IPS 2011 – A Stunning Success, The Best Yet!

Major new products launched to achieve further significant
gains in process efficiency and reduced cost!


Visitors repeatedly witnessed an HEM400 beam, cut in only 83secs

A significant number of new ‘World-first’, advanced machine efficiency claims
were launched at IPS2011 (International Partners in Steel) Event, held at the
Kaltenbach Group Headquarters in Lorrach, Southern Germany between 9-13th
May 2011. Along with some 40 partner companies, 3300 visitors from 52
countries saw the launch of the latest sawing, drilling, coping, profiling and
coating systems, together with an array of closely linked machine technologies,
including an all-new robotic welding system for fabricating fittings to columns
and beams.

Unique AFC (Auto-Feed Control), achieves dynamic, auto-sensing & adjustment of the band-cutting angle ‘during’ the cutting cycle.		AS1051 Auto-Sorter; enables first, 'fully-auto' structural sawing system, with auto removal of trim-cuts & remnants.
MSK471 high-speed straight cutting, rapid processing of solid bar up to 152mm diameter or 140mm square, profiles or bundles.   The KWR Robotic Welding System for fabricating lugs, end plates & webs to columns & beams, with perfect welded seams every time.		Latest generation of high performance shotblast & auto-paint systems, includes new 3D profiling, for advanced auto-painting of fabrications.   KF1606 Plate Processing Centre; now available with robotic 'pick and place' of finished parts.

New machines demonstrated at IPS2011 were for the general engineering, metal stock holding and structural steel sectors.
Kaltenbach Logistical Processing Control (KLPC) was a theme that ran throughout the new machines and processes, in line with the Kaltenbach Group
forte of fully integrating an array of processes and controlling their individual and combined capabilities as a single line. All displayed machines were in
the new, very stylish, Kaltenbach Group corporate colours of turquoise and grey.

Some of the new saws launched at IPS 2011 were:

The KBS1051, revolutionary new mitring structural steel band saw
Live demonstrations repeatedly cut an HEM400 beam in 83 seconds!
A completely new and innovative machine, the Kaltenbach KBS1051 was officially launched at IPS2011 as the world’s fastest band saw. Visitors were given
live demonstrations under normal production sawing conditions, which showed an HEM400 steel beam being repeatedly cut in a remarkable 83 seconds;
up to 300% faster than typical industry norms. The KBS 1051 fully exploits the marked cutting performance benefits of TCT blades (bi-metal blades can
also be used), using powerful and proven servomotor, ball-screw down-feed technology. Combined with Kaltenbach’s unique AFC (Auto-Feed Control),
which achieves dynamic, auto-sensing & adjustment of the band-cutting angle ‘during’ the cutting cycle, throughout a changing cross-section, thereby
optimising cutting performance, with minimum cutting edge contact area and throughout a mitring range of -30°/ 90°/+45°. Maximum material capacity
is 1030 x 500mm, down to 30 x 10mm minimum.

Kaltenbach’s new Auto-Sorter system, the AS1051 was also demonstrated, inter-linked with the KBS1051 band saw to achieve the first ‘fully-automated
structural sawing system’, which includes the auto-removal of trim-cuts and remnants, eliminating the need for time-consuming operator intervention
and the use of a crane for heavier sections.

ParkerSteel; one of the first UK installations of the KBS 1051

Full KBS1051 data at Kaltenbach Group web site.
Video demo of KBS1051

The Kaltenbach KKS463 NA is a revolutionary new design of universal, automatic, high-speed mitring, up-stroking circular saw.
Hailed as the worlds fastest, it was shown for the first time at IPS2011. Designed to achieve high-speed, high-precision, rapid throughput of straight
and mitre cut material, for flat, angle, bar, profiles and thick-walled tube, it has a specially developed, single body rigid machine bed and is fitted as
standard with high-speed input and output gripper feed systems.

The KKS463 uses a 460mm diameter bi-metal blade and Kaltenbach’s patented up-stroking technology as used in more than 40,000 Kaltenbach
machines world wide, but for the first time, a completely new downward clamp system has been introduced that eliminates the sacrificial clamping
block of the established machines. The new clamp sits close to either side of the circular blade and pivots left to right in unison with the blade, in
accordance with any mitre position selected. A sawing feed rate of up to 33 mm/sec is possible with tubing. The KKS463 also eliminates the typical
setup procedures traditionally associated with many circular saws. The machine auto-determines material width and height and automatically makes
a parts calculation and any required correction in case of material variance. Width tolerances of raw material are evenly balanced to ensure
high-precision cuts throughout the material length. The saw auto-selects (or manual intervention) optimum cutting speed and feed rates and ensures
optimal cutting throughout the process. A new innovation, applied when cutting thick-walled tube, auto-adjusts blade feed rate during the cutting cycle
to optimize cutting conditions throughout a changing cut section.

