Ecological equipment designed for sawing and storage

The automatic bandsaw is suited to cutting solid material, tubes and profiles, particularly in steel production and stockholding, machine manufacturing and the automotive industry. Compared with standard KASTOwin machines, the bandsaw can increase production efficiency by between 50 and 100%, more in some instances, depending on the type of blade and the material being cut.

Having an installed weight of 4.3 tonnes and a rigid welded structure with vibration-optimised ribbing, the KASTOwin pro AC 5.6 ensures quiet, low-vibration operation, short processing times and accurate cutting. The saw band is driven by an 11kW, frequency-controlled motor, delivering infinitely adjustable cutting speeds from 12 to 150m/min and providing plenty of capacity for TCT sawing. Maximum size of stock that can be cut is 560mm and the smallest dimension is 25x25mm. Shortest residual length is 10mm for individual offcuts and 35mm in automatic operation, enabling companies to minimise waste.

Helping to dampen vibration are guides mounted at the return side of the blade, inside the top of the saw head guarding on the side opposite from the cutting action, promoting accurate sawing and prolonging tool life. There is a retraction unit for separating the blade from the material to protect the cut surface when the saw head moves back. It also helps to minimise tool wear. Access to the machine is very good and it is compliant with CE safety standards.

The saw incorporates ecological design features that lower energy consumption, especially in the hydraulics. KASTO engineers have complemented this by developing electro-mechanical down-feed of the blade controlled via two ballscrews, each with a servo drive, for precise, infinitely variable control. The hydraulics system is therefore only responsible for workpiece clamping and saw blade tensioning, so is actuated far less than in the past, delivering an energy saving in this area of approximately 93%.

All drives are controlled by intelligent converter technology. KASTO has fitted the frequency converter with a DC link so that excess energy, generated when braking the saw motor for example, can be recovered and used elsewhere in the machine. In contrast, conventional technology disperses this energy via braking resistance, so it is lost as heat.

KASTO also turned its attention to the weight of the moving elements of the bandsaw. The more weight that needs to be moved for each cut, the greater the amount of energy consumed. Using new methods, dynamic parts such as the saw frame have been designed to be lighter, without having to compromise on vibration damping or quietness of operation.

Overall, these measures have made it possible to achieve significant improvements in energy efficiency, consumption being on average 28% lower compared with KASTO's previous bandsaw model of equivalent size. Depending on cutting times, annual energy costs for one saw can be reduced by several hundred pounds over a single shift, without affecting productivity.

KASTOmicut (New at MACH)
Another KASTO bandsaw to make a first appearance at a MACH show will be a representative model from the company's latest range of swing-frame, pivoting-bow bandsaws for workshops. The versatile KASTOmicut is designed for high accuracy cutting to length and mitre cutting of tubes, sections and solid materials.

Four model variants are available: manual (P 2.6), manual clamping with hydraulic down-feed (E 2.6), hydraulically actuated clamping and down-feed (U 2.6), and fully automatic (A 2.6) with ballscrew-driven material feed, carbide blade guides and an optional chip conveyor. A torsionally rigid, vibration-damped, cast iron frame provides support for the saw blade, ensuring top cutting quality, even in difficult-to-cut materials.

The saws supersede six machine models in the KASTOpractical and KASTOfunctional series, compared with which they have higher power motors and greater band tension, allowing a 50% increase in cutting force. Feed rate is constant throughout, avoiding lost productivity due to the blade slowing towards the centre of the cut. Blade speed is infinitely variable from 20 to 120m/min, allowing a range of different materials to be processed cost-effectively.

KASTOmicut saws have a cutting range of 260mm for rounds and 310x260mm for flat stock. Shortest cut length is 6mm, with a residual length of 15mm for manually cut pieces or 40mm in automatic operation. Cutting accuracy is 0.1mm per 100mm of height. Mitre cuts are possible at continuously adjustable angles from -45 to 60°. Many accessories are available including a rotary table to support the material.

KASTOecostore (New at MACH)
In further support of ecology in manufacturing, KASTO introduced in 2017 an energy-efficient storage tower designed to provide a compact, standardised solution for automated storage and retrieval of material. KASTOecostore is available in two variants. The first version is for holding sheet materials while the second, which has not previously been announced and will also be promoted at the show, is for storing bar and other long stock up to 6.5m.

The sheet store accommodates material up to 1,500mm deep by either three or four metres wide. Both types are available with a load capacity per station of either 1.2 or three tonnes. System height can be specified by the customer from 3.1m to 8.0m. The same applies to the level at which loading and unloading takes place, as users can select different loading heights up to 950mm.

The lifting gear drive is equipped with leading-edge frequency converters from Siemens and the motor is stationary to allow precise, dynamic loading and unloading. Robust roller chains ensure long service life and low maintenance. The steel frame consists of standardised rolled sections and can be dimensioned in accordance with the relevant standards for earthquake resistance. Comprehensive safety control measures prevent malfunction and costly down-time.

Advantages of KASTOecostore are its low space requirement, high storage density, inventory traceability and short material access times. A further benefit is the low energy consumption, based on similar energy recovery and storage technology to that fitted to the German manufacturer's larger 3D automated storage and retrieval systems. Surplus kinetic energy produced during braking or lowering of material is converted into electricity and stored for later use as needed. Operating costs are reduced and so also are CO2 emissions.

Besides being suitable for storing sheet metal in a wide range of sizes, KASTOecostore can also hold euro-pallets and stillages. This makes it ideal for applications involving different materials in small businesses, workshops and maintenance shops. It can also be used as a buffer store between production areas in factories, close to machinery if necessary.

KASTOecostore comes as standard with the manufacturer’s own SmartControl, which has an intuitive, touchscreen user interface for rapid, error-free data input by all operators. Loads can be on pallets or special cassettes, which are stored and retrieved automatically and brought to an ergonomic height for ease of handling. Additional lifting equipment such as a forklift is not necessary, keeping access times short.

KASTO offers an extensive range of accessories for adapting the store to special requirements. They include a movable carriage for loading and unloading material from the back of the tower; and insert bolts for subdividing pallets and cassettes. A storage aid with lift-off bolts is available to assist in the handling of sheet metal and other materials using a stacker or crane.