KASTOwin A 4.6 - Customizable

ProControl 9”

Hardware

• Industrial personal computer, fanless, no movable components
• Robust metal casing, front sheet made of aluminium
• Resistive touch screen
• TFT colour screen 9“
• Ambient temperature 0 - 50 °C
• Protection category front panel IP65

Software

• Operating system Windows 10 Enterprise LTSC 2019
• SIMATIC S7 - 1500 Failsafe Software Controller CPU

Decentralized peripheral devices

• Connection of input/output modules and drive control system via Profinet
• All axes/drive controls are equipped with absolute encoders. Thus, referencing after switching on is no longer necessary.

Program function

Visualization:

• Ergonomic, shop-floor-oriented operation via colour touch panel
• Operation based on the standardized user interface and the uniform operation philosophy of all KASTO controls
• Clear separation between navigation and function
• Fast access via status bar
• Title of the current operation page in clear text
• Operator guidance by means of operating advices, e.g. changeover of operation categories, tool exchange etc.
• Online change of language
• Change of units metric/imperial
• Change of material table (EN, AISI, JIS)
• Display of axis for service purposes
• Display of current warnings/disturbances
• Fast access to history of warnings and disturbances with detailed information in clear text via status bar

Job entry:

• Easy and clear job entry
• Simple and understandable symbols
• Selection of material quality (solid square, thick-walled square tube, thin-walled square tube, solid round, thick-walled round tube, thin-walled round tube) via graphic symbols
• Preselection of technology data (cutting speed, saw feed) by means of direct entry or selection in the material table
• Material table with assignment of exemplary materials to the proposed technology data and integrated filter function for fast access. Material table is editable.

Job management:

• It is easy to save the latest job data incl. technology data
• Saving under alphanumeric job number, e.g. drawing number, part number
• Easy selection and recall of saved orders via order number
• Integrated filter function for fast access

Tool management for one tool:

• Easy entry of tool data
• Tool monitoring concerning blade life or cutting surface
• Indication of blade life
• Entry of tooth pitch for the calculation of the optimum saw feed
• Selection of a general reduction or increase of the nominal values for cutting speed and saw feed via slide control

Types to start (may differ, depending on machine type):

• “Automatic start”: Put the material manually to the cutting position and start cutting job.
• “Manual zero positioning start”: Put the leading edge of the material to any position in the outfeed vice. Measure the distance between the leading edge of the material and the saw blade and enter this value in the control system. Start the cutting job. Correcting measures for the cut-off length of the first cut-off piece are calculated by the control system. The first cut-off piece without trim cut is positioned automatically to the cut-off length.
• “Start individual cut”: Move the material manually to the cutting position and start the individual cut. Job entry is not necessary. As an option, a correcting value for the cut-off length can be entered.
• “Automatic start for remnants”: same as “automatic start”, but the material is not clamped anew in the infeed vice.
• “Manual zero positioning start for remnants”:
  same as “manual zero positioning start”, but the material is not clamped anew in the infeed vice.

Process visualization:

• Clearly arranged display of the job in process
• Override function for cutting speed and saw feed speed
• Quantity and length can be changed during the running job
• Further jobs can be entered during automatic operation
• Display of automatic single correction values for cutting speed and saw feed

Operation-hour counter, statistic functions:

• Operation-hour counter for “Machine ON”, “Saw motor ON”, “Automatic operation”, each as a total counter and resettable counter
• Piece counter and cut area counter, each as a total counter and resettable counter
• Display of current cutting times: “Time per cut“ and “Cycle time“
• Pre-calculation and display of current job end time

Special functions:

• Automatic adaptation of technology data, e.g. by cut-in process for new tools, consideration of tooth pitch etc.
• Optimization for remnants (automat) If the material ends in the ongoing cutting job, the length of the existing remnant is measured and it is checked if cutting jobs for shorter cut-off lengths exist in the ongoing block of cutting jobs. If they exist, the cutting job is changed automatically until no more cut-off pieces can be cut from the existing remnant.

Machine Base

Heavy-duty, distortion-free welded construction

Machine Enclosure according to the latest CE Criteria

The KASTOwin A 4.6 is equipped with complete enclosure. A high degree of safety, cleanliness and low-noise cutting is achieved with best accessibility on the material infeed and outfeed side.

Saw Unit (Saw Frame)

Manufactured in robust weldment without distortion, with ribbing optimized against vibration. By using the latest constructional technology and manufacturing methods, an extremely quiet running without vibration is obtained. This means shorter cutting times and longer tool life.

Guide of the Saw Unit

Linear guides, each one with two guide carriages on one guide rail. The recirculating ball unit consists of one solid pretensioned roller running system.The greased guide carriages ensure a maximum usable life.

