TPT January 2017

T E CHNOLOG Y

Fully automatic, integrated, complete machining THE companies RSA cutting systems GmbH and sema Systemtechnik GmbH & Co KG have developed and brought into operation an integrated high performance machining centre for sawing, de-burring, punching, doming, flattening and unloading of tubesmade of steel and square and rectangular tubes for PERI GmbH, a major manufacturer in the areas of scaffolding technology and formwork. Automatic flattening of lateral rods for branches such as scaffolding

The modular and therefore adaptable and extensible sawing machining centre has an RSA-developed, standardised and user-friendly operating concept that allows programming of all stations, including punching, doming and flattening unit from sema, via a single control system. In general, the machining centre is characterised by an efficient chaining of different processes in a single system with short processing times. For example, the cycle time including all single processes like rod feeding from the magazine, sawing, de-burring and double-side punching of up to eight holes for a steel tube 48.3 x 3.25mm is only six seconds. Alternatively, in the same low cycle time a tube of 38 x 3.2mm can be punched and domed from one side. This is not achieved by high-priced special tools, but by a fully optimised overall process that allows parallel processing steps. For instance, the RSA saw uses standard HSS saw blades that can be reground up to 15 times, and the punching units use standard tools. A key component of the new system is the single-cut high-performance saw Rasacut SC from RSA, supplemented by the fully automatic de-burring system Rasaplan, a custom-built punching and doming unit from sema, and RSA’s Rasaport unloading unit. The punching and doming unit can optionally punch each tube on one or both sides at different tube positions with up to four clearance holes and can deform the end of the tube. The punching of blind holes is also possible. The modern programming and control system allows different hole patterns. RSA produced a higher-level control for the special system, with a user-friendly operating concept that includes all plant modules. Another feature of the sawing and machining centre is that round, square and rectangular tubes that should not be punched are guided through the punching unit without a reduced output. For this purpose, belt transports are used in the area of the punching unit. The modular overall concept of the sawing and machining centre also allows the integration of further modules, eg for measuring, washing, drying and marking. The sawing and machining centre can be fully networked with EDP/

Photo credit: RSA/sema Photo credit: RSA/sema

The challenge was to be able to produce individual scaffolding parts as well as shuttering props with the sawing and machining centre faster than before. There were previously individual processing stations for each process, with set-up times of up to 30 minutes. The aim of the new line was to connect all processes in one system and to reduce the changeover time to less than five minutes, which is now being successfully implemented in daily operations at PERI. Project manager Günter Reif con- firmed, “Our ambitious demands for very short cycle and set-up time are already fully met. For this reason we are able to handle extremely economical both large series and fast and individual parts, that are less frequently used and required in lower quantities.”

Punching and doming of tubes

BDE systems to manage, for example, customer products, to report plant conditions, to remind maintenance, to request raw materials or to report the finished material development. The single-cut Rasacut SC saw covers a wide tube diameter spectrum with high output and minimal set-up times. Changes in length and blade change can be carried out in less than one minute, with format changes in less than five minutes. The stopper and saw blade are positioned fully automatically. The Rasaplan fully automatic brush de-burring system for simultaneous inside and outside de-burring is also designed for a high output. When changing a diameter or length section, set-up time is omitted because the necessary settings are made automatically. When developing the sema punching and doming unit, the focus was also on the shortest possible cycle times. To achieve flexibility of the tube length with minimum set-up time, a tool side can be driven and positioned via a servo drive.

Sawing, de-burring, punching, doming, flattening and unloading in one machine

Photo credit: RSA/sema Photo credit: RSA/sema

Double-side punching of up to eight holes simultaneously

RSA cutting systems GmbH – Germany

Email: rsa.d@rsa.de Website: www.rsa.de

sema systemtechnik GmbH & Co KG – Germany Email: info@sema-systemtechnik.de Website: www.sema-systemtechnik.de

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J ANUARY 2017