AUTOMATION. Mesh, Rebar and Precast Industry ENGLISH

Transcription

1 AUTOMATION Mesh, Rebar and Precast Industry ENGLISH

2 The Company Engineering Production Software Innovative from Experience Our Efforts Your Benefits We have been developing machinery and plants for rebar processing from coil for the past 50 years. In the last few years we have successfully realised our vision of implementing innovative leading-edge solutions for our customers all over the world. Our custom-made solutions we design in close collaboration with each customer and the competent advice we give from preparation of the proposal up to technical assistance on handover are the outstanding hallmarks of our company. The continous development of our machines and solutions has made us a full-range supplier for rebar shops and manufacturers of mesh. We not only develop, construct, deliver and install individual machines and plants, we also design whole factories, offer additional equipment and implement software and safety solutions. Whether you intend to start a new business, expand or modernise your production process, our strengths enable us to find the right solution for your individual requirements. Full-range supplier Turnkey solutions for rebar shops, mesh manufacturers and precast concrete plants Expertise Quick, precise, maintenance-free processing from coil in wire diameters of 4-26 mm Flexibility Custom-made plant layouts, feed and logistics systems Software Complete solutions from the machine through work scheduling to complete order processing Efficiency Very little wear and tear and low maintenance costs thanks to the use of electric servo motors and pneumatics Speed Experienced technicians and pre-commissioning at our factory guarantee short installation times Service Our service department offers you uncomplicated, efficient support Passion An enthusiastic, skilled team guarantees customeroriented solutions 2 3

3 Contents Innovative from Experience 6 Mesh Welding Plants M-System Series Tunnel Master Versity Series 14 Further Processing of Mesh Smart BGM BGM 16 Straightening, Cutting and Bending MSR Series ESR 21 Run-offs, Logistics Systems and Tying Systems 22 Automatic Stirrup Benders EBA S Series Pluristar 26 Radial Bending Machines Radial Master 27 Cage Welding Machines VTA Series 28 Additional Equipment 30 Software for Rebar Shops ProFit 32 Solutions for Precast Concrete Plants Shuttering Robots Wire Center 36 Software for Precast Concrete Plants ebos e rp bos 38 In-house Competence 24 Lattice Girder Welding Machines VGA VGA Versa 4 5

4 Mesh Welding Plants M-System Series Flexible just-in-time production Efficiency and cost-effectiveness Integral bending and logistics systems Various performance levels M-System Series The M-System product family makes its mark through accuracy, flexibility and just-in-time production of custommade bespoke mesh from coil. Thanks to the machine s modular design the customers individual requirements can be met. In addition, the low power consumption values achieved by the progress inverter welding process and production without cutting waste and without complicated re-cutting of the mesh result in efficiency and cost-effectiveness. The manufacture and processing based on CAD specifications of the mesh in diameters ranging from 4-20 mm is, moreover, flexible and accurate. Bending systems are also available, which can be used for processing both single bars and whole mesh. An ingenious logistics system and an automatic bar code labelling system for the finished product also contribute to optimising your work flow. Flexible Mesh Production The mesh welding plants strengths lie in their versatility and in the infinite number of possibilities for adapting them to the needs of the individual customer. Whether you are looking for high production output, production from coil or from rebar, just-in-time production or for stock we develop and build the right machinery for your requirements. 6 7

5 Mesh Welding Plants M-System Series Efficient in every respect Low energy and space requirements Low costs Piece production of custom-made mesh Adaptable performance Efficiency M-System BlueMesh M-System Evolution Standard mesh Special mesh Efficiency on the whole line is the hallmark of M-System BlueMesh. This mesh welding plant makes its mark with its low energy and space requirements and its low costs. Like the M-System Evolution it welds and bends the rebar mesh from coil to comply with individual specifications. Moreover, it also guarantees the well-known high quality of the finished product. Standard mesh Special mesh The strengths of the M-System Evolution mesh welding plant lie in the individual production of custom-made and bent mesh. This can be finished with various spacings, dimensions, wire diameters and bending angles. The active feedback from the machine on the producibility of mesh, plus an ingenious logistics system significantly optimise the production process. Mesh with bends and cages In this respect M-System BlueMesh is particularly suitable for factories with low to mid volume production. Mesh with bends and cages 8 9