Saw Blade Guide

Lateral guiding by hydraulically pretensioned carbide slideways, with clearance stroke system for fast exchange of saw blade. Back guiding by rollers. Automatic adjustment of the blade guide in accordance with the width of the material to cut.

Clearance Stroke System for Material

After a cut has been finished in automatic cycle the clamped material to be cut is retracted on the infeed side by approx. 2 mm from the saw blade by means of a clearance stroke system for material (to prolong blade life).

Adjustment of the Saw Unit’s Height

Start of cutting operation and cutting height can be adjusted either via teach function or automatically via the entered material diameter.

Saw Blade Tension

Hydraulic, electronically monitored with automatic pressure reduction if the machine is out of operation, automatic switching-off if the saw blade breaks.

Swarf Removal at Saw Blade by motor-driven, self-adjusting Chip Brush

This smart mechanical system adjusts itself over the complete lifetime of the chip brush.

The brush is thus always in its optimal position, which extends its life considerably.

Material Clamping - Machine Vice

The hydraulically actuated horizontal vice enables an optimum work piece clamping on the outfeed side of the saw blade and cutting of short remnants.

In order to be able to guarantee safe transport of forged material as well, the fixed vice jaw is automatically retracted from the contact edge by approx. 10 mm during material transport movement (clearance stroke system).

Material Clamping - Feed Vice

Hydraulically actuated horizontal vice with integrated material limit switch.

In order to be able to guarantee safe transport of forged material as well, the fixed vice jaw is automatically retracted from the contact edge by approx. 10 mm during material transport movement (clearance stroke system).

Automatic, Numerically Controlled Material Feed

Via feed gripper system. Material feed length 500 mm. Standard multiple feed. Short cut lengths up to 250 mm are achieved by an incremental feed. Material feed via servomotor and ball bearing spindle.

Special feed length up to 1500 mm in one stroke can be supplied for an extra charge (Pos. 1510).

Operation

All operating elements are arranged centrally and ergonomically at the front side of the machine.

Material Feeding

By a roller conveyor, integrated into the machine.

Material Outfeed

Via deposit table. Transfer height 700 mm, container height max. 650 mm.

The material outfeed side meets the effective European and international safety standards. A safety inspection of the complete machine has been performed by the German Professional Association and the French Apave.

A large-dimensioned deposit table with coolant recirculation or equipped with rollers, for connection to roller conveyor, can be supplied on request.

Hydraulic System

Compact system in block construction, removable, integrated into machine base and easy to access and check from outside. In that way, maintenance time for oil-level control and exchange of filter can be minimized.

This extremely energy-saving system only runs when required.

Heating and cooling packages can be supplied on request.

Coolant Tank

In machine base. Coolant supply through nozzles at the blade guides.

Diagnosis of performance and energy consumption

Recording and display of the current data of performance and energy consumption based on non-recurring measuring values for basic functions as well as the calculation of motor performance of all drives during the running process.

Mains voltage: In accordance with EN 60204; 400 V three-phase current (-10 %, +6 %); Control voltage 24 V-DC

Mains frequency: 50 Hz (-1 %, +1 %; transient –2 %, +2 %)

Type of mains: TN mains according to IEC 364/VDE 0100

The power is supplied from the mains to the switching cabinets including advance fusing by the customer. The position of the switch cabinet is to be seen from the lay-out.

Protective measures against indirect contact: Over-current protector (zero balancing). The mains supply of the operator (size and characteris-tic of the main fuse selected as well as the total imped-ance of PE and outer conductor in the supply line to the machine) has to be designed in such a way that the per-missible shutdown time in the event of an error is not exceeded. The use of a differential current switch in the mains in-coming supply is not permitted.

Safety requirements: The offered machine corresponds with the valid safety requirements according to the machinery directive 2006/42/EG

Subject to the individual conditions of use and to the in-stallation site, additional equipment such as fences, safety light beams and barriers in the area of material supply and cut-off removal may be necessary. Possibly, such additional equipments are not included in our scope of supply and must therefore be procured by the buyer.

Delivery terms: Possibly valid company’s own operating material regula-tions have not been taken into consideration when work-ing out the offer, unless they are specifically mentioned in the quotation. The machine will be equipped with proven components selected by KASTO. If you insist on the ob-servance of your operating material regulations we kindly ask you to make these regulations available to us for working out the appropriate offer. After placing the order, any specifications can no longer be considered. This is also valid for so called fire protection regulations.

