Impetus for innovative production processes

Großbandsägen in Gantry-Bauweise werden in Schmiedewerken eingesetzt. © Behringer

After the ninth edition of the Behringer in-house exhibition, Managing Director Christian Behringer draws an extremely positive balance. “Our visitors were enthusiastic and actively engaged with the experts on site.”

In 2003, Behringer laid the foundation for the event and invited visitors to the “World of Sawing Experience”. Since then, the Behringer Group has developed further and expanded its portfolio to include sheet metal and profile machining centers. Under a new name, “Steeldays” now presents the wide range of innovative machines and solutions for efficient manufacturing.

For more than 700 guests from 25 nations, the three-day event provided a platform for discussion, exchange of knowledge and experience. Participants took the opportunity to learn about current industry trends, new machine and plant systems, and interface and software solutions. Exciting guest contributions and keynote speeches as well as the presentation of the new control interface rounded off the program.

New control presented

The presentation of the new BehrCtrl10 machine control system was a strong visitor magnet. In cooperation with the control manufacturer Siemens, a uniform control concept for band and circular saws was created. “During development, we clearly focused on ease of operation. Thanks to our new Auto-Feed-Control with an extensive material and tool database, the sawing machine independently sets the appropriate technology parameters,” explains Christian Behringer.

Automated material handling of aluminum ingots and AGV connection

In the aluminum theme area, a fully automated sawing and machining solution for handling continuous aluminum castings with an initial length of seven meters was presented. Here, the ingots are sawn to section lengths of one meter, the offcuts are disposed of and transported via a transfer line to an automatic lathe. A gripper then transports the peeled ingots into an ultrasonic basin and then places them on pallets. The sections weigh around one ton, depending on the material diameter. Accordingly, the roller conveyors, cross conveyors and gripper systems are designed to be massive and robust.

Saw cuts in a matter of seconds are made possible by the automatic aluminum circular saws from Behringer Eisele. The VA-L 560 NC3 XL can cut diameters of up to 240 millimeters at high speed while still conserving resources. Because the remaining piece length is just 50 millimeters. Coupled to the automatic aluminum circular saw, exhibitor JTA Connection from Finland demonstrated a driverless transport system with robot cell. The AGV picked up the box with the sawn aluminum pieces at the circular saw machine and transported them to the cell, where the robot removed the sections individually from the AGV.

The HDX profile machining center is used to machine steel beams, for example drilling holes and threads, milling slotted holes and scribing markings. © Behringer
The HDX profile machining center is used to machine steel beams, for example, drilling holes and threads, milling slotted holes and scribing markings.
© Behringer

Interlinked solutions for steel construction and steel trading

Automated processing plays a major role in steel trading and steel construction. Steel beams, profiles and angles are prepared for further processing steps, such as drilling holes and threads, milling slotted holes or marking the material. This work is predestined for the HDS and HDX machining centers from Vernet Behringer. The workpieces are machined simultaneously by up to four axes that can move independently of each other. In combination with a band saw from Behringer, the profiles are sawn to final size after machining.

Since its market launch, the HDX profile machining center from Vernet Behringer has focused on speed and energy efficiency. Compared to similar machines, the HDX offers the same or better machining performance with significantly lower power consumption. The 6-pole spindle motors used in combination with a 1:2 transmission ratio between motor and drilling axes enable high spindle torque at lower power.

Large band saws

The visitors were impressed by the large band saw on display in gantry design with two saw heads. The enormous dimensions of 4.40 m in height, a width of 8 m and the 24 m long material table suggested that the saw was designed for large and heavy workpieces. Due to its two sawing units, the long material table can be flexibly loaded and the saws can work unattended for a long time. The centrally positioned material support table is recessed in the foundation and can thus support even the heaviest loads. The gantry saw is often used in forging shops, foundries and steel processing.

Workshop saws

Smaller saws for single cuts and rooms with limited space were also on display. The circular saws of the VMS and PSU series from Behringer Eisele are suitable for smaller diameters as well as trial and single cuts with materials that are difficult to machine. The HBE320-523G miter band saw also impressed as an all-rounder. Supplemented with handy transport and measuring systems, the saw is suitable for miter cuts of beams and solid materials.

The induction furnace is tilted and the molten iron can flow into the casting ladle. © Behringer
The induction furnace is tilted and the molten iron can flow into the ladle.
© Behringer

Sustainable iron casting from Germany

The tour of the in-house and modern iron foundry was also highly frequented. In the block molding plant, production with unit weights of up to 200 kilograms is partially automated. Large castings up to an average of 2 tons are produced in the hand molding shop. 40 percent of the parts produced are installed in the company’s own sawing machines. Orders from regional customers account for around 60 percent of capacity utilization.

Saws for plates and blocks

With the two automatic panel saws LPS25-200-6A and LPS40-160-4A, Behringer presented the ideal solution for fully automatic panel cutting. The 90° rotatable band guide enables sawing of finished parts in one clamping. The panel editor visualizes the sawing tasks very clearly. This avoids errors in advance and reduces waste. The nesting function of the vertical bandsaw reduces machining time and waste.

Partners present their service portfolio

In addition to the Behringer Group as the main exhibitor, other companies participated in the Steeldays with machinery, equipment and information booths. Rösler GmbH from Untermerzbach provided information on their innovative solutions for surface processing. Together with Behringer and Vernet Behringer, the companies form the alliance “Partners 4 Steel” (P4S) with integrated process solutions for digitalized steel construction and steel trading.

Another highlight of the exhibition was the used machine MAG Evo from Vernet Behringer, presented by Nenok from Cologne. The panel processing center is one of the most modern on the market. Equipped with the latest drilling and milling tools as well as a plasma cutting system, visitors were able to see for themselves the performance, precision and speed of the system for processing sheet metal.

To remove the burrs from the workpieces in the downstream step, Spaleck Industries demonstrated the use of a drum deburring machine. The cut out parts are put into the drum together with a grinding granulate. The rotating motion removes the burrs and improves the surface quality.