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Kaltenbach

KBS 1051 DG

BANDSAWING MACHINES

Fast High Performance Band Saw with Mitre Unit for Structural Steel Profiles
Capacity Range 90° [mm]: 1030 x 500

Video

Benefits at a glance

  • Capacity Range (w x h): 1.030 × 500 mm
  • Robust, low-vibration twin-column construction for perfect cutting results
  • Precise NC-controlled cutting-angle setting
  • Powerful clamping system reliably holds material and reduces vibrations to prolong band life and best cutting results
  • Intelligent material measurement integrated into clamping system for greater process reliability
  • Rapid/working feed concept for shorter idle times
  • Swarf brush to improve cutting performance and reduce impurities in the machine
  • Cut monitoring system incl. cutting pressure and slippage control for optimum cutting quality
  • Laser-assisted cutting edge visualisation for manual cuts
  • High process automation can be combined with an autosorter
  • Carbide saw bands for high performance cuts
  • Auto Feed Control automatically controls the saw band angle to suit the profile cross-section, significantly reducing cutting times
  • Powerful drives for carbide applications
  • Fast change of the saw band for low idle times

Alternative Machines

KBS 1051 DG
Saw Blade Changing Made Easy

Saw Blade Changing Made Easy

  • Excellent access when changing band saw blades
  • Easy, user-friendly handling
  • Reduced non-productive times
'Saw Band Friendly' Operation

'Saw Band Friendly' Operation

  • Measurement in both saw band guides
  • Cutting-pressure selection and cutting-pressure display on free-standing control console
  • Self-regulating feed rate accross the range of saw band contact lengths
Contactless Materials Transport over the Saw Table

Contactless Materials Transport over the Saw Table

  • Hydraulic lowering of the entire machine below roller conveyer level after the sawing cycle ends
  • Protection of saw table and workpiece during materials handling
Material Checking through Clamping Device

Material Checking through Clamping Device

  • Hydraulic profile clamping within the automatic sawing control (clamping, sawing, unclamping)
  • Clamping devices with long-stroke clamping cylinders and integrated absolute level gauge
  • Clamping of the workpiece directly alongside the saw band for precise cuts, even with short cutting lengths
  • Material checking and automatic comparison of the target/current values; if applicable, plain-text error message appears on the control console
  • Clamping and sawing of layers and bundles possible
Saw Band Relief when Idling

Saw Band Relief when Idling

  • Electronically monitored, with automatic tension reduction when saw band is idle
  • Automatic shut-off of the saw drive in case of blade breakage
  • Long saw band life
Visual Display of the Cutting Edge

Visual Display of the Cutting Edge

  • Processing of material via feed creep rate through control keys directly on the saw frame
  • Sawing on tracings possible
Virtually Dry Workpiece

Virtually Dry Workpiece

  • Micro-dosing system with level and pressure monitoring to ensure the functional efficiency of the cooling lubricant system
  • Optimum tool lubrication when sawing profiles
  • Disposal of lubricant unnecessary
  • Long saw band life
Extremely Fast and Precise Miter Adjustment

Extremely Fast and Precise Miter Adjustment

  • Adjustment on free-standing control console
  • Angle setting via servo motor with planetary gears and absolute rotary encoder
  • Automatic, hydraulic clamping of the machine after reaching the mitre setting
  • Reduced non-productive times when changing mitres
Reduction in Sawing Times of Up to 50%

Reduction in Sawing Times of Up to 50%

  • Automatic adjustment of the saw band angle to suit the profile cross-sections in order to minimise the tool contact length
  • Additional positioning axis for the saw frame in connection with special guides on the machine frame
  • Higher feed rates and considerably shorter cutting times
New: Use of Carbide Band-Saw Blades

New: Use of Carbide Band-Saw Blades

  • Strong drive power for increased cutting speed
  • Saw band feed via ballscrew spindle and servo motor with absolute pressure encoder infinitely adjustable on the control console
  • Low-vibration, constant and repeatable feed
  • Alternative use of Carbide and HSS tools
  • Improved cutting performance when using Carbide band saw blades
Band Deflection Monitoring

Band Deflection Monitoring

  • Control of cutting path through the material when saw band begins to wear
  • Input of threshold values on the operating console in addition to cycle interruption if maximum parameters are exceeded
  • High cut quality, no material waste
Saw Band Protected from Wear

Saw Band Protected from Wear

  • Brush separately driven by three-phase motor
  • Automatic motor-driven adjustment of the swarf brush
  • Long saw band life and excellent cut quality
Fast Marking Process

