Automation, networking and robotics are rapidly gaining ground in metalworking – and in storage and sawing technology. Storage systems and sawing machines are increasingly being integrated into a uniformly controlled material flow in which all processes between incoming and outgoing goods are fully automated – from the storage of the long goods raw material to the dispatch of the palletized finished parts. This enables users to make their production processes much more flexible and efficient, improve working conditions and significantly reduce operating costs. At Kasto, these topics have long since ceased to be visions of the future.

Whether they are in the steel trade, the automotive and supplier industry or in mechanical and plant engineering, metalworking companies across all industries have been facing increasing demands for years. Customers expect ever greater production flexibility, from batch size one to mass production. The variety of materials and sizes is steadily increasing. At the same time, quality standards are rising and there is continuous pressure to cut costs. To hold their own against international competitors, companies need versatile and efficient solutions for a wide variety of production tasks.

Kasto offers efficient raw material management through fully automated storage systems

More and more users are relying on the automation and intelligent networking of individual workflows in production and logistics. This begins with the storage of the delivered raw material – instead of the previously widespread floor or cantilever storage, companies are increasingly relying on fully automatic long goods storage systems. These automated software-controlled systems have completely convinced users with their significantly higher storage density, fast access times and maximum stock transparency.

Cassettes are usually used as load handling devices for the storage of long goods. A storage and retrieval machine automatically transports these to one or more transfer stations in line with the “goods to the next process” principle. These can be designed differently for the respective requirements, as fixed stations, for example, or in movable form as longitudinal or transverse transfer carriages. Automatic storage and retrieval is not only much faster than by hand, it also protects employees from accidents and injuries as the heavy and bulky goods do not have to be moved manually. Orders are processed at the push of a button via the warehouse control system – or directly via a higher-level ERP system to which the control system is connected via an interface.

Optimized added value thanks to the linking of the storage systems with fully automatic sawing machines

The sawing of the articles removed from storage is often the first step in processing or manufacturing. Here too, all processes are increasingly organized without any human participation. The modern Kasto sawing machines can be seamlessly connected to the raw material warehouse by means of manipulators and conveyor technology and are supplied with the required materials. Depending on how it is equipped, the sawing machine can also run by itself. Material is fed to it automatically, and an intelligent machine control system sets all parameters, such as cutting length and cutting speed, based on the job data. State-of-the-art production saws can thus carry out a variety of jobs in succession with different materials and diameters, and operate autonomously for long periods.

High performance and perfection thanks to the integration of intelligent robots

Industrial robots also have considerable potential when it comes to handling and processing finished cut parts. Depending on the production cycle, for example they can remove the sawn parts from the machine at maximum speed, so employees no longer have to carry out this repetitive task. In addition, the robots can be used with the appropriate tools to add value for deburring, chamfering, marking, centering, cleaning or measuring and testing the workpieces. The sections can be weighed, sorted by size or order, and stacked on pallets or in tightly packed containers. For complex processes with different work steps, combinations of several robots and clamping devices can also be realized with Kasto systems. Further connection to driverless transport systems (AGVs) is also common practice nowadays.

Downstream processes are relatively easy to automate with volume saws that process only a few different component geometries. The situation is somewhat different with individualized job saws, however; they have to flexibly process numerous materials and dimensions, and the greater the diversity, the more challenging it is to fully handle all the tasks. For example, the optimal selection of robot tools is important, because the robot should be able to manipulate all the objects to be handled with as few aids as possible. This reduces procurement costs, minimizes idle times and increases productivity. Users can choose from mechanical, magnetic or vacuum-driven grippers. The grippers should be as compact as possible to give the robot easy access to the cut parts. Kasto supports users in defining the optimal tools for the upcoming tasks. In regular operation, the robot then independently decides which tool is best suited for the current task. The decision criteria may be the accessibility of the workpiece or the optimization of the stacking pattern.

