CutMaster is here!
The previous number of CI introduced the Masters of Elematic and implied that a new master would soon take to the scene. We now present you with CutMaster, an innovative concept for turning your hollow-core production into highly automated, streamlined, and efficient action generating less dust, less noise, and better quality end products. For the first time, your entire hollow-core production can move along the same line from beginning to end, through one station only. This means that automation can be taken much further, as slabs do not need to be lifted to separate points in the factory. The main idea of the CutMaster concept is to cut hollow-core slabs into just a few large pieces on the bed and then forward these to a fixed sawing station for further cutting operations.
Shorter production cycle time
With traditional production systems, the slab is cut into a large number of piecesof 6-8 meters each directly on the bed, which produces a huge amount of dust and concrete waste on the beds as well as on the factory floor. The cutting together with the cleaning of the bed takes some two hours. With CutMaster, the slab is only cut into 2-3 long pieces and the bed is ready for the next slab in less than thirty minutes.
Notable improvements to the working environment
The CutMaster concept brings significant improvements to the working environment of factories. Perhaps most importantly, the amount of health hazardous quartz dust is cut down dramatically. Equally noteworthy is the greatly reduced noise level. Elematic has delivered silent casting machinery since 1985 and now even the last noisy piece of equipment in the factory is sealed off - the saw. From now on, the foreman's voice can be well heard in the production area and workers can enjoy a less stressful, much more pleasant working environment. Work safety is also improved by the reduced number of dangerous lifts resulting from the fewer slab pieces. These larger pieces and the larger cranes required are also easier to watch out for. "We find it vital to be able to serve our old customers as well as new ones, and CutMaster has been designed to fit just as well into existing production systems, where it significantly improves the air quality and working environment", says Mr. Lassi Järvinen, Technical Director at Elematic. "Factories can seldom be entirely rebuilt and therefore it is important to improve the production technologies for modernization purposes and increased productivity."
Higher cutting accuracy
With the fully automated CutMaster concept in action, you can take advantage of the data saved all the way from design to storage. Cutting accuracy is greatly improved, fault tolerance drops to within a few millimeters and human errors lessen significantly. CutMaster also provides the possibility to do special sawing, such as different angles to the ends of slabs, with a special robot saw. Further, the system aims at reducing the handling of slabs at the end of the line. The intention is to make loads straight from the line onto the truck, ready to go the construction site. This way the slabs do not need to be piled up in the yard or moved to the storage.
New levels of quality control
The R&D efforts on the CutMaster concept continue through cooperation with the Lappeenranta University of Technology, among others, where an automatic quality verification system is being advanced. The data measured by the system can be fed straight into Elematic's ELiPLAN (ERP) for analysis and with this information end products as well as production can be further improved. The quality data can also be read into an RFID-tag or a bar code, which is automatically labelled onto the slab and can be read even 50 years later, if needed. Thus a quality history is available. "Since, for example, all products are passing the same station in the plant we will shortly be able to install a special camera right behind the fixed sawing station and a laser system to carry out the quality control on all slabs. With this system, customers will be able to take all measurements of the hollow core slab automatically - even the slippage of the prestressing strands will then be detected automatically", Mr. Järvinen concludes. For more information, please contact: email@example.com