Build Better Machines: The World's First Fully Automated Production Line For Reinforcing Steel Mesh
The construction industry needs many busy hands. After all, manual work is still standard in many areas. Terhoeven GmbH & Co. KG has now tackled a typical example - the monotonous and time-consuming cutting of reinforcing steel mesh.
The medium-sized mechanical engineering company relies on drive and automation technology from Mitsubishi Electric and the expertise of Orgassa GmbH. The result is an innovative system that is unique to the market.
At A Glance:
- Fully automated cutting, handling and stacking of reinforcing steel mesh
- Outstanding precision despite difficult conditions
- Drive and automation technology from a single source
The Challenge - Cutting and Lifting the Mesh is Complex
ASA (automatic cutting system) is the name of the newly developed machine that handles, cuts and stacks the reinforcing meshes fully automatically. Lifting the top mat from the stack is a major challenge because the manufacturing tolerances of the rebar mats are in the centimetre range, but handling requires an accuracy of less than one millimetre. In addition, the individual mats do not lie neatly in the stack. 3D image processing is therefore used to identify six suitable pick-up points. When the grippers lift the mat, the next challenge comes: the mat bends.
So three separate devices are needed for each of the six points to move the grippers in all three spatial directions. During operation, the drives must be controlled precisely and synchronously.
The Solution - Drive and Automation Technology from a Single Source
To compensate for the deformation of the mats during lifting, 18 drives are required for the lifting gear, plus four drives for transporting the mats within the system. Mitsubishi Electric servo drives with the corresponding servo amplifiers are used here. The MR-J5 series motors are very compact and offer high dynamics.
The matching servo drives can be couples via intermediate circuits, which contributes to the high energy efficiency of the system. The required synchronisation of the drives can be optimally implemented with the motion controller. All other automation components are also supplied by Mitsubishi Electric. FR-E800 frequency inverters are used for simple conveyor tasks. And a safety PLC from the MELSEC iQ-R series controls all the processes in the system.
This is supplemented by three C-Controllers which run the image processing. The protocol used is CC-Link IE TSN, which provides real-time capability as well as the necessary safety-related communication. With the gigabit bandwidth offered by the open CC-Link IE TSN standard, communication between the controller, motion control and safety can be easily integrated into one network.
The Result - Huge System Can Be Operated By One Person
After almost two years of development, the first ASA, measuring six metres in height and more than 40 metres in length, was commissioned in the spring of 2024. It is operated by a GOT control unit from Mitsubishi Electric. In addition to the touch screen, a number of buttons and switches are integrated to facilitate operation with gloves. Conversion of the system, for example to a new mat size, is very easy with the GOT control unit. Only a few manual operations are required during set-up. In routine operation, the system can then be operated by one person.
Looking for more information? We can help with that...
If you want to know more about building better machines with Mitsubishi Electric, or have any questions, don't hesitate to get in touch on 01254 685900 and our Internal Sales Advisors or Technical Support Engineers will be happy to chat!
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