KPS / KPSA Punching-Shearing Machines

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1 If Steel is Your Deal! KPS / KPSA Punching-Shearing 1

2 The complete KALTENBACH program for profile and beam processing 4

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4 The High Performer Applications: medium to heavy steel fabrication and steel service center KPS 503, KPS 506, KPS 513 Powerful Punching-Shearing Machine for Plates and Angles High performance brings shorter turn around time. The KPS punching and shearing system processes sheets and angular steels. Top plate and foot plate, reinforcement ribs, gussets and many more things can be manufactured as fast as connecting elements. The systems have various applications owing to the 13 punching tools with 20 stencils and a stencil table with carousel magazine. The sheet steel shaving unit processes the parts up to remainder piece of only 20 mm! Advantages at a glance Capacity Range (w x h): 50 5 mm to mm KPS 503: 3 punching tools and 3 dies KPS 506: 6 punching tools and 6 dies KPS 513: 13 punching tools and 20 dies Fast punching-shearing movement through completely re-developed, powerful hydraulic system and the shortest punch/shear path High flexibility with mitre cuts through zero-point offset Optionally with angle processing and plasma cutting Machine operation via modern MULTILINE steel-construction software package 54

5 KPS 503 KPS 506 KPS 513 Plateprocessing Centers Circular Sawing Coping/Welding Robots Drilling Band Sawing Punch-/Shear Punch Tools / Dies 13 tools (KPS 513) for the highest production throughput Cutting clearance can be optimally adjusted to punch diameter according to material thickness through the wide choice of dies High quality punching and long tool life Cutting Clearance Setup (Optional) Automatic shearing procedure depending on thickness of the material High-quality shear edges Angle Shears (Optional) In addition to flat steel shears: Moveable angle shears Double-cut shearing unit: No deformation of the cut pieces Shotblast Technical Data KPS 503 KPS 506 KPS 513 Process Punching Punching, Punching Punching Working range mm 500 x x x 25 Working range Flatmaterial mm 500x25 500x25 500x25 Working range min. mm 50x5 50x5 50x5 Vertical punch diameter mm Number of tools vertical punch unit Pieces Number of tools horizontal punch unit mm Number of tools horizontal Punch unit Pieces Mitre range Flat shear unit Degrees +/-60 +/-60 +/-60 Angle shear double cut kn Angle shear single cut kn Tools HSS-Tools HSS-Tools HSS-Tools 55 Painting Service Automation

6 Everything in Motion Huge potential for increasing efficiency in steel machining We know how: KALTENBACH Logistic + Process Control L OGISTIC+P RO Production process Customer requirements Planning Logistics CAD/CAM- Data processing Transport Storage Handling Plate processing Profile processing Tube processing Sawing Drilling Stamping 68

7 The automatic production control with LPC (Logistic Process Control) systems is already widespread in the manufacturing industry. Up to now in steel machining, however, only stand-alone solutions have been implemented in steel construction and the steel trade and these only automate individual machining steps. As one of the first suppliers to do so, KALTENBACH has now developed the KLPC (KALTENBACH Logistic Process Control) system which fully automates all machining steps such as sawing, drilling, flamecutting, coping to shotblasting and painting as well as the transport of the work piece between the respective machining processes, and visualises them in real time. Via the DSTV interface, the KLPC system can adopt CAD/ CAM data directly from higher-level ERP systems. At the same time, it visualises and reports the processing status of each job in real time back to the ERP system. The production manager thus gains for the first time a complete overview of the current processes in the machining and thus optimises existing machine capacities and the utilisation of production. With the KLPC system, KALTENBACH is heralding a new era in steel machining. On the one hand, it offers huge potential for increasing efficiency with the automation and optimisation of processes. On the other, it creates the prerequisites in the first place for capturing the entire machining process, visualising it and thus gaining a detailed overview of it. Every company that uses KLPC can thus draw up more comprehensive and detailed plans and generate a clear competitive advantage with this. Key issues How the right material and associated information reaches the right location at the right time and how, when and where the current process data gets reported back? Circular Sawing Band Sawing CESS C ONTROL Painting Systsems Drilling Coping/Welding Robots Plateprocessing Centers Punch-/Shear Logistics Construction site Shotblast Shearing Coping Shot Blasting Painting Measuring Transport Transport Storage Handling Fastening Mounting Handling 69 Service Automation

