Flying saw controller

A flying saw cut control system is used to cut products while they are moving. The products are already moving before the cut starts and keep moving throughout it. Mechanically, the saw or cutting unit is mounted on a carriage. When the product reaches the required length, the controller, following its application program and a set motion profile, brings the carriage up to the product's speed and then starts the cut. Throughout the cut the carriage must stay synchronised with the product so the saw blade is not damaged and the cut is clean. As soon as the cut ends, the carriage returns to its start point and waits for the next cut. Flying saw automation raises cutting accuracy and production efficiency, and greatly reduces the stress on the mechanical parts. Today many of the country's pipe and profile mills use one of two approaches. Some use a PLC as the cutting controller; because of its long cycle time, a PLC usually gives very poor accuracy (1 to 5 cm). Others use foreign controllers, which, given the country's particular circumstances, usually lack good support when they fail. The RA⁠-⁠FSC⁠-⁠9162 cut control system is fully local and independent of any PLC or computer. It is designed and built around a very powerful FPGA processor. Its cutting accuracy is better than 3 mm, and it works with AC, DC and servo drives. The RA⁠-⁠FSC⁠-⁠9162 controller has many advantages: it needs no preparation at each line start and works across the industrial operating temperature range; its software runs on Windows in Persian; the cut length can be adjusted during operation; carriage speed, line speed and the number of cuts are shown on the display, and more. It also comes with a warranty and after-sales service. So far three units have been installed at two plants, one of which bought two units, and the customers have approved all three. The two plants are Reza Pipe & Profile in Amol and Keyhan Pipe & Profile in the Shamsabad Industrial Estate. The video below shows the controller at work.

Features of the automation system for cold and hot saw cutting:

• Higher cutting accuracy and tighter length tolerance of the finished product
• Fewer saw blade breakages thanks to precise synchronisation of the saw with the product, even during sudden line stops
• Precise speed matching of the product and carriage, even with severe line speed fluctuations
• Lower cutting noise
• Less scrap, as no set-up is needed at each line start
• Compatible with AC, DC and servo drives
• Easy configuration via the controller's front panel
• Persian-language software for parameter settings
• Operating temperature range: ⁦-40⁩ to ⁦+85⁩ °C (versions V2 and V3)