Increasing efficiency requirements and the growing shortage of skilled workers pose major challenges for manufacturing companies. KASTO addresses these developments with a completely newly developed control generation for its saw machines. It combines a modern operating concept with practical functions and enables both experienced professionals and newcomers to quickly, safely, and productively use the machines.
The specialist in metal sawing technology has completely revised its saw control. 'It was important for us to actively involve the employees who are on-site with customers every day from the very beginning,' says Sönke Krebber, member of the management board, research & development at KASTO. 'Through close collaboration with our experts from the service and commissioning departments, a control system has been created that is consistently oriented towards practical use and significantly eases many work steps for operators in their daily tasks.'
The new control system will initially be used in the KASTOwin series and will subsequently be expanded to other saws. An optimized software architecture ensures significantly reduced loading times, quick responses to inputs, and higher machine availability.
Clear dashboard and quick navigation
The heart of the new control system is a clearly structured dashboard that graphically displays important key figures such as running and standby times, current orders, or machine statuses. Operators can see at a glance what is currently happening, can flexibly rearrange orders, and comfortably switch between different views even during an ongoing cut. Parallel usable function windows and context-sensitive help reduce the necessary clicks and noticeably speed up operation.
Safe entry with the Simple Mode
The central element of the new control system is the Simple Mode. It reduces the display to the essentials and safely guides even untrained users through the sawing process.
Different user roles ensure that operators, masters, or maintenance personnel receive only the information relevant to their tasks. Individual settings, such as language, units of measurement, or preferred evaluations, can be personalized and significantly ease the onboarding process.
Efficient functions for recurring tasks
With the material library, pre-filled material data is available. Additionally, material data created at once can be accessed at any time. This reduces input times for follow-up orders.
Using a cutting plan, multiple sawing orders can be quickly, clearly, and intuitively created – even if they have different cut lengths or complex requirements. The cutting plan is clearly assigned to a specific item, ensuring clear structuring and traceability throughout the entire production process.
For each individual sawing order, individual process parameters can also be defined. This flexible parameterization allows for precise adjustments to the respective requirements while ensuring maximum efficiency.
In combination with the software module 'Optisaw light', the cutting plan unfolds its full potential. The solution ensures that all sawing orders are automatically and precisely assigned to the available bars. The system not only considers the desired cut lengths but also optimizes the order and placement of the cuts. Through this intelligent optimization process, each bar is utilized as efficiently as possible, significantly reducing waste and greatly increasing material efficiency. This not only leads to lower material costs but also supports a more sustainable and resource-saving production.
The functionality package is complemented by the new cycle stop, which allows orders to be specifically interrupted and later resumed exactly. Interruptions are transparently displayed and can be resumed without re-entering data.
Transparent diagnosis and analysis
The new control generation enables a clear fault diagnosis in case of disturbances, with a clear assignment to mechanical or electrical causes at the base machine, discharge, or feed. Time-consuming fault searches are eliminated. Extensive analysis functions also create transparency about running times, downtimes, and the condition of the saw band – an important basis for reliable shift planning and trouble-free unmanned operation.
Proven in real production environments
Even before the market launch, the new control system was intensively tested in everyday operations at Günther + Schramm at the Königsbronn location, where it completely replaced an existing saw. The southern German system service provider operates over 100 saws and produces more than ten million sawing sections per year. 'We can no longer do without the new control system,' says Angelo Faraci, one of the shift leaders and operators of the machine with the new control generation.
'When I operate three to four machines simultaneously, I need to be able to rely on the saws. Each shift is precisely timed – we need to be able to process all orders quickly, safely, and with few clicks.'
The successful practical test confirms the high everyday suitability and clear added value of the new control system. With this innovation, KASTO once again underscores its claim as a technology leader in metal sawing technology and offers a future-proof solution for modern manufacturing environments.
Author: Fabian Reiße
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