KASTOwin A 3.3 - Edition „More Performance“

New machine KASTOwin A 3.3 in the KASTOshop Edition „More Performance“

The comfortable fully automatic machine for daily unmanned operation.

Only here in the KASTOshop: Brand new, directly from the manufacturer, with original KASTO service, at the best price!

Automatic high-performance bandsawing machine for serial cutting of solids, tubes and profiles in material qualities which are easy to difficult to cut. The standard precise linear guides (re-circulating ball units with grease lubricated guide carriage) guarantee maximum life.

The standard AdvancedControl offers the optimum operation of the machine.

Easy and clearly arranged job entry via job wizard.

After making the desired number of cuts, the machine shuts off automatically. By reducing set-up times to a minimum, maximum cutting performances are achieved in automatic mode. The precise drive via ball bearing spindle in material feed guarantees an accurate material length positioning.

Frequency controlled spur gear driving with overload monitoring and clamping pressure monitoring for blade clamping and both vices belong to the standard equipment for working processes regarding cutting of individual pieces, smaller and average lot sizes and large series.

An infinitely variable electromechanic saw feed with servomotor and ball bearing spindle offers the best conditions for an efficient, sensitive and tool-saving cutting operation.

Equipment:

• Machine Base
• Machine Enclosure according to the latest CE Criteria
• Saw Unit (Saw Frame)
• Guide of the Saw Unit
• Saw Blade Guide
• Clearance Stroke System for Material
• Adjustment of the Saw Unit’s Height
• Saw Blade Tension
• Swarf Removal at Saw Blade by motor-driven, self-adjusting Chip Brush
• Material Clamping - Machine Vice
  
• Material Clamping - Feed Vice
• Automatic, Numerically Controlled Material Feed
• Operation
• Material Feeding
  
• Material Outfeed
• Hydraulic System
• Coolant Tank
• KASTOrespond
• Diagnosis of performance and energy consumption
• KASTO Control for Sawing Machines AdvancedControl

Included optional equipment:

• Saw blade dimensions 5090 x 41 x 1.3 mm
• Safety Package
• LED machine lamp
• Automatic zero positioning start/KASTOsense
• KASTO worm-type chip conveyor
• Performance package
• Coolant hose for machine cleaning
• Clamping power regulation
• Vertical roller
• Clearance stroke system for material feed and machine vice

Equipment details and scope of supply

Equipment:

• Machine Base
• Heavy-duty, distortion-free welded construction
• Machine Enclosure according to the latest CE Criteria
• The KASTOwin A 3.3 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 guide 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.
• Material Clamping - Feed Vice
• Hydraulically actuated horizontal vice with integrated material limit switch.
• 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.
• 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.
• 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.
• Coolant Tank
• In machine base. Coolant supply through nozzles at the blade guides.
• 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.
• 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 calcula-tion of motor performance of all drives during the running process.

Included optional equipment:

• Saw blade dimensions 5090 x 41 x 1.3 mm
• 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 number of pieces 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
• Performance package
• For cutting of predominantly difficult to cut material qualities, power 5.5 kW, total power 8 kW, V = 12 – 150 m/min.
• 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.
• Clearance stroke system for material feed and machine vice
• In order to be able to guarantee safe transport of forged material as well, the fixed vice jaw at the machine vice is automatically retracted from the guide edge by approx. 10 mm during material transport movement (clearance stroke system).
• During return stroke movement, the fixed vice jaw of the material feed vice is retracted automatically by approx. 5 mm from the guide edge. By the clearing stroke system, the remnant length is reduced to 35 mm.

KASTO Control for Sawing Machines AdvancedControl

Hardware

• Industrial personal computer, fanless, no movable components
• Robust metal casing, front sheet made of aluminium
• Resistive touch screen
• TFT colour screen 7”, WQVGA, colour depth 16 bit
• Seamless front foil
• Protection category front panel IP65

Interfaces

• 1 x Ethernet (10/100 Mbit)
• 2 x USB Master
• 1 x CANopen (interface for connection of decentralized peripheral devices)
• 1 x serial RS232

Software

• Operating system Windows CE 6.0
• Soft-PLC (programming language Step7®)

Decentralized peripheral devices

• Input/output module(s) with 16 digital inputs and outputs each as well as one analogue input and output. Display of signal condition via LED.
• Connection of input/output modules and drive control system via standard field bus CANopen

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 via job wizard
• Display of current wizard position in clear text
• 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:
• 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
• Number of pieces 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” and “Saw motor ON”.
• Further operation-hour counter “Saw motor ON” resettable.
• Display of current cutting times: “Time per cut“ and “Cycle time“
• Pre-calculation and display of current job end time
• Piece counter total and piece counter resettable
• 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.

Scope of Supply

• KASTOwin A 3.3 including the described standard and optional equipment
• Bi-metal saw blade
• Glue anchors to dowel the machine
• Operating instructions manual according to the EU Machinery Directive and EN 82079

We will be pleased to advise you individually if you require equipment which is not sold through the KASTOshop.

Technical Data

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.

Warranty

This sawing machine is particularly suitable for easily to normally machinable materials in solid material, tubes and profiles. Only conditionally suitable are materials that are difficult to machine as well as plastics. An application up to two-shift production operation is envisaged. The specified cutting ranges and performance characteristics must be observed. The use of uneven, twisted or burred starting material can severely impair the cutting accuracy. For more detailed information on the correct use of the machine, please refer to the operating instructions. Disregarding this area of application and/or General Terms and Conditions can lead to the warranty claims becoming void.