TPT September 2019

T E CHNOLOG Y

Automated storage and sawing systems SINCE 1993, storage and sawing technology from Kasto has provided dependable service to hydraulic equip- ment manufacturer Liebherr-Compo- nents Kirchdorf GmbH. However, to meet increasing demand for its hydrau- lic cylinders, the company decided to modernise and expand its production systems. Kasto was commissioned to upgrade the existing storage system for steel bar and tube as well as one of a pair of bandsaws and equip it with cus- tomised robotic handling. automatic cantilever arm and a large bandsaw from the KASTOhba series provided reliable service for 26 years. Until recently a production circular saw, which was of a similar age from the same manufacturer, was also in use. “We have granted this saw a well- deserved retirement, as in 2016 we modernised our sawing technology and increased cutting capacity to 430mm diameter with the addition of a KASTOtec SC 4 bandsaw, which is particularly effective at processing difficult-to-cut materials.

The robot is equipped with several exchangeable magnetic grippers able to pick up various cut lengths weighing up to 350kg from the sawing machines. Along the linear axis there are 18 storage locations for pallets and containers, the position of each being stored in the robot’s control system. The cut pieces are finally transported to elsewhere within the factory by lift truck for further processing. Mr L tzel said: “It was a major advantage having a single partner undertake all this work, as it made communication easy and avoided having to coordinate the activities of different suppliers. This was especially important as we had to carry out the work while the factory continued operating, without introducing too much disruption. Thanks to excellent organisation by Kasto, everything ran smoothly.” The benefits to production within the Kirchdorf factory are evident. One improvement is a lowering of the noise level in the working environment, as the robot places cut pieces quietly in their designated location, whereas before they used to drop into a bin and every time make what Mr L tzel described as “a horrible noise”. He added that for the same reason, chrome plated material remains undamaged after it is sawn. Further improvements include an ability to undertake material cuts up to three metres in length, higher quality of cut than previously, shorter processing times, minimisation of waste and a significant increase in production efficiency. An operator simply enters a cutting order at the control, whereupon the operating gantry crane of the storage system automatically transfers the required bar to one of the two saws, where the material is cut and the pieces handled and sorted, again without manual intervention. It is not only a safe operating environment, but also one in which long periods of unattended production are possible. Since it has been in operation, the system has run reliably without any noteworthy disruptions and with high availability, according to Mr L tzel.

Liebherr-Components has specialised in the production of hydraulic cylinders since 1958. Every year approximately 75,000 hydraulic cylinders, suspensions and system solutions for cylinders leave the plant to be used worldwide. Stefan L tzel, in the industrial engineering department at Liebherr- Components, recalled: “AKasto cassette storage system with 733 locations, an

“The saw is able to operate with either a high-speed steel or a carbide blade and is equipped with the Kasto Performance Cutting (KPC) package, which includes improved band guidance and vibration absorption for even higher cutting efficiency.” The bar storage system and KASTOhba bandsaw were in good mechanical working condition, but the drives, measuring systems, controls and cabling needed modernising. Kasto offered a turnkey package to update them as an economical alternative to replacing these two pieces of capital plant, and at the same time bring safety features up to current standards. Liebherr-Components, together with Kasto, developed a custom-made solution to automate the handling of cut pieces with an industrial robot moving between the two saws on a linear track.

For 26 years, Liebherr-Components Kirchdorf GmbH has relied on Kasto for storage and sawing

Kasto Maschinenbau GmbH & Co KG – Germany

Mounted on a linear track, the robot deposits cut pieces precisely and without damage

Email: kasto@kasto.de Website: www.kasto.com

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SEPTEMBER 2019