KASTOtec SC 4
With a turnover of €4.5 billion, SEW-Eurodrive is one of the market leaders in drive technology. During a press day, media representatives were given the opportunity to tour a honeycomb warehouse that uses Kasto technology to fully automatically supply semi-finished products for production runs of 1 to 10,000 units.
Kasto and SEW-Eurodrive developed a complete solution in which metal saws and storage technology seamlessly integrate, centrally supplying the production facility of the drive technology specialist. Fifteen-ton bundles of long steel products are demagnetized, separated, and transported to the saw for cutting and cutting of three- or six-meter-long tubes and bars with diameters from 22 to 260 mm. Segments are then picked and packed for production – all fully automatically and virtually unmanned. SEW and Kasto had set themselves an ambitious goal for supplying the new production hall. For the experts in sawing and storage technology, this was one of the largest orders in the company's 180-year history.
KASTOpick split dispensing station
When planning and implementing the new warehouse on approximately 4000 square meters for the northern production hall in Graben-Neudorf, Kasto and SEW are relying on the combination of a Unicompact honeycomb storage system with 5140 storage places for cassettes up to 3 t and a Kastocenter sawing center with 450 places for individual bars.
Unicompact is characterized by its efficient use of space. The two compact storage and retrieval machines (SRMs) transport the material to the seven KastoPick split output stations installed along the sides of the machine, where it is separated by lifting mechanisms and transferred to the saw's feed roller conveyor. To ensure the material is positioned correctly, all 5140 cassettes are equipped with angled base rails. Three additional stations can be connected to the system if required.
Demagnetization included
Because steel can develop a certain degree of magnetism through transport and friction, which can be problematic in subsequent manufacturing steps, Kasto installed a demagnetization system in the receiving area. A crane places the entire bundle from the truck onto a material polder chain conveyor (MPK). Depending on the barcode specifications, the system either stores the goods directly in the trolley storage area or transports the bundle to the bypass leading to the demagnetization coil – an alternating magnetic field that demagnetizes the entire material fully automatically.
Photos: Kasto/A1
Kasto sawing centers are a combination of buffer storage and CNC sawing machines. SEW relies on the fully automated Kastocenter varioplus 2 cantilever storage system. From here, a computer-controlled stacker crane automatically transports individual bars to the integrated saws. To save space, Kasto built the sawing stations as tunnels directly into the racking block of the Unicompact storage system.
Eight fully automatic Kastovariospeed C 18 production circular saws cut workpieces up to 180 mm in diameter. These heavy-duty, CNC-controlled production circular saws cut solid material, profiles, and pipes of all grades. Their robust components guarantee high cutting performance and long service life.
The fully hydraulic, high-performance Kastotec SC 4 automatic band saw cuts pipes and bars with larger cross-sections into individual pieces. The horizontally parallel saw blade cuts round, square, and flat materials, as well as pipes and profiles of all grades, including tool steels and difficult-to-machine materials such as titanium, Hastelloy, and Inconel. The cutting speed is infinitely variable, and the height of the saw unit can be adjusted fully automatically via light sensors.
The sorting area is located within the section-length transport line. Here, the Kastosort robotic handling system sorts and stacks the sawn sections. The innovative AI solution makes autonomous decisions, selecting grippers, containers, and stacking patterns independently. Automated guided vehicles (AGVs) then collect the boxes and transport them to their destination in production.
Variospeed C 18.
The Kastologic Warehouse Management System (WMS) ensures a smooth flow of materials. Its consistent user interface supports users in their daily warehouse tasks. The software also optimizes the routes of the stacker cranes and monitors and evaluates system changes. Kasto integrated the sawing machines and material handling systems into the WMS to fully automate the entire workflow. Kastologic communicates with the SAP ERP system via an interface to complete the automation process.
Kasto impressed SEW with its comprehensive design and planning, carefully analyzing specific customer requirements and integrating them into a customized overall solution. This approach ensures maximum efficiency and optimal adaptation to individual needs, which distinguishes Kasto as a reliable partner. "Kasto supplies our new production hall at the Graben-Neudorf site fully automatically with the appropriately processed materials – starting from batch size 1," explains Max Schmidt, Group Leader Production Systems Project Management at SEW-Eurodrive. He was involved in the planning and implementation of the logistics solution from the very beginning. "The entire system can be operated by just three to four people. In times of skilled labor shortages, this is a huge advantage," he emphasizes.
