Automated Precision: Metal cutting has been revolutionized with servo-controlled traverse system

Above: Servo-controlled traverse systems automate force and feed rates on band saws.

January, 2025- Band saw technology’s precision and efficiency have made it essential in modern metalworking. Among recent innovations, HE&M Saw’s servo-controlled traverse (SCT) systems stand out for their ability to revolutionize cutting processes.

SCT technology automates the band saw arm’s force and feed rate to achieve a specified chip removal rate determined by the operator. This automation significantly enhances productivity and extends blade longevity by minimizing human error. This innovation is a game changer, offering exceptional accuracy and adaptability for various cutting applications.

HOW SCT WORKS

SCT employs a ball-screw mechanism powered by a servo motor at its core. This configuration precisely manages the band saw arm’s position, fall rate and force, allowing for fine adjustments as minimal as 0.005 inches per minute and ensuring positioning accuracy to ±0.010 inches. This level of precision is essential for cutting operations involving intricate materials or demanding tolerances.

The SCT system dynamically adjusts cutting force and feed rate, optimizing the cutting process for each material type and thickness within parameters set by the operator. Operators can rely on automated controls to maintain consistency, reducing variability due to manual settings. A built-in material library further simplifies the process, offering preset parameters for bimetal blades, such as blade speeds and chip removal rates for common metals and sizes.

ADVANTAGES OF SCT

A. Extended system and motor life: The SCT system’s ability to use the minimum necessary force for each cut reduces stress on the motor and mechanical components, resulting in longer equipment life. This not only decreases maintenance costs but also maximizes manufacturers’ return on investment.

B. Optimized blade longevity: By maintaining consistent and accurate feed rates, the SCT significantly reduces blade wear. Its automated adjustments prevent excessive force use. This control over force extends blade life, minimizes downtime for replacements and decreases overall operating costs. Additionally, the SCT is equipped with the Active Cut Watcher, which adjusts blade tension during cuts, resulting in longer blade life and improved performance, particularly while the blade is deteriorating.

C. Adaptability to diverse cutting applications: The versatility of SCT technology is one of its most robust features. The SCT operates in two modes simultaneously.

1. Chip removal rate mode: Entering the desired chip removal rate in square inches per minute along with the material’s width causes the SCT to calculate and apply the ideal linear fall rate, which minimizes the risk of operator error.

2. Force-controlled mode: This mode operates in a pressure-limiting configuration and is suitable for applications with variable material cross sections. It allows the arm to descend at a specified rate below a set force limit. The arm slows down when force thresholds are reached, ensuring precise control when cutting irregular shapes. The controller automatically switches between both modes by identifying the limiting factor during the cutting operation and selecting the appropriate mode. This adaptability makes the SCT ideal for cutting exotic alloys, structural shapes, pipes and round materials.

MATERIAL LIBRARIES

The SCT features an intuitive touchscreen interface and a comprehensive material library capable of storing thousands of entries. HE&M Saw provides a preloaded list of common materials and sizes that can be customized to meet specific user requirements. Each material entry includes essential details such as the material name, rough dimensions, blade speed, chip removal rate and feed force. This functionality streamlines the cutting process, reduces setup time and ensures operators access optimal parameters for each job. By automating these inputs, the SCT significantly minimizes the potential for human error, ultimately enhancing efficiency and accuracy across operations.

SCT VS. TRADITIONAL SYSTEMS

1. Hydraulic systems: Traditional hydraulic systems often assume uniform material shapes, leading to inefficiencies when cutting complex profiles. Hydraulic systems also rely on fluid mechanics, which can be influenced by temperature changes, resulting in inconsistent daily performance.

Automation can significantly enhance productivity and extend blade longevity by minimizing human error.

SCT addresses these challenges by dynamically adjusting force and feed rate to suit each material’s unique properties. Its ability to operate in force-controlled mode allows it to optimize cutting speeds for irregular shapes, avoiding the limitations of hydraulic systems that treat all materials as square or rectangular.

2. Manual control: While manual systems rely heavily on operator skill and experience, SCT offers consistency through automation. This automation eliminates variability between shifts and operators, ensuring reliable results regardless of external factors such as temperature or operator fatigue. The material library further enhances this advantage by providing consistent starting points for various materials and sizes.

APPLICATIONS

The precision and adaptability of SCT systems make them valuable assets in industries that demand accuracy and efficiency:

Aerospace: Cutting high-performance materials like titanium and Inconel requires precise control to avoid tooling and material damage. SCT’s automation easily handles these materials, ensuring clean cuts and minimal waste.

Construction: Structural components often have irregular shapes. SCT’s force-controlled mode ensures consistent cutting performance across varying cross-sections while keeping the gullets from overfilling.

Manufacturing: SCT’s reliability and reduced downtime benefit high volume production environments, enabling manufacturers to maintain tight schedules and high-quality standards.

METALWORKING IMPLICATIONS

The introduction of servo-controlled traverse technology marks a significant advancement in the metalworking industry. Its capability to automate complex cutting processes, improve precision and extend the lifespan of equipment meets the increasing demand for efficiency and sustainability.

As manufacturers face mounting pressure to deliver higher-quality products at lower costs, technologies like SCT provide a competitive advantage. Investing in SCT-equipped band saws is a strategic choice for companies aiming to excel in fast-paced manufacturing environments. By reducing reliance on operators, minimizing errors and optimizing blade performance, SCT systems offer a transformative approach to metal cutting that promises long-term value and consistency.

SCT’s advanced features, such as automated force and feed rate adjustments, material libraries, and various cutting modes deliver precision and efficiency that traditional systems cannot achieve. For metal shops seeking to maintain a competitive edge, investing in SCT equipped band saws is not merely an upgrade but a strategic advantage. As the metalworking landscape continues to evolve, HE&M Saw’s SCT technology ensures that users have the precision, consistency and versatility necessary for success, providing an innovative and reliable way to meet customers’ demands.

HE&M Saw, 888/729-7787, hemsaw.com.

 

Home page horizontal banner 4