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TECHNOLOGY
© Behringer
Automated band saws for precise linear cuts
Four modern band saw systems from
Behringer GmbH separate parts for largescale
industrial and private constructions,
subway and aircraft construction and the
machine construction and energy sectors
for an Asian customer of Behringer
GmbH.
Integrated in an existing roller conveyor system, the HBP800-1201 aluminium
bandsaw from Behringer ensures fast, high-precision cutting of the lightweight
material
With an annual volume of 500,000 tonnes,
the company is one of the major processors
for aluminium. Window and door profiles
are mainly manufactured for the private
and industrial sectors as well as components
for ships, aircraft and for the energy sector.
Processing is usually with profiles and tubes
but also solid materials with highly diverse
cross-sections and diameters. In the past years
Behringer from Kirchardt in Germany has
supplied a total of four partly automated band
saws that with their highly precise linear cuts
ensure ready-to-mount sections that are postprocessing
redundant.
First pressed, then sawn
Two of the saw systems are each connected
to large aluminium presses for bringing the
profiles into form prior to sawing. “The
HBP800-1201 and HBP410-923N straight cut
aluminium band saws are not isolated solutions
but were integrated into an existing periphery
consisting of diverse roller conveyors
and cross conveyor systems,” explains Achim
Müller, head of Sales at Behringer. They take
the place of two large circular saws that were
previously integrated in the peripheral setup
and ensure problem-free processing, characterised
by convenient tool changing and highly
reliable operation. Following the separation
process the profiles are transported onwards
via the roller conveyors either to the packing
location for dispatch or into an intermediate
storage area for subsequent processing.
A second HBP800-1201 of aluminium with
a cutting range of
up to 1,200 mm
in height and 800
mm in width operates
independently
without connection
to other systems.
This is equipped
with a 25 metrelong
feed and discharge
roller conveyor,
and loading
of the machine is
via a hall crane
from a blank piece
storage area. Following
the separation
process the
crane takes up the
cross-cut profiles
and deposits them
for subsequent dispatch.
Both large band saws feature a saw band
inclined by four degrees for efficient cutting
of grouped, square hollow sections. Controlled
by computer, the feed function and cutting
speed of the saw band are adapted automatically
to the input material width. A cut monitoring
system controls cutting progression of
the material to be cut. Dynamic sawing and retracting
achieves increased band service life as
well as optimal cut edges. The ejection height
of the chip container is 1,200 mm due to the
large volume of chips produced
during aluminium sawing.
Both HBP800-1201 aluminium
saw systems also feature
a hydraulic vertical tensioning
device with a wide thrust piece
installed to the machine. The
horizontal tensioning device
and this supplementary vertical
tensioning device enable several
tubes in a single position
or package to be cut up to the
height of the fastening clamps.
All fastening clamps have a
smooth, hardened surface for
avoidance of imprints into the
material. The movable fastening
clamp features plastic plates to achieve
effective clamping of packages, for example
with rectangular tubes.
High efficiency and maximum precision
The HBM540ALU automatic band saw ensures
high performance machining with enormous
precision. “The cutting performance is
many times higher than with conventional
band saws,” testifies Mr Müller. A servo drive
and ball screw enable point-precise, rapid infeed
to the band saw as well as a highly constant
and precisely adjustable saw feed rate.
Constant cutting feed rate or constant cutting
force can be optionally specified, and this ensures
an optimal service life of the tool and
optimal separation results as well.
Sawing and retracting is also dynamic with
the HMB540ALU. As with the HBP800-1201
large band saws, the benefits are optimal cut
edges with the separation of tubes and profiles
as well as protection of the band. The high efficiency
band saw has an extended supply axis
and the stroke length of the feed gripper is
1,440 mm. With this version the feed gripper
is configured permanently for linear directions
and the fixed jaw automatically moves away
from the stop edge during the return stroke.
A hydraulic vertical tensioning device enables
economic sawing of packages and layers. A
cutting channel extension means the saw band
can be freely retracted following the separation
process.
With this investment in the new saw machines
the company has not only planned for
the moment. “A further expansion of production
capacity is expected, and the currently
existing machine park readily permits such an
increase,” summarises Mr Müller. ■
Aluminium profiles with different diameters are cut with maximum
speed and precision on Behringer bandsaws
ALUMINIUM · 9/2013 73