TPT January 2025

TECHNOLOGY

Fully automated order picking in the steel tube and bar industry FEATURING nine million measuring points and ensuring a fully automated and secure grip: KASTO has introduced its KASTOpick tube and bar robot solution. This system can pick and deliver flat, square and round materials, as well as round and profile tubes, without the need for human intervention. The solution is available for new systems or for retrofitting existing storage systems.

For many years, manipulators, such as KASTOpick sheet, have been used to separate metal sheets neatly stacked on load carriers. However, handling a bar stock cassette with chaotic storage is considerably more difficult. Dealing with non-oriented objects is challenging because their position and arrangement are hard to predict. A complex recognition and adjustment process is required to grip and place the bars correctly. KASTO offers a smart solution for efficient separation: KASTOpick bar optimises the removal of magnetic bright and black steel in both new and existing warehouse systems. This solution allows users to remove and manipulate different bars from storage cassettes without the need for human intervention in three-shift operation. This system recognises and grips not only flat, square and round bars but also round and profile tubes. Users can conveniently link several production steps using this system. KASTOpick bar accomplishes two tasks: it picks the bar stock and prepares bundles for shipping or supplies individual bars for further processing on the saw. Another special feature is that there is no need for teach-in by the user. To start the process, KASTOpick bar moves a 3D sensor measuring probe over the storage cassette, which can be up to 6m in length. An algorithm developed by KASTO is used to process the 3D point cloud generated by this scan. The software analyses the data to identify the bar locations and potential gripping points for the robots. Only those points are considered that allow the machines to deposit the bar without causing a collision. This intelligent calculation of the travel path prevents the robots from colliding and the bar from striking an obstacle in its path.

After scanning, the two robot arms grip a metal bar or tube at the optimum attachment points

To perform this procedure, the software predicts the proposed movement and optimises the route to the target position. The process starts anew with the next scan. The gripper system separates and moves a variety of different formats. This makes the user more flexible in handling and processing steel. The flat, round and profile materials can also be wrapped or labelled. KASTOpick bar also communicates with the ERP system and the upstream and downstream machines to provide the right workpiece at the right time and location. It connects storage system, saws or strapping units. The software also ensures the bars are stacked in an ideal pattern based on dimensions and order volume, using individual bar manipulation. KASTOpick bar can position rectangular material so that it can be ideally formed into a bundle. In its standard version, the system can grip a bar weight of up to 500kg. Higher loads are also possible upon request. A wide range of grippers are available to provide customised solutions – depending on the shape of the objects to be moved. KASTOpick bar automatically selects the ideal gripper for the specific task to safely separate and transport the material. Thanks to the fully automated removal of bars from storage cassettes, the workload of employees is reduced. Employees no longer need to remove and transport heavy and cumbersome material manually or by crane. Companies can therefore reduce physical demands on employees, preventing injuries and accidents. With its intuitive interface, the KASTOpick bar is easy and efficient for operators to use without requiring extensive training or specialised technical knowledge. Following brief instructions, users can work efficiently and productively with the operator-friendly separation system.

KASTO www.kasto.com

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JANUARY 2025