lubricating, dry-operating nature of igus plain bearings, which eliminates the risk of lubricant contamination. These properties also reduce maintenance requirements — a crucial factor in quarries where regular cleaning is not always feasible. Kriegl noted that dirt ingress in plastic bearings poses fewer problems than in brass, making the components more forgiving. Each MDS 5034 currently contains 40 bushings of various sizes, and up to 100 more bearing points may be added in the future.

Cable Protection with Energy Chains

Alongside the Q2 bushings, Schwing has installed igus energy chains to ensure safe and reliable cable guidance when the saw extends and aligns. Although many systems were considered, Schwing chose igus based on positive experiences with their bearings. Early machines used the H4.56 series, while later models adopted the H4Q.58 series, which offer a larger inner height of 58 mm.

Thanks to the igus components, the MDS 5034 can withstand demanding quarry conditions while offering a cost-effective, sustainable solution for on-site stone cutting. By reducing transportation, material waste, and environmental impact, the collaboration between Schwing and igus represents a meaningful advancement in the field. As Kriegl notes, the level of support and the suitability of the products have made igus a reliable partner for this innovative development.