Reliable saw line for shipbuilding

The Chantiers de l’Atlantique shipyard in Saint-Nazaire uses large quantities of profile steel in a wide variety of geometries, lengths and bends, which is why it has invested in a modern production line featuring an automatic mitre bandsaw from Behringer. The Behringer HBP410-723GA saws round profiles up to a diameter of 410 mm and flat material up to 600 mm wide.

The saw line is loaded on the infeed side by means of a transversal lift truck, which enables the buffering of round, square and flat bars with an initial length of up to 12 m. Material is positioned using two grippers, one on the infeed side and a section gripper on the outfeed side. The combination of the two grippers ensures safe material handling; even short sections sawn on a mitre are transported away reliably. The system is supplemented by an automatic marking system with inkjet technology for marking the sawn parts, eliminating manual labelling and reducing sources of error.

Cuts and offcuts are removed from the machine using a section gripper and disposed of on a material table directly behind the mitre bandsaw with a push-off device. The operator does not need to do anything. The sawn good parts are also removed by the gripper on the discharge side, moved over the discharge roller conveyor and placed on a material store arranged parallel to the roller conveyor with another push-off device. The discharge gripper easily clamps and moves cuts, offcuts and parts from 50 mm to 12 m in length.

Using this sawing solution, Chantier de l’Atlantique was able to reduce its cycle times by 50% compared with the old sawing system and drastically increase throughput – all with fewer personnel.

For further information
www.behringer.net

Kerf to unveil cutting technologies

In Hall 17 on Stand 309, Kerf Developments will be expecting its RUR2500P high-definition plasma cutting machine (pictured) to create a spark of attraction for show visitors. The machine, with its UltraSharp cutting technology, incorporates a rigid frame design that is ultrasonically stress-relieved and manufactured to highly accurate tolerances to provide high performance. The RUR2500P has a cut width of 2 m, while the modular design permits the tailoring of table dimensions to the requirements of the end user.

Alongside the RUR2500P, Kerf will be introducing innovations like the new Fineline 300 Plasma unit from Lincoln Electric that incorporates advanced piercing technology and a new water mist system. The Fineline 300HD allows full user control from a single interface, so customers can rapidly change plasma current and gas pressures for better cut quality and longer consumable life.

For further information
www.kerfdevelopments.com

PL Lehmann turning the tables

Making its MACH debut will be the 900 series of direct-drive rotary tables from PL Lehmann (Hall 17, Stand 28). The new range of versatile rotary tables is suitable for HSC milling, mill-turn machining, modern hobbing (power skiving) and even demanding grinding operations. With the 900 series, users are able to transform simple three-axis milling centres into multi-functional five-axis machines. The durable housing is fully sealed to IP67 and able to withstand rotational speed in excess of 2000 rpm. A range of accessories and clamping options is available for the standardised front and rear interfaces.

For further information
www.lehmann-rotary-tables.com

Automated storage halves handling and inventory

To streamline its production and logistics, Bavarian precision engineering firm Werner Weitner, which primarily manufactures components and assemblies for the global automotive and medical sectors, has centralised a large part of its activities in a new factory building at its headquarters in Eichstätt. In the process, raw material storage has been updated with the installation of two UniTower systems from Kasto, which not only save time and space, but are ergonomic and economical.

CEO Heinz Weitner says: “Our logistics was becoming a challenge, as we had expanded organically over the years. The material that is now held in the two towers of our new production and storage unit was not long ago distributed in manually operated warehouse areas across several factory buildings on our site. Now everything is bright, clean and tidy, resulting in a pleasant working atmosphere.

“We’ve used sawing machines from Kasto for many years and been extremely satisfied with their performance,” he continues. “We were aware that the company also manufactures automated storage systems for bar stock and sheet material, so we sat down together to find a solution to our requirements.”

To optimise efficiency of material flow in the new factory, Kasto recommended installing two freestanding dual tower storage systems. The UniTower 1.0 is suitable for storing and retrieving bar stock up to 3 m in length, while the UniTower 2.0 has the capacity to handle material up to 6 m long. A KastoMicut E4.6 swing-frame, pivoting-bow bandsaw is located between the two towers’ output stations. The saw is designed for the cross and mitre cutting of bar, tube and profile.

There are six other Kasto saws on site, most of which are from the KastoWin bandsaw machine series, half of which have been replaced with more recently introduced models.

For further information
www.kasto.com

Work holding aids efficiency at Opus

Having identified a gap in the UK automotive market for a highly-efficient subcontractor that specialises in the production of premium-quality, low-volume components, the founders of Opus International Products established their business in 2013. In less than 10 years the company has grown to become a major force within its sector.

Given the company’s relatively short production runs, to help reduce changeover times and increase its machining efficiency, managing director Rob Coles recently searched for an advanced work-holding system, opting for a selection of solutions from Lang Technik UK.

“By using our Lang Technik work-holding systems on our Haas machine tools we’ve achieved the incremental production increases we were seeking,” he says. “Now, before inserting a workpiece blank into one of our new Lang Makro-grip vices, staff can use our Lang Technik stamping unit to make very accurate, minute indentations into the workpiece. Then, as the ‘male’ features on the jaws of our Lang vices engage exactly with the workpiece’s pre-stamped ‘dents’, we are able to achieve excellent holding power with the application of only minimal clamping forces. We are therefore able to hold, from the softest to the hardest of materials, under all machining conditions without fear of deformation. In addition, as the Lang Technik stamping unit makes its indentations into only the last 3 mm of workpieces, we are able to make savings on material.”

Coles adds: “As all of the indenting preparation work is carried out before each workpiece is placed into the machine tool, the use of our new Lang stamping unit and Makro-grip vices has slashed machining downtime. As we continue to ramp-up our production levels, we will be returning to Lang Technik UK for further products.”

For further information
www.lang-technik.co.uk