Fast Marking Process

  • Fast marking process for applying letters and numerals
  • Up to 22 characters without material movement
  • Can be integrated into fully-automated handling processes
  • Imprint still clearly visible after galvanizing or painting
Drive performancekW12,9
Dimensions (L x W x H)mm4370 x 1435 x 2650
Weightkgapprox. 5.800
ProceduresSawing
Sawbandmm8.900 x 54 x 1,6
Sawband inclinationDegrees1,5-10
Cutting speedm/min15-150
Feedratemm/min0-600
Rapid advance/return movementmm/min6.000
Workspace max.mm1.030 x 500
working range Profilemm1.030 x 500
Working range min.mm30x10
Mitre range-40°/90°/+30°
ToolsBi-Metal Tools
Carbide Tools
Degree of Automationautomatic infeed
automatic outfeed
automatic sorting of trim and remnant cuts
Full-Automatic
MaterialclassSawing
ProcessProfiles
Bundles
Layers
Fully-Automatic Sorting System

Fully-Automatic Sorting System

AS 1051 Autosorter
T 13 Transport System for Steel Construction and Steel Service Centers

T 13 Transport System for Steel Construction and Steel Service Centers

T 13 Modular Expandable Conveyor Roller System
Cross Transport with lifting pins

Cross Transport with lifting pins

Cross Transport with lifting pins
Connection to Steel Roller Conveyor

Connection to Steel Roller Conveyor

Cross Transport by Means of Lift-and-Carry System (As an Alternative to Drag Chains)
Fast Material Cross Transport

Fast Material Cross Transport

  • Material stock in heavy-duty steel construction
  • Sliding rails of synthetic material (polyamide) for low-noise material cross transport
  • Drag chains with transport claws
  • Drive system with continuously-variable frequency-controlled gear motor

 

Standard Measuring System on the Feed Side

Standard Measuring System on the Feed Side

M 150 P Sliding Measuring Carriage with Pusher Plate
Universal Measuring System on the Feed Side

Universal Measuring System on the Feed Side

M 151 G Sliding Measuring Carriage with Gripper
Space Saving Measuring System on the Feed Side

Space Saving Measuring System on the Feed Side

M 152 GG Sliding Measuring Carriage with Two Grippers
Standard Measuring System on the Feed Side for Sawing Machines

Standard Measuring System on the Feed Side for Sawing Machines

  • Positioning drive through frequency regulated three-phase motor with absolute rotary encoder
  • Automatic NC positioning via machine software
  • Rapid pivoting of the squaring arm
  • Manual adapter for processing short lengths

 

 

Universal Measuring System on the Outfeed Side for Sawing Machines

Universal Measuring System on the Outfeed Side for Sawing Machines

  • Positioning drive through servo motor with absolute rotary encoder
  • Automatic NC positioning via machine software
  • Rapid pivoting of the squaring arm
  • Automatically-extending adapter for processing short lengths
  • Material weights of more than 8 t can be processed through additional brake cylinder (optional)

 

 

Low-Noise Material Cross Transport

Low-Noise Material Cross Transport

By lightly raising the material using polyamide-coated rollers integrated into the roller conveyor, the traditional “steel on steel” noise from cross transporting profiles is significantly reduced. Transport technology in steel construction and steel trading will be revolutionized through this new system.

  • Fully-automatic control
  • Contributes to enhanced occupational safety and the protection of personnel and the environment

 

PROFILINE

Modern Software Package for KALTENBACH Drilling and Drilling-Sawing Machines

 

PROFILINE - Easy, user friendly machine operation

PROFILINE - Easy, user friendly machine operation

  • Programming of orders via color touchscreen with large keypads directly on the machine control console
PROFILINE - Order manager

PROFILINE - Order manager

  • Create, copy and delete orders
  • Graphic display of individual positions within an order
PROFILINE  - Profile database

PROFILINE - Profile database

  • Comprehensive profile database
  • Easily expandable
  • Graphic display of workpiece forms
PROFILINE - Tool manager

PROFILINE - Tool manager

  • Tool Changer setup based upon the tool type and diameter
  • Allocation of the drill diameter to rotational speed settings and feed rates
PROFILINE - Production data report

PROFILINE - Production data report

  • Recording of production times of individual pieces or entire orders
PROFILINE - Data transfer and data response

PROFILINE - Data transfer and data response

  • Data input directly on the machine’s control console
  • Data import in DSTV or DSTV+ format
  • Data export of previously produced parts in DSTV feedback format to any directory

* Required

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