6 Mesh Welding Plants M-System Series High performance Flexibility Efficiency Maximum production Maximum speed Efficiency M-System PowerMesh M-System PowerMesh HS Standard mesh Special mesh The crowning characteristic of the M-System PowerMesh mesh welding plant is its high performance. Innovative technical solutions ensure high production. By this process a double line longitudinal and cross wire straightening machine speeds up steel preparation. In addition, the number of welding heads can be adjusted to the desired performance. Standard mesh The recently developed M-System PowerMesh HS is configured for maximum production performance. This is achieved by the high cutting speed of the flying shears, the revolving run-out and the elaborate bar transport system. The high speed model is also extremely flexible. The wire diameter is changed automatically, the mesh size can be individually set and the machine can also produce small batch sizes

7 Mesh Welding Plants Welding Machine for Ladder Production Versity Series High level of automation Flexible and precise production Serial production of mesh with regular geometry Optimum production performance Wire fed from coil or from rebar Straight ladders Tunnel Master The Tunnel Master welding machine makes possible fast, sophisticated, cost-conscious production of straight and curved ladders from coil for tunnel segments and similar precast concrete elements. The Tunnel Master processes up to four longitudinal wires and arranges them, in the same manner as the cross wires, according a continuously variable grid. Versity Series Versity is a mesh welding plant which concentrates on the serial production of standard mesh with regular geometry. The wire is fed through by rebar material and if required, also from coil. Versity also guarantees the highest operation reliability, while also providing the very best production performance. Curved ladders Standard mesh 12 13

8 Further Processing of Mesh Smart BGM BGM Fully automated mesh bending machine Serial production Versatility in bending shapes Fully automated mesh bending machine Bending of individual bespoke mesh Beam and individual bending device Smart BGM BGM This innovative machine is flexible and precise. The Smart BGM comprises two independently driven bending machines, which bend mesh fully automatically. The BGM is designed for the fully automatic bending of individual bespoke mesh. The machine can be fitted with a beam and individual bending device. Various bending angles and forms There are many possible configurations and bending angles. Square, rectangular, triangular and open forms with angles of 90 to 135 can be produced. Depending on the mesh it is possible to produce various cage sizes with different wire diameters. Even the number of cages to be stacked can be determined according to need. The Smart BGM is suited to the fully automatic series production of storage cages. Various bending angles and forms In combination with the grid-less mesh production and with the beam bending system it is possible to produce cages to an exact size with bars in the corners of the cages. Single bars can also be bent automatically for door and window openings. Complete plant concepts and flexible transport and logistics systems round off this solution

9 Straightening, Cutting and Bending MSR Series High production output Unrivalled product accuracy Optional double bending system MSR Series The MSR product family is designed for high production output. The tried and tested multi-rotor straightening technique, the flying shear, the precise formers and the robust bending heads ensure precise, gentle straightening, cutting and bending. This guarantees constant high quality for the finished product. The processing from coil and the custom-made collection systems optimise the production flow and minimise storage costs. This leads to an exceptionally cost-efficient production. Coupled with a double bending system with automatic former changeover, the machines become a multi-functional, high-performance coil processing centre. Rotor Straightening Technology progress rotor straightening technology combines a variety of benefits in one system. It guarantees optimum straightening quality for all types of steel and is particularly gentle in processing the wire surface. This results in a finished product of highest quality and a trouble-free production output. It is a particularly energy-efficient system. In addition, thanks to the separated wire feed and the straightening system, it has exceptionally low maintenance requirements

10 Straightening, Cutting and Bending MSR Twin MSR Processes large wire diameters from coil Rotor straightening technology ensures gentle, reliable and precise processing The highest production output thanks to double strand processing Adjustable straightening, collection and logistics systems MSR Twin MSR Straightened, cut bars Bars with bends and closed stirrups The various types of MSR can process wire diameters of 6-26 mm. When large diameters are processed, a wire insertion tool facilitates feeding the wire in the machine frame. It is also possible to work with coils weights up to 6.5 tons. This takes the tried and tested characteristics of the MSR machines into a new dimension of rebar processing from coil. Straightened, cut bars Bars with bends and closed stirrups The Twin MSR is the ideal solution for businesses with high production volumes. This high-performance machine features double strand processing on two lines, each independent of the other. Both the bending and the cutting system are designed for processing two bars with diameter up to 20 mm at the same time. Production is further increased by various straightening, collection and logistics systems, which can be adapted based on the customers requirements