Cutting accuracy: On perfect conditions with perfect tools the deviation of cut is within ±0.1 mm per 100 mm cutting height with standard steel qualities. For material with a perfect geo-metric surface an accuracy of length of cut-off pieces in accordance with ISO 2768-1, degree of accuracy fine is achievable with individual bars and cut-off pieces longer 6 mm. When using uneven, twisted or burred initial ma-terial, the achievement of the mentioned cutting accura-cies is restricted. The tolerance of length of cut-off pieces is valid for machines with automatic material feed.

KASTOrespond

The new KASTOrespond system, especially designed for this machine line, provides ideal settings of the machine for solid materials, pipes and profiles of all material types and is available for all sizes of the KASTOwin series.

The system continuously records the forces on the tool without using an additional and often error-prone sensor system. It intelligently converts information into the optimum digital downfeed speed. Thick-walled and thin-walled material, constantly changing contact length in round material as well as hard spots in solid materials are recognized on time by KASTOrespond and the feed speed is smartly adapted accordingly. The operator only needs to program the relevant data such as the cutting lengths, the quantities and the type of material to be cut. Everything else is taken care of by the KASTOwin.

Safety package

Recommendable if the machine partly works in unmanned shift, consisting of:

Supervision of the non-driven blade running wheel by SpeedControl (electronic supervision of minimum number of revolutions). If the minimum number of revolutions is too low, e.g. by reason of a lade break, the machine tops automatically.

Supervision of deviation of cut by BandControl. If a programmable value of deviation is exceeded, the machine stops automatically.

Supervision of coolant quantity by FlowControl. If the coolant flow rate is too low, the machine switches off automatically.

LED machine lamp

Automatic zero positioning start/KASTOsense

After having entered the requested cut-off length and quantity and after having activated the control function “zero positioning”, the first cut-off piece is at once positioned fully automatically at the requested cut-off length and then cut. The system is designed for material heights from 30 mm.

Function expanded by two additional types to start:

• “Automatic zero positioning start”: Put the leading edge of the material to any position in the outfeed vice and start the cutting job. The first cut-off piece will be positioned automatically to the cut-off length.
• “Automatic zero positioning start for remnants”: same as “automatic zero positioning start”, but the material is not clamped anew in the infeed vice.

These types to start are possible from a material height ≥ 30 mm.

They are selectable and deselectable. When they are deselected, the types to start “Manual zero positioning start” and “Manual zero positioning start for remnants” are active.

KASTOsense:

• Automatic recording of the material height from any position of the saw feed in all types to start.
• With all types to start, except for zero positioning starts, the recording is active also for restart of cutting operations that have begun already.

KASTOsense is possible from a material width ≥ 30 mm.

KASTOsense is not possible for very easy to cut special materials (e.g. plastics, partly aluminium).

KASTOsense is selectable and deselectable.

KASTO worm-type chip conveyor

Ejection height 450 mm

Coolant hose for machine cleaning

With spray pistol

Clamping power regulation

By means of handwheel with reading at pressure gauge

Vertical roller

In extension with the material supporting edge, guarantees undisturbed material feed.

KASTOrespond

The new KASTOrespond system, especially designed for this machine line, provides ideal settings of the machine for solid materials, pipes and profiles of all material types and is available for all sizes of the KASTOwin series.

The system continuously records the forces on the tool without using an additional and often error-prone sensor system. It intelligently converts information into the optimum digital downfeed speed. Thick-walled and thin-walled material, constantly changing contact length in round material as well as hard spots in solid materials are recognized on time by KASTOrespond and the feed speed is smartly adapted accordingly. The operator only needs to program the relevant data such as the cutting lengths, the quantities and the type of material to be cut. Everything else is taken care of by the KASTOwin. 

Safety package

Recommendable if the machine partly works in unmanned shift, consisting of:

Supervision of the non-driven blade running wheel by SpeedControl (electronic supervision of minimum number of revolutions). If the minimum number of revolutions is too low, e.g. by reason of a blade break, the machine stops automatically.

Supervision of deviation of cut by BandControl. If a programmable value of deviation is exceeded, the machine stops automatically.

Supervision of coolant quantity by FlowControl. If the coolant flow rate is too low, the machine switches off automatically.

LED machine lamp

Automatic zero positioning start/KASTOsense

After having entered the requested cut-off length and quantity and after having activated the control function “zero positioning”, the first cut-off piece is at once positioned fully automatically at the requested cut-off length and then cut. The system is designed for material heights from 30 mm.

Function expanded by two additional types to start:

• “Automatic zero positioning start”: Put the leading edge of the material to any position in the outfeed vice and start the cutting job. The first cut-off piece will be positioned automatically to the cut-off length.
• “Automatic zero positioning start for remnants”: same as “automatic zero positioning
  start”, but the material is not clamped anew in the infeed vice.

