Installation and testing of the machine
Inside a tube sawing machine: how does it work?
Like many other machines, a modern automatic pipe cutting machine uses a large number of components to control its movements. In this article, we provide an insight into the parts and technologies contained within the machine.
PLC (Programmable Logic Controller)
At the heart of the control system is the PLC. This is where the commands from the production programme are converted into signals: the right signal at the right time for the right action. Production commands can be entered by the operator or loaded from an externally linked system, such as an ERP (Enterprise Resource Planning) system.
Once the job has been entered into the machine, the PLC determines the sequence in which the various actions are carried out. The programme uses sensors to check that all conditions are met before the next step is initiated. These checks include, amongst other things, the safety systems and the operator’s confirmations.
Machine set-up
An automatic sawing line is equipped with numerous moving parts to separate, transport, cut and discharge profiles. The machine is suitable for processing different types and sizes of products and requires various changeover and adjustment operations.
Most settings can be carried out fully automatically using electric motors which, for example, adjust the height guide. Sensors check whether the correct position has been reached, after which the next step is authorised.
SERVO motor
To get the most out of the machine, various movements are carried out using servo motors. A servo motor is ideally suited to movements requiring high dynamics, high load capacity and high positioning and speed accuracy. The servomotor is controlled by the drive, with the built-in encoder enabling it to determine its position with great accuracy. This information is continuously shared with the drive. The result is a system that is powerful, capable of moving at high speed and highly accurate.
An example of the benefits of using servo technology is the feed gripper system, which feeds the tubes into the saw at speeds of up to 4 metres per second, with acceleration and deceleration of 40 m/s², which equates to approximately 4g of G-force during acceleration and deceleration, whilst maintaining an accuracy of within 0.01 mm. By way of comparison, the fastest electric car (1020 pk) achieves ‘only’ 1.4 g during acceleration.
Open TCP/IP Communication Protocol
All movements, sensors and control systems must work together in a precisely coordinated manner. To achieve this, all components are connected to the machine’s internal network, with all parts ‘speaking’ the same ‘language’ (protocol).
The network is already prepared for any external connections. This allows the pipe cutting machine to be easily connected to, for example, a deburring machine, a robot or other external systems and software. All systems work together in a coordinated manner and can be controlled from a single control panel.
Software & online support
The conversion of the cutting job into the coordinated sequence of all movements is carried out by the software. The Bewo software in the cutting line has been further developed over the years and is designed to accommodate every conceivable option and configuration.
The machine can be updated with the latest software via a connection, and adjustments to further optimise the process are continually being developed.
Bewo Easy Access Covers
The Bewo Easy Access Covers have been developed with maximum accessibility, safety and ease of use as the guiding principles. Thanks to the fully hinged covers extending the full length of the machine, all key components are easily accessible for maintenance, cleaning and inspection. This reduces maintenance times, increases machine availability and simplifies servicing.
The hoods are fitted with high-quality safety plexiglass panels, ensuring that operators retain an excellent view of the entire production process even when the hoods are closed. This allows operations to be monitored safely without opening the machine, whilst the machine remains fully shielded.