Smart Steel: Fully Automated Order Picking in the Steel Industry

Featuring nine million measuring points and ensuring a fully automated and secure grip: KASTO introduces its KASTOpick bar robot solution. This system can pick and deliver flat, square, and round materials, as well as round and profile tubes, without the need for human intervention. The solution is available for new systems or for retrofitting existing storage systems.

For many years, manipulators, such as KASTOpick sheet, have been used to separate metal sheets neatly stacked on load carriers. However, handling a bar stock cassette with chaotic storage is considerably more difficult. Dealing with non-oriented objects is challenging because their position and arrangement are hard to predict. A complex recognition and adjustment process is required to grip and place the bars correctly. KASTO offers a smart solution for efficient separation: KASTOpick bar optimises the removal of magnetic bright and black steel in both new and existing warehouse systems.

This solution allows users to remove and manipulate different bars from storage cassettes without the need for human intervention in three-shift operation, i.e. 24/7. This system recognises and grips not only flat, square and round bars but also round and profile tubes. Users can conveniently link several production steps using this system. KASTOpick bar accomplishes two tasks: It picks the bar stock and prepares bundles for shipping or supplies individual bars for further processing on the saw. Special feature: There is no need for teach-in by the user

To start the process, KASTOpick bar moves a 3D sensor measuring probe over the storage cassette, which can be up to six metres in length. An algorithm developed by KASTO is used to process the 3D point cloud generated by this scan. The software analyses the data to identify the bar locations and potential gripping points for the robots. Only those points are considered that allow the machines to deposit the bar without causing a collision. This intelligent calculation of the travel path prevents the robots from colliding and the bar from striking an obstacle in its path. To perform this procedure, the software predicts the proposed movement and optimises the route to the target position. The process starts anew with the next scan.

Link between storage system and saws

The gripper system separates and moves a variety of different formats. This makes the user more flexible in handling and processing steel. The flat, round and profile materials can also be wrapped or labelled. KASTOpick bar also communicates with the ERP system and the upstream and downstream machines to provide the right workpiece at the right time and location. It connects storage system, saws or strapping units. The software also ensures the bars are stacked in an ideal pattern based on dimensions and order volume, using individual bar manipulation. KASTOpick bar can position rectangular material so that it can be ideally formed into a bundle. In its standard version, the system can grip a bar weight of up to 500 kilograms. Higher loads are also possible upon request.

A wide range of grippers are available to provide customised solutions – depending on the shape of the objects to be moved. KASTOpick bar automatically selects the ideal gripper for the specific task to carefully and safely separate and transport the material. 

Focusing on ergonomics and efficiency

Thanks to the fully automated removal of bars from storage cassettes, the workload of employees is reduced. Employees no longer have to remove and transport heavy and cumbersome material manually or by crane. Companies can thus reduce physical demands on employees, preventing injuries and accidents. With its intuitive interface, the KASTOpick bar is easy and efficient for operators to use without requiring extensive training or specialised technical knowledge. Following brief instructions, users can work efficiently and productively with the operator-friendly separation system.

Steel processors and distributors also benefit from operator-free order picking thanks to optimised material flows. They can use resources such as labour efficiently, lower operating costs, and speed up production processes. The intelligent solution is ideal for high-mix-low-volume tasks because it recognises different materials and always selects the most suitable gripping strategy. The high-precision control system ensures reliable movements with maximum repeat accuracy.

The new KASTOpick bar solution is the perfect addition to the KASTOpick separating solutions. KASTOpick sheet enables users to pick different sheet formats, while KASTOpick select (previously known as KASTOksg) supports handling as a manual picking crane. KASTOpick split utilises the lift motion for separating of bar stock and is suited for bars with larger diameters that are arranged neatly next to and on top of each other. However, this system reaches its limits when used for an unsorted configuration, since the bars fall end over end and can only be handled with a calculated grip. KASTOpick bar has filled this gap and its small footprint makes it an impressive option.

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