11 Straightening, Cutting and Bending ESR Run-offs, Logistics Systems and Tying Systems Run-offs progress run-off systems are multi-talented and make a significant contribution to ensuring production continuity. The fixed length run-off serves the buffering and tying of the straightened material. With the 2BK bending run-off it is also possible to make bars with bends on one or both ends and to produce large shapes and closed stirrups. The fully automatic former changeover ensures efficiency and flexibility. Flexibility and low costs A variety of possible uses Logistics Solutions Custom-designed logistics solutions create optimum processing, a good material flow and the conditions for efficient production. These solutions are always adapted to suit each plant and its specific requirements. There is a varied range of logistics solutions available, from collection pallets through distribution carriages and roller conveyors to chain conveyor systems and robot grippers. Straightened and cut bars Bars with bends and closed stirrups ESR The ESR single rotor straightening machine is an all-rounder and has been designed for flexible production, together with high output. As in the MSR line the rotor straightening technology and the flying shear ensure a consistently high-quality result and fast processing. The Vario Rotor processes different wire diameters and types of wire with one rotor fully automatically. A number of accessories and individual components plus various automation stages make the ESR into a machine which gives optimum conditions for satisfying specific production requirements. Whether for rebar in fixed lengths, bent bars or large stirrups, the variety of possibilities we offer will allow you to create an efficient logistics system to achieve your production output. Tying System A range of automatic tying systems supports production and prepares finished products perfectly for further transportation

12 Automatic Stirrup Benders EBA S Series Pluristar Adapts flexibly to customer requirements Versatility in production Four in one: automatic stirrup-bender, straightening and double bending machine with 3D bending system High-quality finished products thanks to the combined straightening system EBA S Pluristar Stirrups The EBA S line automatic stirrup benders are robust, compact and high-performance. A fast system for wire changeover, an automatic changeover from double to single strand processing and automatic roller adjustment ensure high productivity, while the robust bending system ensures precision. A 3D bending system is also available for the production of three-dimensional stirrups. If the EBA S is combined with a run-off, straight bars with or without bends can be produced. Stirrups 3D stirrups Pluristar is an automatic stirrup-bender, straightening and double bending machine in one and thus covers the whole spectrum of rebar processing from coil. It allows flexible production of stirrups, straight bars and bars with end bends in a range of wire diameters from 6-16 mm. The central core of the Pluristar is the fully automated combined straightening system, featuring a roller and a rotor straightening unit. Thanks to the optional 3D bending system which can produce three-dimensional stirrups in various forms the Pluristar is a complete solution. 3D stirrups Straightened bars ad bars with bends 22 23

13 Lattice Girder Welding Machines VGA VGA Versa Serial production of standard lattice girders from coil Efficient, flexible configuration Just-in-time production of custom-made lattice girders Fully automatic height adjustment and wire diameter changeover No waste KT lattice girders VGA The VGA lattice girder welding machine is ideal for producing standard lattice girders from coil in large batches. A combined roller and rotor straightening system, a diagonal wire bending unit and fully automatic spot welding machine ensure highest quality standards for the finished product. The two basic versions of the VGA which differ from each other in terms of production speed can be adapted on request to individual requirements. KT lattice girders with flexible height KTS lattice girders (for taking transverse or shearing loads) VGA Versa The VGA Versa facilitates flexible just-in-time production of lattice girders from coil. The highlight is the fully automatic height adjustment and diameter setting during production, which makes it possible to manufacture each product exactly to measure, without having to waste time in refitting. This eliminates high storage costs, and the problem of waste. In addition, the variable length adjustment of the welding spots of the diagonal wire allows the wire to be cut exactly to measure. The Versa can also be specifically designed for the manufacture of KTS lattice girders for taking transverse or shearing loads