Industry 4.0 has long since arrived in the world of storage and sawing technology

With the right components, storage, sawing, automation and robotics technologies can be combined to form decentralized and highly integrated systems that are seamlessly integrated into one continuous material flow. The manufacturer Kasto realizes combined storage-sawing-robot systems for its customers, in which all storage, handling, sawing, marking, palletizing and bundling processes run fully automatically, from the storage of the raw materials to the picking of the sections. The big advantage here is that the entire system functions with a uniform control software, which can be connected to existing Erp systems such as Sap with only one interface. This significantly increases transparency and efficiency. With additional production machines, such as for turning or milling, the storage, sawing and robotic systems can be linked to form a fully digitalized and automatic production system that organizes itself decentrally and independently, in line with industry 4.0.

Automation and robotic support offer significant advantages for the user, who can significantly increase productivity with less personnel, since many processes are not only unmanned, but also run much faster. It is easier to compensate for staff absences due to illness, and production simply continues even during breaks or after shifts. The result is lower personnel costs and a high degree of flexibility in terms of capacity utilization. For example, companies can process order peaks much better and drastically reduce non-productive times. This also quickly becomes noticeable from a profitability point of view.

Users and their customers benefit equally

Working conditions are also improved by the automated technology, because employees are relieved of heavy, tiring and monotonous work, reducing the risk of accidents and injuries. The quality of the sawn sections is also enhanced, because the robot processes all the parts uniformly and precisely, sorts them reliably and stacks them cleanly. This ultimately benefits not only the plant operators, but also their customers.

Manufacturers of steel tubes and bars are increasingly confronted with the fact that their products must meet higher quality requirements. Tight specifications for precise outer diameters are established in the market for many years, but demands for product straightness are now increasing.

In the past, a few off-line samples were used to analyze the entire production. Important process information was lost and a complete quality control across the entire production could not be guaranteed.

With the new Bendcheck system from Zumbach, straightness, diameter and ovality can be measured directly in the production process. With an extension of the number of measuring points, head and tail bend of the product can be determined in addition to the straightness. Each pipe or bar is therefore completely recorded, measured and logged. Deviations are indicated in real time, so that the production process can be optimized quickly and profitably and unsatisfactory products can be sorted.

A customer-friendly display and control unit visualizes all important and relevant data at a glance. Measured values, statistics, trend charts and process data can be displayed clearly and conveniently. Thus, the new Bendcheck system offers a complete measuring solution for the increasing demands of the market.

As part of the fourth industrial revolution, Industry 4.0; in-line measuring systems are taking over increasingly more important roles. Also in this area the new Bendcheck system can fulfill the high expectations. The seamless acquisition and processing of measured data enables exchange with higher-level systems via communication protocols such as OPC UA and therefore making an important contribution to the digitalization of production processes.

With the Bendcheck system from Zumbach an industrial solution is now available which records and makes available all important data of a modern production.

Collaboration with Warwick Manufacturing Group Yields Synergy Effects

The recently opened Solutions Centre on the campus of the University of Warwick/UK is equipped with the latest systems for sample preparation and material characterisation. 

Buehler ITW Test & Measurement, a leading manufacturer of instruments, consumables and accessories for metallography and materials analysis, has opened a new European Solutions Centre in a collaborative venture with Warwick Manufacturing Group (WMG) with over 600 staff and a strong relation with over 1000 global companies, offering support to over 1800 SMEs through dedicated programmes. Part of WMG’s Materials Engineering Centre at the University of Warwick campus, Buehler’s new Solutions Centre aims to support academic and industrial research on various technologies ranging from additive manufacturing, energy storage, machining and processing of metallic and composite materials to joining technologies.

The new laboratory is equipped with latest metallographic sample preparation equipment, including several abrasive and precision sectioning machines, high-end grinder-polishers and a spectral analysis system for chemical characterisation of materials. Available equipment also includes Buehler’s latest hardness testers in varying degrees of automation and testing capabilities, and Nikon optical microscopes interfaced with Buehler’s own image analysis software for ideal metallographic analysis.

