Manufacturing companies face significant challenges such as rising efficiency requirements and a growing shortage of qualified personnel. KASTO addresses these issues with a new control generation for its sawing machines. This innovative system combines a modern operating concept with practical features, allowing both experienced operators and first-time users to operate the machines quickly, safely, and productively.
The specialist in metal sawing technology has completely overhauled its saw control system. “From the very beginning, it was important for us to actively involve the employees who work at our customers’ sites on a daily basis,” says Sönke Krebber, a member of the Board of Directors for Research & Development at KASTO. “Working closely with our service and commissioning experts allowed us to create a control system that is tailored for practical use, simplifying many operational steps for operators in their everyday tasks.” The new control system will be implemented in the KASTOwin series and will later be extended to other saw models. The optimised software architecture will provide significantly shorter loading times, quicker response to inputs, and improved machine availability.
Well-designed dashboard and quick navigation
The core element of the new control system is a well-structured dashboard that visually presents key metrics, including runtimes, downtimes, current job orders, and machine status. Operators can quickly see which job orders are currently running, re-sort job orders flexibly, and toggle between different views even during an ongoing cut. The interface includes function windows that can be used simultaneously, along with context-sensitive help, which reduces the number of clicks needed and significantly speeds up operations.
Safe access thanks to the Simple Mode
The key feature of the new control system is the Simple Mode. This mode simplifies the display to focus only on the essential information and guides novice users safely through the sawing process. Different user roles ensure that operators, supervisors, and maintenance personnel receive only the information relevant to their specific tasks. Additionally, users can customise individual settings, such as language, units of measurement, and preferred assessments, which greatly simplifies the initial training process.
Highly efficient functions for repeat tasks
The material library offers a selection of pre-filled material data. Users can retrieve previously entered material data at any time. These features help reduce data entry time for future job orders.
A cutting plan facilitates the quick and intuitive creation of multiple sawing job orders, accommodating varying cut lengths and complexities. Each cutting plan is assigned to a specific item, ensuring clear organisation and traceability throughout the production process. Additionally, individual process parameters can be set for each sawing job order, allowing for precise customisation to meet specific requirements and maximise efficiency. When used in conjunction with the “Optisaw Light” software module, the cutting plan reaches its full potential. This solution automatically assigns all saw job orders to the available bars, considering the desired cut lengths while optimising the sequence and placement of cuts. This intelligent optimisation minimises waste and enhances material efficiency, resulting in lower material costs and promoting a more sustainable and resource-efficient production process.
The function package now includes a new cycle stop feature. This feature allows job orders to be paused at specific points and resumed exactly where they left off. Any interruptions are clearly displayed, and users can continue from the pause point without the need to re-enter any data.
Transparent diagnostics and analysis
The new control generation allows for precise fault diagnosis in the event of a malfunction. It clearly identifies whether the issue is mechanical or electrical—whether it originates from the base machine, or infeed or outfeed systems. This capability eliminates the need for time-consuming troubleshooting. Additionally, comprehensive analysis functions offer transparency regarding runtimes, downtimes, and the condition of the saw band. This information is crucial for effective shift planning and ensures smooth, operator-free operation.
Tested and proven in a real production environment
Before introduction to the market, the new control system underwent thorough daily testing at Günther + Schramm’s facility in Königsbronn. This system completely replaced an existing saw. The southern German systems service provider operates over 100 saws and produces more than ten million cut sections each year. “We couldn’t imagine working without the new control system now,” says Angelo Faraci, one of the shift supervisors and operators of the machine equipped with this new control generation. “When you operate three to four machines simultaneously, you need to be able to count on the saws. Every shift runs on a precise schedule – we must process all job orders quickly, reliably, and with just a few clicks.”
The successful field test confirms that the new control system is perfect for everyday use and significantly enhances the sawing process.