14 Radial Bending Machines Radial Master Cage Welding Machines VTA Series Processes diameters up to 40 mm Different radii within one rebar Optional bending machine Versatile configuration possibilities Various stages of automation Low wear and maintenance costs Radial Master VTA Series Bent bars Bent bars with end bends The Radial Master radial bending machine bends rebar for tunnel, tower and foundation construction. The machine can bend even rebar 40 mm in diameter with the highest accuracy. The bending roller is adjusted automatically by computer. This enables several different radii to be produced within one bar. Specially designed collection systems collect the finished products. An additional bending machine allows completely different bend shapes to be produced at each end of a single rebar. Round and bell-shaped cages Rectangular, oval and egg-shaped cages ( special forms) The VTA Series cage welding machines are used for the manufacture of cylindrical and, on request, oval or rectangular cages. The configuration possibilities for these machines are almost infinite. The longitudinal bars can be fed manually or automatically. Alternatively, it is possible to process from coil in combination with a progress rotor straightening machine. The inverter welder, an automatic winding wire cutter, plus automatic cage removal ensure an efficient and precise production output

15 Additional Equipment Wire Feeding Device When processing large wire diameters the reel section can be fitted with a wire feeding device. This facilitates and speeds up wire feeding. Pre-straighteners Pre-straighteners from progress make the processing of large wire diameters easier and ensure that the wire feeding into the machine is under control. Bar Code Scanners Coil Claw The bar code scanner allows production dates to be registered easily and rapidly. Instead of expensive typing, bar codes can be scanned with this machine and be included in digital administration. Faster, safer coil changeover is very important for smooth production. With the progress coil claw, suitable for the various diameters, wound coils can be transported saftely and without hazard. Extra safety is provided by an automatic locking and unlocking mechanism. Stirrup Collectors Manufactured stirrups can be collected by a two-arm stirrup collector. At the same time this serves as a buffer. As soon as one arm has reached the pre-programmed number of stirrups to be collected, the collection device can swing and bring the second arm into operation. Butt Welder When a coil comes to its end, it is recommended to weld the ends of the wires together with a butt welder. This eliminates the time wasted in feeding in the new wire and production can be started up again immediately. Equipment for Safety at Work A comprehensive safety plan is included in the scope of delivery. This consists of safety fences and doors, plus safety light barriers. This equipment creates a safe, convenient working environment

16 Software for Rebar Shops ProFit Control of production output, order sequences and machines Direct entry and/or acceptance of reinforcement from CAD systems Machine feedback and materials tracking Modern surfaces and simple operation Main Module ProFit Report Print ERP Link ProFit is a custom-made software solution for the control and organisation of production process in rebar processes. Coil Control Material Tracebility CAD Link This tool controls and manages production processes, order lines and the machines themselves. Reinforcement data can either be directly entered or transferred by CAD systems. In addition, ProFit functions as the interface to ERP systems such as SAP, GESYS and e rp bos. Standard Mesh ProFit PTS Production Test Service The machines are controlled via the network or bar code labels. Machine feedback ensures smooth production, while the possibility of tracking material contributes to efficient quality control. Together with a vast range of program functions, such as coil management and calling up statistics, ProFit provides a freely expandable bending form library. Flex Mesh Production Scheduler Machine Feedback Machine Control Production List 30 31

17 Solutions for Precast Concrete Plants Shuttering Robot De-shuttering Function Once the finished concrete element has been removed, a scanning device scans the pallet surface and communicates the position of the shutters to the de-shuttering robot. It then releases the magnets, removes the shutters and transports them to the storage. Shuttering Systems Fully automatic shuttering process Gap-free shuttering Modular to suit production requirements Cost-efficient and reliable The innovative, patented Infinity Line system makes it possible to shutter precast concrete elements without any gaps and without using polystyrene extensions. The aim is to use as few types of shutters as possible. The notch-free system also allows shuttering to be performed without any notches. The elimination of filler elements and notches guarantees perfect outer edges. Form Master An efficient shuttering system is the core of a fully automated precast concrete plant. The Form Master shuttering and de-shuttering robot performs all the individual operations fully automatically. This guarantees high precision and exact compliance with production times. The Form Master is the ideal solution for the manufacture of all types of precast elements, starting from lattice girder floors through double walls to solid slabs and walls. The possibility to distribute the shuttering, storage and deshuttering functions across several robots allows scaling the capacity individually. Moreover, the flexible machine layout of the Form Master makes it ideal for upgrading any existing plant. Emplacement of Built-in Parts The shuttering robot can be used for the fully automatic emplacement of electrical outlet magnets. The magnets are cleaned manually, stored temporarily in a magazine and aligned by means of recording templates. The robot then transports the electrical outlet magnets to the pallet with a special magnet receiving rail and places them precisely