They are selectable and deselectable. When they are deselected, the types to start “Manual zero positioning start” and “Manual zero positioning start for remnants” are active.

KASTOsense:

• Automatic recording of the material height from any position of the saw feed in all types to start.
• With all types to start, except for zero positioning starts, the recording is active also for restart of cutting operations that have begun already.

KASTOsense is possible from a material width ≥ 30 mm.

KASTOsense is not possible for very easy to cut special materials (e.g. plastics, partly aluminium).

KASTOsense is selectable and deselectable.

KASTO worm-type chip conveyor

Ejection height 450 mm

Coolant hose for machine cleaning

With spray pistol

Clamping power regulation

By means of handwheel with reading at pressure gauge

Vertical roller

In extension with the material supporting edge, guarantees undisturbed material feed.

Performance package

For cutting of predominantly difficult to cut material qualities, power 5.5 kW, total power 7.5 kW, V = 12 – 150 m/min

Mechanical hold-down clamp

For processing of several bars in layers. Consisting of two vertical, manually adjustable hold-down clamps, one in the material feed vice, one in the outfeed vice. Suitable for round and square material, tubes and profiles from approx. 20 mm diameter. Including a mechanical opening and closing limitation in the outfeed vice.

Insertion at A 4.6: Height min. 20 mm / max. 165 mm

Width min. 95 mm / max. 460 mm

Remnant length: 60 mm (only when cutting in layers)

Min. cut-off length: 45 mm (only when cutting in layers)

The material must be straight and the material diameter should be proportionate with the number of bars per layer.

KASTOrespond

The new KASTOrespond system, especially designed for this machine line, provides ideal settings of the machine for solid materials, pipes and profiles of all material types and is available for all sizes of the KASTOwin series.

The system continuously records the forces on the tool without using an additional and often error-prone sensor system. It intelligently converts information into the optimum digital downfeed speed. Thick-walled and thin-walled material, constantly changing contact length in round material as well as hard spots in solid materials are recognized on time by KASTOrespond and the feed speed is smartly adapted accordingly. The operator only needs to program the relevant data such as the cutting lengths, the quantities and the type of material to be cut. Everything else is taken care of by the KASTOwin.

Safety package

Recommendable if the machine partly works in unmanned shift, consisting of:

Supervision of the non-driven blade running wheel by SpeedControl (electronic supervision of minimum number of revolutions). If the minimum number of revolutions is too low, e.g. by reason of a blade break, the machine stops automatically.

Supervision of deviation of cut by BandControl. If a programmable value of deviation is exceeded, the machine stops automatically.

Supervision of coolant quantity by FlowControl. If the coolant flow rate is too low, the machine switches off automatically. 

LED machine lamp

Automatic zero positioning start/KASTOsense

After having entered the requested cut-off length and quantity and after having activated the control function “zero positioning”, the first cut-off piece is at once positioned fully automatically at the requested cut-off length and then cut. The system is designed for material heights from 30 mm.

Function expanded by two additional types to start:

• “Automatic zero positioning start”: Put the leading edge of the material to any position in the outfeed vice and start the cutting job. The first cut-off piece will be positioned automatically to the cut-off length.
• “Automatic zero positioning start for remnants”: same as “automatic zero positioning start”, but the material is not clamped anew in the infeed vice.

These types to start are possible from a material height ≥ 30 mm.

They are selectable and deselectable. When they are deselected, the types to start “Manual zero positioning start” and “Manual zero positioning start for remnants” are active.

KASTOsense:

• Automatic recording of the material height from any position of the saw feed in all types to start.
• With all types to start, except for zero positioning starts, the recording is active also for restart of cutting operations that have begun already.

KASTOsense is possible from a material width ≥ 30 mm.

KASTOsense is not possible for very easy to cut special materials (e.g. plastics, partly aluminium).

KASTOsense is selectable and deselectable.

KASTO worm-type chip conveyor

Ejection height 450 mm

Coolant hose for machine cleaning

With spray pistol

Clamping power regulation

By means of handwheel with reading at pressure gauge

Vertical roller

In extension with the material supporting edge, guarantees undisturbed material feed.

Performance package

For cutting of predominantly difficult to cut material qualities, power 5.5 kW, total power 7.5 kW, V = 12 – 150 m/min

Mechanical hold-down clamp

For processing of several bars in layers. Consisting of two vertical, manually adjustable hold-down clamps, one in the material feed vice, one in the outfeed vice. Suitable for round and square material, tubes and profiles from approx. 20 mm diameter. Including a mechanical opening and closing limitation in the outfeed vice.

