Digitization and networking of production and logistics processes are rapidly on the rise in metal processing, according to KASTO.
With the robotic handling system KASTOsort tower, KASTO enables the automation of upstream and downstream manufacturing processes.
The KASTOsort robot connection can be used to automate processes such as the removal of cut sections and various other tasks, from deburring and chamfering, centering and threading, marking and printing to sorting, stacking, and order picking.
The KASTOsort robotic handling system can pay for itself after only nine months compared to a manual system in three-shift operation, KASTO reported.
KASTOsort for robotic handling features intelligent program sequences to enable the user to work more efficiently while increasing machine utilization and extending tool service life.
Space-saving storage systems and high-performance saws are crucial for metalworking companies to store and cut sheet metal and metal bar stock. When processes need to run seamlessly and without operator intervention, robots come into play. They help ensure automated handling and perform the entire prefabrication of the cut sections.
Intralogistics focuses on speed and flexibility. High-cost pressures and international competition make digitalized production necessary. KASTO offers technologies in all storage system processes, as well as the logistics and processing steps before and after. It also offers bandsaws, such as the KASTOtec series or KASTOvariospeed circular saws.
Automated Palletizing and Order Picking
More often than not, the saw by itself no longer meets the needs of metalworking companies. They need to produce small batch sizes; the prefabrication, including all downstream processes, should be integrated into the package, while simultaneously ensuring personnel costs do not increase. Companies are reassessing their processes and considering either integrating a robot directly into the saw or retrofitting it later. KASTO is prepared for automated production and assists its customers in fully automated discharging, reworking, and palletizing using a robotic handling system.
As the Robotics Team Leader, Volker Bühler is an expert in automated metalcutting machines: "KASTOsort is an elegant and efficient solution in our product range that offers users a comprehensive concept."
The robotic handling system loads and unloads machines and operator-free transport systems while also integrating deburring, chamfering, weighing, length measurement, marking, labeling, extraction, and chip removal.
The KASTOsort system utilizes industrial robots from ABB and is based on a decentral self-organizing program logic. Due to this system, no teach-in or programming is required by the user. The diligent colleague acquires all necessary information by communicating with the company's ERP system or the upstream and downstream machines. This enables a high degree of flexibility and enables the handling of any required dimensions.
"We cover a wide range-our robots can handle items as small as a coin or as heavy as large bars without operator assistance," said Bühler.
Individual Concepts
An ideal stacking pattern is calculated based on the order to achieve the highest packing density in the storage containers. The robot is capable of automatically adjusting this stack neatly and orderly to the item to be stored. Grippers and gripper concepts also enhance packing density and process reliability. KASTO custom designs these gripping assistants to meet its customers' specific needs-these may include vacuum suction devices and mechanical or magnetic grippers.
The engineers also develop the software and electrical design. The team, led by Bühler, is responsible for selecting changing stations, pallet receivers, and chip removal systems to best meet the application's requirements.
According to the company, benefits of using KASTOsort for robotic handling include intelligent program sequences that enable the user to work more efficiently while increasing their machine utilization and extending tool service life. If changes are made in the machining center, it can react flexibly. This enhances competitiveness and enables employees to concentrate on more challenging tasks.
"Companies that invest in automation can significantly reduce their operating costs," said Bühler. "A KASTOsort system can pay for itself after only nine months compared to a manual system in three-shift operation."
The System in Operation
Already over 100 users work with the KASTOsort robotic handling system. One of these customers wished to automate several saws. An industrial robot now moves between the two saws on a linear axis. This robot is equipped with several exchangeable magnetic grippers to pick up various workpieces from the material disposal of the sawing machine. The robot arm can lift up to 350 kg. Along the linear axis, there are 18 storage locations for pallets and containers. The robot's control system stores the positions of the various load carriers, enabling precise and careful placement of each part in its designated location. Employees then transport the cut sections to the next station via forklifts or lift trucks.
At another user station, an industrial robot is linked to the saw. The robot removes the finished sections automatically from the machine's work area, using various grippers that deburr and sort them according to the order. The parts are stored in cardboard and plastic boxes of various sizes as specified by the customer, which are also provided by the machine.
KASTO developed a unique solution in this case: a container carousel with eight pallet spaces on which the robot can independently place and fill the respective boxes. The cardboard and plastic boxes, each in six different sizes, enter the robot's work area via inclined roller conveyors. The control system of the sawing center uses order data to select the appropriate container for the respective workpieces. The robot then uses a suction device to place them on the provided pallet. While the sections are being cut and stacked, a printer creates a shipping label for the current order in parallel. The robot also places this in the respective box using a suction device. Once a pallet is filled, the carousel rotates one space further, making a new load carrier available. The employees then use the lift truck or forklift to transport the pallets with the prefabricated goods to the shipping department.
Due to the integrated KASTOsort tower sorting solution, more storage space is available in a smaller footprint. This fully automated system enables 24/7 operator-free operation.
For more information contact:
KASTO Inc.
3002 Venture Court
Export, PA 15632
724-325-5600
sales@us.kasto.com
www.kasto.com