Dr. Evans Mogire, European Technical and Laboratory Manager at Buehler, comments: “The new Solutions Centre allows us to better address complex customer applications and/or technical requests relating to metallography and provides exceptional facilities for conducting and hosting seminars in the metallographic sector. The collaboration with WMG is a win-win relationship, offering both resident material scientists and Buehler access to latest characterization technologies for metallic, polymer, ceramic and composite materials.”

Paul Johnson, Technical Services Manager at WMG, adds: “This well-equipped microscopy, metallographic and materials preparation laboratory provides a valuable resource for the entire group. It offers us the opportunity to work side by side with a leading developer, producer and supplier providing us with leading-edge, perfectly maintained metallographic preparation and characterisation equipment, whilst Buehler can benefit by working with the very latest materials that we are developing and gain valuable insights for the further development of its product range.”

Written by:

Dr.-Ing. Jörg Wolters, Konsens PR GmbH & Co.

Frickenhausen/Stuttgart, 3 June 2019 – The 14^th Blechexpo, in combination with the 7^th Schweisstec, will welcome exhibitors and expert visitors to Stuttgart with world-class process competence covering all aspects of sheet metal, pipe and profile processing from the 5^th through the 8^th of November, 2019. The two complementarity industry events provide expert visitors with comprehensive product and service offerings dealing with all facets of thermal and mechanical processing, as well as welding, joining and fastening technology.

Floor Space, Exhibitors, Internationalism: New Dimensions in Sight

The Blechexpo-Schweisstec trade fair duo takes place once every two years. Roughly five months before the event opens its doors, project manager Georg Knauer from trade fair promoters P. E. Schall GmbH & Co. KG is already registering more exhibitors, more exhibition floor space and higher levels of internationalism for Blechexpo and Schweisstec than two years ago. An increase amounting to more than 150 primary exhibitors and a 20% rise in exhibition floor space as opposed to the corresponding timespan in 2017 has already been verified, and it’s becoming apparent that the results from the record-breaking year in 2017 will be topped. A total of roughly 1500 exhibitors will set the tone at Blechexpo-Schweisstec in nine exhibition halls in Stuttgart. Bookings and reservations from foreign countries near and far have even doubled as compared with 2017 – a full year before the trade fair opens, the figures from 2017 for technology companies from Italy, China, Turkey and Spain had already been exceeded. The reason for this boom is the strictly practice-oriented concept of the trade fair duo: Blechexpo-Schweisstec covers all relevant issues and trends with relevance for the digitalised, automated world of sheet metal and metals processing.

Sheet Metal Still Dominates as a Structural Material in Machinery and Equipment Manufacturing

As a structural material – along with pipe and profile materials – sheet metal has evolved into a common alternative to conventional cast iron, steel and plastic constructions. FEM optimised lightweight design and modular component systems characterise the image of modern, material, weight and cost-saving vehicle, machinery and equipment manufacturing – all the

more reason to focus on precision cutting, stamping and forming of steel, aluminium and non-ferrous sheet metal at Blechexpo and Schweisstec.

Expert visitors are presented with solutions and systems covering all aspects of pre-processing and final processing, module assembly and surface finishing for sensitive, visible components. The issues of lightweight design, design engineering solutions, handling, quality assurance, automation and digitalisation in sheet metal processing and joining technology are also dealt with extensively.

Exchange of Ideas and Knowledge Transfer: Stahlnews Expert Meet on Opening Day

stahlnews.de GmbH & Co. KG, in cooperation with the trade fair promoters, will organise the 4^th Stahlnews Expert Meet on the evening of the first day of the trade fair on 5 November 2019, in order to promote an intensive exchange of ideas and knowledge transfer. This event will be held in keeping with the motto “The Steel Industry in Times of Globalisation and Industry 4.0”, and renowned speakers will hold short presentations on the latest developments concerning all aspects of steel and production. Further representatives of renowned companies will hold brief presentations on the following day at the Blechexpo Forum. Participation at the meet will provide expert visitors with an extensive knowledge update.

www.Blechexpo-Messe.de

The Schall Group of Companies
Trade fair promoters P. E. Schall GmbH & Co. KG and Messe Sinsheim GmbH of the Schall group organise pioneering technical trade fairs and crowd-pulling public exhibitions. Depending upon event scheduling, 17 international technical trade fairs are held both nationally and globally, and six renowned exhibitions are promoted in Germany covering leisure activities each year.