Insertion at A 4.6: Height min. 20 mm / max. 165 mm

Width min. 95 mm max. 460 mm

Remnant length: 60 mm (only when cutting in layers)

Min. cut-off length: 45 mm (only when cutting in layers)

The material must be straight and the material diameter should be proportionate with the number of bars per layer.

KASTOapp – application software for mobile devices (only in conjunction with KASTO Pro- and ExpertControl)

Operating system independent view on each smartphone, tablet computer or PC.

Status request of your sawing machine, quite simply from everywhere over internet.

Data from the control system to the server is transmitted unidirectionally via encrypted connection.

All registered KASTO machines and the current status of the saws (automatic operation, manual operation, tool change, fault) are visible in the KASTOapp at a glance.

Visualisation of pending error messages.

Detail view in automatic operation with information on the current cutting job

• Job overview: item, cut-off length, quantity, etc.
• Technology parameters such as feed speeds and cutting speeds

KASTOlink MQTT interface for process machine data entry

Provision of machine, order and process data via an MQTT broker. The prerequisite for the interface is a customer-side TCP connection to the network and customer-side integration into an appropriate software. The following individual data points can be observed independently of each other:

Machine data

• Machine number
• Machine type
• Running time
• Control status (on/off)
• Error pending (operator intervention required)

Order data

• Order number
• Order position
• Article (only with option ProControl
  12“)
• Material group (material name only with option ProControl 12“)
• Cut-off length
• Actual quantity
• Target quantity
• Target feed
• Target cutting speed
• Time of order start
• Time of expected end of the order

Process data

• Actual feed
• Actual cutting speed
• Tool number
• Sawn tool cutting surface

Linear laser

For projecting the cutting line at the work piece

Signal lamp in three colours

Round three-coloured signal lamp to which the following colours and functions are assigned:

• Top: yellow off = no failure, yellow flashing = failure
• Centre: blue off = no intervention necessary, blue flashing = intervention necessary, e.g. to refill coolant, to change tools because “tool life accomplished” etc.
• Bottom: green shining = automatic operation active, green flashing = automatic operation active but interrupted

Cutting depth adjustment

Additional possibility to preselect a defined cutting depth in the cutting job. The entered measure includes the remaining material height in relation to the material support.

Remark: If the machine is equipped with the option “zero positioning start/KASTOsense”, the accuracy of the cutting depth adjustment may be restricted.

Opening and closing limitation

For both horizontal vices, recommendable for processing of very thin-walled tubes and profiles.

Situated in 90° position to the worm-type chip conveyor, ejection height 900 mm

For liquid cooling lubricants with automatic monitoring. Recommended for cutting of tubes and profiles. The standard flood coolant device remains unchanged. Filling: 1.8 l. Incl. 3 l cooling lubricant. Working pressure at least 5 bar. Waterless and dustless air supply by customers.

Horizontally working, hydraulic hold-down clamp for clamping of several bars in one layer. The clamping element at the material feed vice is positioned and fixed before being used. Including a mountable hold-down clamp, manually adjustable. Including a mechanical opening and closing limitation in the outfeed vice and in the material feed vice.

Suitable for round and square material, tubes and profiles from approx. 20 mm.

Insertion at A 3.6:

Height min. 20 mm / max. 165 mm (only with mounted outfeed hold-down clamp)

Width  min. 95 mm / max. 360 mm

Remnant length: 135 mm (only with swivelled-in clamping element)

Min. cut-off length: 45 mm (only when cutting in layers)

The material must be straight and the material diameter should be proportionate with the number of bars per layer.

When ordering this position and the Performance package, the mechanical hold-down clamp inthe Performance package is omitted.

For processing of several bars in layers or in bundle.

Horizontally working, hydraulic hold-down clamps at the material feed vice and in the outfeed vice are positioned and fixed before being used. Including a mechanical opening and closing limitation in the outfeed vice and in the material feed vice.

Suitable for round and square material, tubes and profiles from approx. 20 mm.

Insertion at A 3.6: Height min. 20 mm / max. 300 mm (only with swivelled-in clamping element on the outfeed side)

Width: min. 105 mm 7 max. 360 mm

Remnant length: 135 mm (only with swivelled-in clamping element)

Min. cut-off length: 35 mm (only with swivelled-in clamping element)

The material must be straight and the material diameter should be proportionate with the number of bars per layer.

When ordering this position and Pos. 1070 Performance package, the mechanical hold-down clamp in Pos. 1070 is omitted.

Large-dimensioned deposit table, with coolant recirculation. Transfer
height 700 mm, container height max. 650 mm