For metal processing companies, space-saving storage and powerful saws are indispensable helpers for stocking and cutting sheet metal and long materials. When processes also need to run smoothly and without friction, robots come into play. They ensure automated handling and take over the complete processing of the sawn sections.
In intralogistics, speed and flexibility are key – high cost pressure and international competition demand a digitized production. The potential of smart logistics is known by the storage, sawing, and handling technology specialist KASTO. The company from Achern is known for its technologies for all processes in storage, as well as for the logistics and processing steps before and after. For example, band saws of the KASTOtec series or the circular saws KASTOvariospeed have become indispensable in the daily operations of many metal processors. "Sawing today means much more than just separating a piece of metal."
"This is an important step that usually comes at the beginning of a process chain," explains Sönke Krebber, a member of the management board at KASTO.
Automatically palletizing and picking
Often, the saw alone no longer meets the demands of metal processors. They need to produce small batch sizes, and the processing along with subsequent processes should be included in the package, while personnel costs must not increase. Companies are rethinking; they either plan to integrate a robot directly at the saw or retrofit later. KASTO is ready for automated production and supports its customers in fully automated removal, post-processing, and palletizing with a robot handling system. Volker Bühler, as team leader in robotics, is an expert in automated processing machines. He is enthusiastic about his extremely flexible helpers: "With KASTOsort, we have an elegant and efficient solution in our portfolio that offers users a comprehensive concept." The robot handling system loads and unloads machines and driverless transport systems, but also includes deburring, chamfering, weighing, length measurement, marking, labeling, dust extraction, and chip cleaning.
The KASTOsort system uses industrial robots from ABB and is based on a decentralized self-organizing program logic. This means that no teach-in is required, nor does the user need to program anything. All necessary information is obtained by the tireless colleague through communication with the company's ERP system or the preceding and following machines. This ensures flexibility and enables the handling of all dimensions. Volker Bühler explains: "We cover an incredible variety – the robots can grasp parts the size of a coin as well as very heavy bars without the operator's assistance."
Individual concepts
Depending on the order, an optimal stacking pattern with the highest packing density in the storage containers is calculated. The robot is capable of automatically adjusting this stack cleanly and neatly to the item being stored. Grippers and gripping concepts also promote packing density and process safety. These gripping helpers are developed individually by KASTO – they can be vacuum suction cups, mechanical, or magnetic grippers. Software and electrical design also come from the engineers in Achern.
But the team around Volker Bühler also selects suitable change stations, pallet pickups, and chip removal systems according to the application.
The advantages of robot handling with KASTOsort are convincing: The user works more economically, increases their machine utilization, and the uptime of their tools through intelligent program sequences. If something changes in the machining center, they can respond flexibly. This improves competitiveness and allows employees to focus on more demanding tasks. "Those who invest in automation significantly reduce their operating costs," summarizes Volker Bühler. "A KASTOsort system can already pay for itself in a three-shift operation compared to a manual system after nine months."
Successfully in use
More than 100 users are already working with the robot handling system KASTOsort. One of the customers wanted to automate several saws. An industrial robot now moves along a linear axis between the two saws. This robot is equipped with several interchangeable magnetic grippers to pick up the different workpieces from the material removal of the saw machines. The robot's arm can effortlessly lift up to 350 kilograms. A total of 18 storage locations for pallets and containers are lined up along the linear axis.
The position of the various load carriers is stored in the robot's control – so it can precisely and gently place each part in the designated spot. Subsequently, employees transport the sawn sections to the next station using a forklift or pallet truck.
At another user, an industrial robot is connected to the saw, which automatically removes the finished sections from the machine's work area using various grippers, deburrs them, and sorts them according to the order. The parts are placed in various sizes of cardboard and plastic boxes specified by their customers, which are also provided by the machine. KASTO has developed a very special solution here: a container carousel with eight pallet spaces, where the robot can independently place and fill the respective boxes. Through sloped roller conveyors, the cardboard and plastic boxes in six different sizes reach the robot's work area. The control of the sawing center determines the suitable container for the respective workpieces based on the order data, which the robot then places on the prepared pallet using a suction cup. While the sections are being sawed and stacked, a printer simultaneously creates a shipping label for the current order. The robot also places this in the corresponding box using a suction cup. Once a pallet is completely filled, the carousel rotates one position further, so a new load carrier is available. Employees then transport the pallets with the pre-packaged goods to shipping using the pallet truck or forklift.
Everything from a single source
Both users are thrilled with the positive changes that are clearly visible in their production. And above all, the employees are pleased with the significant relief provided by the new mechanical colleague. The KASTOsort robotic handling system is just one proof of the high automation and processing expertise of KASTO engineers. With the integrated sorting solution KASTOsort tower, significantly more storage space is available in a smaller area. This fully automated system enables a manless 24/7 operation.
Sönke Krebber adds: “Our individual products can be connected to form a complete system. This allows us to support the customer throughout their entire process chain and provide them with a one-stop solution for processing from round steel to the ready-to-pick saw section in the box.”
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