Trade Fairs Organised by P. E. Schall GmbH & Co. KG: Control, Motek, Bondexpo and Optatec are global frontrunners, and are recognised as leading international trade fairs. Fakuma and Blechexpo/Schweisstec have also established themselves at the international level and place second in the global rankings for their respective sectors.

Exhibitions Organised by Messe Sinsheim GmbH: Faszination Modellbahn, Faszination Modellbau Friedrichshafen, Echtdampf-Hallentreffen Friedrichshafen, Modellbahn Cologne.

The Schall group of companies traces its origins back to 1962 and has evolved into an internationally esteemed nucleus for the promotion of technical issues.

The 74th General Assembly of the National Association of Non-Ferrous Metals Industries was held in the sign of the handover by Italo Amedeo Romano, now at the conclusion of his second presidential term, and the managing director of Intals Spa, Ing. Marco Vedani.

In his parting speech, the outgoing President said he was confident “to leave an association capable of proceeding towards increasingly ambitious goals representing an important manufacturing sector that sees Italy occupy a leading European role”.

In fact, the non-ferrous metals industrial supply chain in our country employs 25,000 people, with a consolidated 2018 turnover of 25.7 billion euros and almost two million tons of raw metals produced, including copper, aluminum, lead, zinc and precious metals. With regard to semi-finished products (rolled sections, bars and sections, pipes, wires, etc.), production reached 2.4 million tonnes last year, with a substantial export volume of almost 40%. The jets, on the other hand, reached 915,000 t. The contribution of scrap is increasingly relevant: for aluminum we are around 50% with over one million tons on a total use of 2,116,000 tons, while for copper the use of scrap is around 600,000 tons. . Lead and zinc are instead, respectively, at 250 thousand tons and 70 thousand tons.

Marco Vedani, having thanked those present for the trust given to him, underlined how he intends to proceed with the association commitment on the long-established established line, aiming however to take more into account the dynamics of each single sector represented by Assomet and implementing the actions of associative marketing in order to have the widest and most articulated base possible.

The presentations by Dr. Fabrizio Maronta (Limes-Italian Geopolitical Magazine) and Dr. Livio Romano of the CSC-Confindustria Studies Center were particularly appreciated by those present. The first presented a study entitled “The battle for the new world order” in which he highlighted the factors that contribute to determining the US-China opposition and the different territories on which this challenge is being played and will be played. Beginning with the US maritime dominance in all the oceans to move to the new silk roads and related economic corridors, continuing with the analysis of the countries that hold American credit (in particular China and Japan, which together reach over 30%) for to reach the current relations between Europe and Russia and the new iron curtain, the concrete presence of China in Europe (ports and maritime routes, financial centers, logistic centers), and the future scenario that in 2100 will see the world population reach 11 billion, of which 4.3 billion in Africa, almost four times the current population (and with other areas of the world in slight growth and Europe in decline).

With the report “Where the Italian industry is going in the difficult global context” Livio Romano explained the reasons (Brexit, election of Trump, US protectionism) for which the uncertainty in the world is currently at its maximum and how US duties can represent a danger for Italian exports. “The world is entering a new phase of development – said the representative of the Confindustria Study Center – the propensity to export is decreasing and the growth of manufacturing production is structurally slowing down”. The German locomotive has stopped racing and this is not good news for Italian industry if we consider that Germany is the first partner for Italy (12.5% ​​of our exports) while domestic demand is sluggish.

“But – he concluded with a note of Roman optimism – in this scenario we are witnessing the reorganization of the Italian industry, with the quality of production constantly growing even if not in all the markets in the same way”. And, with regard to investments in 4.0 technologies, where the small and medium-sized manufacturing companies in the north prevailed, he added that in a global context that certainly does not help Italian companies are the choices of national economic policy to be fundamental to restore confidence and sustain competitiveness in the medium-long term.