Control is made easy via colour touch screen. Material capacity is 153mm diameter, 140 square or 250 x 75 flat, with a range of options for automatic
bar in feed magazines or conveyors. Full KKS463 NA full details at Kaltenbach Group web site.

The KBS2101 mitring band saw is a completely new model and is the largest of Kaltenbach’s band saws, with a material capacity to enable it to
handle 2050 x 800mm structural steel welded beams. The saws rapid mitring NC controlled capability is from -40 to +30 degrees. Using a powerful
11kW band drive and Kaltenbach’s proven, ball screw and servo-motor band feed technology the KBS2101 will readily cut single, layered and bundled
material. A range of optional equipment is available, including; Band Deflection Monitoring to monitor and control any band deflection as a the blade
begins to wear; Laser line cutting edge indicator and a KHS integrated automated Marking System.
Full KBS2101 details at Kaltenbach Group web site.

The MSK471 is a high speed, straight cutting, 370mm circular blade sawing system, for the rapid cutting and processing of solid bar up to 152mm
diameter or 140mm square, profiles or bundles, using bi-metal or TCT blades. Typical of Kaltenbach’s modular approach to matching customers
precise and varied requirements, a range of options are available, including in-feed magazines and out-feed sorting and handling systems, including
a pick and place sorting robot for cut material. The MSK471 is an ideal high production saw for metal stockholders or companies with regular batch
runs. Control is highly user-friendly and intuitive via a colour touch-screen mounted on a pendulum console. Routine maintenance and general access
is made easy through the machines generously sized, easy access sliding doors.Full MSK471 details at Kaltenbach Group web site.

The latest KKS451 NA universal up stroking 450mm diameter blade machine was also demonstrated. With less sophisticated feed and sorting options
than some other KKS machines (for example the new KKS463), it provides high-precision mitre cutting of +/- 60 degrees, for flat, angle, solid, tube
and profiles up to 150mm diameter for mild steel and stainless. User-friendly operation is via the machines integral touch-screen.
Full KKS451 NA details at Kaltenbach Group web site.

MAJOR NEW STRUCTURAL & FABRICATION PRODUCTS AT IPS2011

Anumber of completely new machines were launched at IPS2011, for the structural steel and fabrication sectors, including new ultra-fast drilling,
new highly advanced, high-efficiency surface preparation and finish technology and a unique robotic welding system.

The latest Sprint 1504 shot blasting system was shown, fully integrated with amazing new inTEC laser sensing, auto-painting technology.
This latest Kaltenbach SPS system achieves significant advances in material preparation and finish, including the even control of paint coverage over
fabrications, with associated cost and finish benefits. Shot blast cleaned and preheated material entering the painting tunnel, passes through a new
laser sensing system that rapidly creates a 3D profile of the material, which is graphically shown on the machines colour touch-screen. A new CNC
automated multi-gun paint spraying system is directly influenced by the 3D laser readings. The results achieved give dramatic reductions in paint
usage and therefore operating costs, with excellent even paint coverage throughout and the minimum of any evenly applied over-spray that a
material configuration demands. The new systems filtering and recycling technology achieves the highest levels of environmental standard.

Full Range of Kaltenbach Shot Blast Systems
Full Range of Kaltenbach Shot Blast Systems

New Robotic Welding System, the KWR601 for columns and beams.
Shown for the first time, the KWR601 enables perfect seam, robotic welding of lugs, end plates and webs or similar items to columns and beams.
A state-of-the-art CNC scanning system tracks and maps the precise contours of the material to be welded. The robot then auto-welds the entire
material, precisely as required. The system is said to eliminate one of the last remaining labour intensive processes in structural steel fabrication.
More KWR601 details.

A new multi-axis, heavy-duty range of drilling machines and a robotic ‘pick and place’, plate profiling system, were shown for the first time.
A new flagship, heavy-duty, 3-axis, 18 tool, high-performance NC structural drilling system, theKDL range was announced at the show and the
latest KF plate profiling systems were demonstrated, including a KF 1606, with a new high-speed robotic 'pick and place' system that removes
and auto-sorts finished parts.