18 Solutions for Precast Concrete Plants Wire Center Spacers The use of spacers guarantees that the concrete fully covers the reinforcement emplaced on the pallet. Spacers are available in a range of heights. Custom-made sorting and feeding devices ensure fast preparation of the spacers. Single Bar Reinforcement Custom-made solution Fully automatic reinforcement preparation: Straightening, cutting, bending, emplacement Spacer automation where required The longitudinal and cross wire required for the reinforcement is produced by a fully automatic MSR straightening and cutting machine. The bars are transported from a buffer magazine to the pallet by a robot and emplaced fully automatically. Wire Center Wire Center is a fully automated solution for reinforcement preparation in modern circulation plants. This system straightens and cuts wire from coil fully automatically and, in a second stage, emplaces it with or without spacers based on CAD data. The production and emplacement of lattice girders is also possible. Wire Center optimizes production output and processes, increases precision, and helps minimize defects. The compact, modular structure also makes the system flexible in use. Lattice Girders The lattice girders required are transported from active storage to a GTA lattice girder cutting machine. There they are cut to size and then emplaced on the pallet. A welding machine is used to weld the residual pieces

19 Software for Precast Concrete Plants ebos e rp bos A complete solution for all aspects of production Intuitive user concept 5 years of free updates A comprehensive, custom-made solution for all aspects of your business Maximum networking Perfect compatibility of all components ebos ebos is much more than just a master computer. It is a comprehensive solution for work preparation, production, and process analysis, and addresses all aspects of the manufacturing process, from start to finish. With ebos, you can replace a large number of stand-alone software solutions with a single, well-integrated system. Complicated interface problems become a thing of the past, and workers can carry out their entire work process in a single, homogeneous, and user-friendly system. PROGRESS GROUP has joined forces with ebos to develop a software product combining a wide range of services with extremely simple user navigation. The result has been an extremely innovative tool for manufacturing facilities. e rp bos e rp bos is a custom-made complete software solution for the precast concrete industry. As a planning and management tool for all business and production processes, it helps in accurately setting off manufacture against logistics for each construction project. The different versions of e rp bos are designed for the specific requirements of various processes structural precast concrete parts, concrete blocks, concrete ceilings, staircases or garages and together are a complete solutions family for the concrete industry. A large range of central applications and features, such as data transfer from CAD or CAM, DMS integral document management, working time and operational data capture and central maintenance of master data provides support for every function in the industry. Calculation of quotations, production and logistics planning are not organised as separate applications in e rp bos ; they form part of a powerful and efficient ERP system. These components are perfectly compatible, which reduces induction costs and makes future expansion and modification of the system easier

20 In-house Competence PROGRESS Klimadecke air-handling ceiling PROGRESS XM lattice girder floor Form Master shuttering robot Spacing laying robot M-System Evolution mesh welding plant VGA Versa lattice girder welding machine Automatic concrete distributor Tried and Tested Technology PROGRESS lattice girder floor In our in-house precast concrete plant we compile ideas for new developments. This is a unique situation and guarantees innovative, reliable machines and plants, responding to ever-changing production demands in the real world. Two fully automated pallet circulation plants produce lattice girder floors and double walls. PROGRESS double wall PROGRESS Thermowand thermal wall PROGRESS lattice girder floor with insulation 38 39

21 Progress Maschinen & Automation AG Julius-Durst-Straße Brixen (BZ), Italy Tel.: