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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

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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
Foldaway, Hydraulic Vertical Clamping Device

Foldaway, Hydraulic Vertical Clamping Device

  • Excellent access when changing band saw blades
  • Easy, user-friendly handling
  • Reduced non-productive times
Automatic Hydraulic Cutting Pressure Control

Automatic Hydraulic Cutting Pressure Control

  • 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
Automatic Lowering of the Saw

Automatic Lowering of the Saw

  • Hydraulic lowering of the entire machine below roller conveyer level after the sawing cycle ends
  • Protection of saw table and workpiece during materials handling
Horizontal and Vertical Profile Clamping

Horizontal and Vertical Profile Clamping

  • 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
Hydraulic Band Tensioning

Hydraulic Band Tensioning

  • 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
Laser (Optional)

Laser (Optional)

  • Processing of material via feed creep rate through control keys directly on the saw frame
  • Sawing on tracings possible
Lubricant Savings via Micro-Dosing System

Lubricant Savings via Micro-Dosing System

  • 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
NC-Controlled Cutting-Angle Setting

NC-Controlled Cutting-Angle Setting

  • 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
NEW: AFC - Auto Feed Control (Optional)

NEW: AFC - Auto Feed Control (Optional)

  • 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
Saw Band Drive (12.9 kW) / Saw Band Feed

Saw Band Drive (12.9 kW) / Saw Band Feed

  • 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
Cut Monitoring System (Optional)

Cut Monitoring System (Optional)

  • 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
Swarf-Chamber Brush

Swarf-Chamber Brush

  • Brush separately driven by three-phase motor
  • Automatic motor-driven adjustment of the swarf brush
  • Long saw band life and excellent cut quality
KHS Marking System (Optional)

KHS Marking System (Optional)

  • 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
ProcessSawing
Sawbandmm8.900 x 54 x 1,6
Sawband inclinationDegrees1,5-10
Drive performancekW12,9
Cutting speedm/min15-150
Dimensions (L X W X H)mm4.370 x 1.435 x 2.650
Feedratemm/min0-600
Rapid advance/ return movementmm/min6.000
Machine Weightkg5.800
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
MaterialclassSteel
ProcessProfiles
Bundles
Layers
AS 1051 Autosorter

AS 1051 Autosorter

  • Process-assured full automation of the feed side in profile handling
  • Disposal of front cuts and end pieces
  • Variable sorting positions possible
  • For parts with mitre or straight cut from a length of 50 mm and up to a width of 1000 mm
T 13 Modular Expandable Conveyor Roller System

T 13 Modular Expandable Conveyor Roller System

  • For material feed and removal
  • Executed in welded construction with maintenance-free, ball-bearing conveyor rollers of solid material
  • Roller-conveyor drive on the feed and removal sides with frequency-controlled gear motor
Cross Transport with lifting pins

Cross Transport with lifting pins

  • Hydraulic liftable and lowerable lifting pins running in both directions
  • Drive system with continuously-variable frequency-controlled gear motor
  • Each lifting pin has its own hydraulic unit
Cross Transport by Means of Lift-and-Carry System (As an Alternative to Drag Chains)

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

  • Hydraulic liftable and lowerable lifting beams running in both directions
  • Drive system with continuously-variable frequency-controlled gear motor
  • Each lifting line has its own hydraulic unit

 

Cross Transport by Means of Drag Chains

Cross Transport by Means of Drag Chains

  • 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

 

M 150 P Sliding Measuring Carriage with Pusher Plate

M 150 P Sliding Measuring Carriage with Pusher Plate

  • Positioning drive through servomotor with absolute rotary encoder
  • Automatic NC positioning via machine software
  • Additional pusher plates (optional) enable the handling of layers and bundles with stand-alone sawing machines

 

 

M 151 G Sliding Measuring Carriage with Gripper

M 151 G Sliding Measuring Carriage with Gripper

  • Positioning drive through servo motor with absolute rotary encoder
  • Automatic NC positioning via machine software
  • Additional pusher plates (optional) enable the handling of layers and bundles with stand-alone sawing machines
  • Hydraulic height adjustment for measuring various profile cross-sections

 

 

 

 

M 152 GG Sliding Measuring Carriage with Two Grippers

M 152 GG Sliding Measuring Carriage with Two Grippers

  • Positioning drive through servo motor with absolute rotary encoder
  • Automatic NC positioning via machine software
  • Additional pusher plates (optional) enable the handling of layers and bundles with stand-alone sawing machines
  • Hydraulic height adjustment for measuring various profile cross-sections
  • Automatic transposition of the measuring carriage position from the rear to the forward gripper

 

L 220 Heavy-Duty Measuring Stop

L 220 Heavy-Duty Measuring Stop

  • 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

 

 

LS 270 Heavy Duty Measuring Stop

LS 270 Heavy Duty Measuring Stop

  • 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)

 

 

Silencer

Silencer

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

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

PROFILINE - Order manager

  • Create, copy and delete orders
  • Graphic display of individual positions within an order

PROFILINE - Profile database

  • Comprehensive profile database
  • Easily expandable
  • Graphic display of workpiece forms

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

  • Recording of production times of individual pieces or entire orders

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


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