Kaltenbach KBS1010-KDX-S1015

Kaltenbach KBS 1010 DG - KDX-S 1015 PROFILED STEEL SAWING AND DRILLING SYSTEM

The Kaltenbach KBS 1010 DG - KDX-S 1015 sawing and drilling system combination consists of a CNC-controlled Kaltenbach KBS 1010 DG band saw and a Kaltenbach KDX-S 1015 drilling system.

This sawing and drilling system is ideally suited for the cost-effective sawing, drilling, center punching, marking (scribing), and thread cutting of profiles and flat steel bars in the steel construction and steel trading industries. The Kaltenbach KDX-S drilling system is equipped with 3 drilling units, each with 26 kW of drive power and a 5-position tool changer. The Kaltenbach M150 length measuring device (measuring carriage), together with the T13 transport system, is designed for profile lengths up to 18 m. The comprehensive transport system for moving structural steel also features cross conveyors at the infeed and outfeed for the transverse transport of the sections.
The CNC control system, together with the Kaltenbach Profiline III software, enables data processing in DSTV and DXF formats.
The entire system has an ergonomic working height of 640 mm from the material level to the top edge of the floor, providing the operator with a clear view. The removal and ejection of the initial cut or the further transport of the profile to the discharge area is performed by a gripper located after the saw.

The Kaltenbach KBS 1010 DG – KDX-S 1015 sawing and drilling system combination consists of:

• Kaltenbach KDX-S 1015 Steel Profile Drilling System
• MITER BAND SAW Kaltenbach KBS 1010 DG
• MACHINE CONTROL Kaltenbach Profiline III
• LENGTH MEASURING DEVICE Kaltenbach M 150
• TRANSPORT SYSTEM Kaltenbach T13

The Kaltenbach KDX-S series of drilling machines was designed to meet the specific market requirements of the steel construction and steel trading industries and is ideally suited for the efficient drilling, center punching, and thread cutting of rolled sections such as double-T steel, T-steel, U-steel, angle steel, hollow sections, and flat steel.

Kaltenbach KDX-S 1015 Basic Configuration:

• 3 drilling units, each with 26 kW drive power, frequency-controlled
• Automatic tool changer in drum design. 5 tool holders per axis
• 3-axis contour marking
• Spindle speeds and drilling feeds for the respective drill diameters stored in the program, manually adjustable
• Horizontal and vertical clamping devices integrated into the automatic cycle control
• Hydraulic horizontal clamping system for the movable clamping jaws; clamping pressure manually adjustable
• Programmable web scanning to determine web offset and zero point
• Automatic cross-section measurement via the horizontal and vertical clamping devices
• The measured width and height values are compared with the target values specified by the program. An error message is displayed in case of a deviation.
• Automatic web center measurement and zero-point determination for web holes (web center) by measuring the actual web width.
• Micro-spray dosing device
• Thread-cutting device for all 3 drilling spindles (with corresponding tool holders)

Technical Data:

• Min. profile dimensions: 80 x 65 x 10 mm
• Max. profile dimensions: 1,000 x 450 mm
• 3-axis—with motor power: 26 kW each, frequency-controlled
• Drilling diameter: 8 – 40 mm
• Spindle speed (frequency-controlled): 90 – 1,400 rpm
• Rapid feed / rapid retract mm/min: 3,850 / 8,000
• Drill spindle feed, mm/min: 0 – 500
• Weight of KDX-S drilling system: approx. 7.8 metric tons
• Machine dimensions: approx. 5,950 x 1,300 x 3,600 mm (LxWxH)
• Automatic tool changer on each axis with 5 magazine slots
• Compressed air connection: 6–8 bar

Kaltenbach KBS 1010 DG Basic Configuration:

High-performance KBS 1010 DG band saw for cutting steel structural profiles, featuring a double miter device in a sturdy double-column design

• High cutting performance and precision due to the angled position of the saw blade.
• Continuously variable cutting speed adjustment
• Infinitely variable saw blade feed adjustment
• NC-controlled cutting angle adjustment at the freestanding control panel. Automatic, hydraulic clamping of the machine once the miter setting is reached.
• Automatic cycle control (clamping – sawing – unclamping)
• Automatic switching from saw blade rapid feed to working feed
• Automatic, electrohydraulic cutting pressure regulation.
• Electrically monitored hydraulic band tension. Sawing process shuts down in the event of a band break.
• Economical lubrication via a micro-dosing system

Technical Specifications KBS 1010 DG:

• Saw drive: 7.5 kW
• Hydraulics: 2.2 kW
• Sawdust brush: 0.18 kW
• Working feed, infinitely variable, max: 400 mm/min
• Rapid forward/reverse feed: 2,500 mm/min
• Air consumption with minimum quantity lubrication: 60 l/min at 6 bar
• Band saw blade dimensions: 7,470 x 41 x 1.3 mm
• For saw blade types: Bi-Metal M2, Bi-Metal M42, Bi-Metal M51
• Weight: approx. 2.9 metric tons
• Machine dimensions: 3,630 x 1,160 x 2,420 mm (L x W x H)

Working area, material dimensions (max. W x H)

• at 0°: 1,010 x 500 mm
• at 30° left / right: 870 / 840 x 500 mm
• at 45° left / right: 710 / 670 x 500 mm
• at 60° left: 500 x 500 mm

Software and PC Equipment:

Profiline III is a Kaltenbach-specific software package for steel construction, designed for file servers or office computers (Windows XP Professional ML), used to create programs for machine control. A high-performance PC processes the entered workpiece data and generates the NC program for the drilling – sawing system, consisting of a CNC control with a touchscreen integrated into the control panel, for fully automatic positioning of the axes and angle adjustment in the sawing and drilling center.

Industrial-grade machine PC with:

• Remote diagnostics integrated into the computer (maintenance contract required)
• Profile database storing the geometric dimensions of DIN steel structural profiles. Large storage capacity for profile data and jobs.
• DSTV data interface
• Programmable speed and feed rate adjustment, based on diameter and material
• Graphical display of profiles to scale in 3 views
• Display of miter cuts on profiles
• Display of drill holes and grit sizes

Order Management:

Clear display of individual items within an order, including graphical representation.

Kaltenbach T13 Transport System

Working height: 640 mm
Infeed side:

• 18 m measuring length (gripper system—lateral clamping of profiles)
• Roller conveyor approx. 20 m long
• 6 x cross conveyors with chain drive—9 m each

Outlet side:

• Roller conveyor, approx. 30 m long
• 6 x cross conveyors with chain drive – 7 m each

Profile – Direction of transport: from right to left

Kaltenbach M 150 length measuring device

Pushing measuring car with hydraulic gripper collet on the inlet side.