An automatic KastoTec FC 4 bandsaw (www.kasto.com) has led to a three- to four-fold increase in productivity for a family-owned Austrian firm that develops and manufactures solutions for managing torsional vibration in large diesel and gas engines.

Its product range includes flexible couplings and vibration dampers made from steel and composite materials; these are typically used in ship propulsion systems, power generation, bulldozers and locomotives.

Moreover, the saw has been equipped with a robotic system for sorting cut lengths; and by connecting the saw-based cell to the company’s manufacturing management system, the user can keep track of all production data while ensuring reliable, safe and minimally attended operation.

The KastoTec, with its 430mm cutting capacity and minimum cut size of 10x10mm, efficiently handles all the different sizes of steel bar — and uses the type of tungsten-carbide-tipped blades for which the saw was designed.

Furthermore, Kasto Performance Cutting adds to the saw’s productivity by using capabilities that minimise vibration and optimise damping of the blade.

The saw was also supplied with a magazine that can hold four bars up to 3,500mm long, allowing production to run unattended for long periods.

Furthermore, it receives order data — including material type, dimensions and number of cut pieces — from the manufacturing execution system (MES) via a custom-designed interface; Kasto’s EasyControl also ensures simple
and intuitive operation of the bandsaw cell.

A clearly structured graphical interface quickly guides the operator to the required functions, while the link to the MES allows processes such as switching between orders to take place automatically, making work easier and ensuring greater process security; remote access to the system also allows any problems with the saw or robot to be quickly rectified.

The dramatic increase in productivity at the Austrian factory (which prefers to remain anonymous) is due in part to automation, the connectivity of the sawing machine and the short set-up and cycle times.

The robot-assisted sorting of cut parts has proved so successful that the company plans to use the technology to automate an additional saw.