Digitalized and networked sawing processes are now indispensable in metal processing. KASTO is driving this trend forward with intelligent solutions. From seamless system integration via KASTOlink to optimal cutting plans with KASTOoptisaw, live status overview of the saws via KASTOapp, to automatic cutting optimization through KASTOrespond. Users benefit from maximum efficiency, reduced costs, and high process reliability when sawing.
Manual or isolated processes are no longer up to date in metal processing. Thanks to smart concepts from the storage and sawing specialist KASTO, machines and systems communicate autonomously with each other. The result: even more efficient processes. 'When it comes to sawing, we no longer think only of the machine itself, but of the entire material flow. Our experts develop solutions that optimize cutting strategies, automate processes, and intelligently network machines.'
An important aspect is the interfaces – we have been offering OPC UA and many other standards for over ten years. This turns every saw cut into a building block in a well-thought-out digital process chain – with maximum efficiency, safety, and transparency for our customers,” says Sönke Krebber, member of the management board at KASTO.
Seamless system integration with KASTOlink
KASTOlink allows for seamless networking of KASTO saws with other processing machines, storage solutions, as well as warehouse management and ERP systems. It ensures a continuous digital process chain from order to production. The versatile interface solution not only enables integration into KASTO systems but also flexible connection to machines from other manufacturers. This allows users to efficiently and transparently network their KASTO products with the entire IT and machine environment via interfaces such as OPC UA, MQTT, or REST-API. DSTV+, CSV, or KASTO's own HOST coupling.
Cutting plans at the push of a button with KASTOoptisaw
When sawing, users face the challenge of utilizing the material used as effectively as possible and avoiding waste to keep resource consumption and thus costs low. This is where KASTOoptisaw comes into play, which is fully integrated into the warehouse management system (WMS) software suite KASTOlogic.
On the one hand, it ensures optimal allocation of the stored long goods to the respective sawing orders, taking into account various machine parameters such as cutting gap width and minimum gap lengths. Different lengths of bars, pipes, and profiles with various miter angles can be used with minimal waste – this reduces costs and saves space in the warehouse, as unusable remnants no longer need to be stored. On the other hand, KASTOoptisaw also assists directly at the saw: The module automatically determines the best cutting plan by gradually varying and combining potential section arrangements. However, the creation of cutting plans can also be done manually. For this purpose, a graphical wizard based on geometric data is available. This also offers the possibility to further improve the results through a new optimization with altered stock selection.
Live status overview of the saw machines with KASTOapp
The KASTOapp provides a status overview of all KASTO saw machines present in the network at a glance and in real-time. Additionally, the app shows the designation for each saw with machine number and type, the current operating condition, as well as a historical timeline of the machine status and cutting figures. This way, users always keep track of the usage and performance of their saws.
For saws running in automatic mode, the program directly accesses the data stored in the machine control. Users – one or several users simultaneously – receive precise information on all relevant process parameters, such as items, section lengths, target and actual piece counts, as well as feed and cutting speeds. If an error occurs in the operational process, the app visualizes the upcoming error message, allowing the user to react quickly. Downtimes can thus be minimized.
Automatic cutting optimization with KASTOrespond
Regardless of whether solid material, pipes, or profiles are processed individually or in bundles, KASTOrespond ensures the optimal setting of the sawing machine. Without additional necessary sensors, the system continuously measures the forces occurring at the tool and translates the data obtained into the appropriate digital feed speed. KASTOrespond detects different wall thicknesses, varying engagement lengths, or particularly hard material areas early on and automatically takes them into account.
For the operator, this reduces the effort to entering a few relevant parameters such as section lengths, piece counts, and materials. The result: shorter engagement times and a significantly extended tool life.
Smarter, more intuitive, more efficient with the new control generation
To complete the package of intelligent solutions, KASTO will launch the new generation of its controls at the beginning of next year. It has been completely newly developed to make daily work even easier, faster, and more efficient. The new user interface, designed with a modern design, smart functions, and a role-based user guidance, provides significantly more overview and efficiency. A 'Simple Mode' facilitates the quick and safe processing of sawing orders without many clicks, while browser-based access allows for flexible and comfortable machine control via PC or tablet, for example from the office of production planning. Different lengths of the same material can now be bundled in one cutting plan, allowing multiple orders to run automatically one after the other. Important statistics are always clearly available in the dashboard, and for questions, context-sensitive help provides targeted support exactly where it is needed.
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