8 Keep it Flowing! Transport & Measuring Efficient Flow of Materials is the Basis for Ultimate Productivity There s no production without transport equipment. Sturdy roller conveyor systems and cross transport systems guarantee an efficient flow of materials in plate and steel processing. An extensive range of measuring equipment generates full flexibility and required dimensional accuracy. Advantages at a glance Highest accuracy and productivity All from one source for highest production reliability Modular and future-proof system A variety of automation levels from semi to full automation for complete processing lines Heavy and robust design Cross Transport by Means of Drag Chains Material stock in heavy-duty steel construction Sliding rails of synthetic material (polyamide) for low-noise material cross transport Drag chains with transport claws Drive system with continuously-variable frequency-controlled gear motor Cross Transport by Means of Lift-and-Carry System Hydraulic liftable and lowerable lifting beams running in both directions Drive system with continuously-variable frequency-controlled gear motor Conveyor Roller System Modular Expandable Executed in welded construction with maintenance-free, ball-bearing conveyor rollers of solid material Roller-conveyor drive on the feed and removal sides with frequency-controlled gear motor Fully automatic Plate Processing centre Automatic part removal and sorting Flexible programmed sorting location The size of the sorting range can be customised 72

9 Painting Systsems Shotblast Plateprocessing Centers Coping/Welding Robots Drilling Band Sawing Circular Sawing Punch-/Shear Pusher Measuring System Positioning drive through servo motor with absolute rotary encoder Automatic NC positioning via machine software Hydraulic height adjustment for measuring various profile cross-sections Length Stop Measuring System Positioning drive through servo motor with absolute rotary encoder Automatic NC positioning via machine software Rapid pivoting of the squaring arm Autosorter Process-assured full automation of the feed side in profile handling Variable sorting positions possible For parts with mitre or straight cut from a length of 50 mm and up to a width of 1000 mm Contour Marking Application of reference boundaries for welding add-on pieces DSTV-Data import Use of high-speed carbide tools In addition to the three drill axis - marking from the bottom (4th axis) Marking System Fast marking process for applying letters and numerals Up to 22 characters without material movement Can be integrated into fully-automated handling processes Imprint still clearly visible after galvanizing or painting T13-Silencer Contributes to enhanced occupational safety and the protection of personnel and the environment Low-Noise Material Cross Transport Fully-automatic control 73 Service Automation

10 The Originals From practical experience to be put to practical use! A Service Network that is there for You Right from the Start! KALTENBACH sets new standards in the area of customer service: Remote maintenance of all equipment ensures the fastest possible repair in case of malfunction, and therefore the highest possible equipment availability. Our specialists can be reached via a service hotline that offers professional support worldwide. A dense network of national and international service partners in over 40 countries ensures the presence at short notice of a skilled expert when needed. Our parts service ensures that users can get the spare parts they need for their machines even after many years. Originale die passen! Advantages at a glance Over 150 service technicians are available at more than 40 locations worldwide 1st level support through the local service organization 2nd level support through the specialists at the service helpdesk INITIAL ASSEMBLY: Consulting, Project planning, Organization, On-schedule, professional assembly/initial operation, Training Breakdown prevention through maintenance contracts (preventative maintenance) Worldwide express delivery of necessary replacement parts and tools Service Find your local Service Partner: 74

11 Original Spare Parts for KALTENBACH/Gietart Shotblasters To ensure a smooth production process a shotblaster should be maintained regularly. We would be pleased to help you with this! We can offer you the complete package, directly from the Circular Sawing Band Sawing manufacturer: original spare parts service maintenance repair assembly consultancy Drilling Spareparts for Shotblast spareparts@ kaltenbach-sps.nl Shotblast Coping/Welding Robots Plateprocessing Centers Original KALTENBACH-Tools: Assemble and produce Punch-/Shear Tools for Drilling Saw Blades Saw Bands Painting Systsems Tools Additives and Coolant All Information on our Homepage spareparts@ kaltenbach.de Order here 75 Service Automation

12 Transport Band Sawing and Circular Sawing Drilling Measuring Robotic Coping Painting System Plate Processing Centers Shotblast system Robot Welding System Punching/Shearing Kaltenbach GmbH + Co. KG PP.O. Box D Lörrach, Germany Blasiring 4 D Lörrach, Germany Phone: +49 (0) 7621 / Fax: +49 (0) 7621 / info@kaltenbach.de