Kraftech sets a new standard for steel processing with X-Calibre
Steel processing specialists and integrators seek versatile, high-performance solutions that can effortlessly manage diverse project requirements and integrate with advanced automation systems. To meet these needs, Kraftech developed the X-Calibre™, a pioneering robotic plasma coping machine that combines precision, speed, and adaptability to accommodate a wide range of steel profiles. The X-Calibre provides a comprehensive solution capable of performing layout marking, scribing, four-side processing, cutting holes, coping, slotting, weld preparations, mitres, and bevels—all within a single unit. Kraftech’s ambitious development was powered by Beckhoff’s PC-based control technology, which offered the seamless integration, communication flexibility, and safety features required to bring this innovation to fruition.
Kraftech is a premier provider of heavy-duty robotic equipment. Recently relocated to larger premises in southern Sydney, it collaborates with some of the globe’s most innovative industrial machinery manufacturers. With expertise in CNC machinery, plasma and oxy cutting systems, robotics, and fibre laser cutting machines, the company is dedicated to engineering state-of-the-art steel processing technologies.
Engineered to excel in heavy-duty environments, the X-Calibre is customised for demanding projects that require precision and reliability. Designed for mass production and high accuracy, it can process a diverse range of steel profiles, including 1200 I-beams, 380 PFC, 400 SHS, and 200×200 angles, with a piercing capacity of up to 60 mm. With its advanced features and robust construction, the X-Calibre sets a new benchmark in steel processing, delivering precision and efficiency for even the most intricate projects.
How the XCalibre operates
For any construction project, the structural steel requirements are compiled into a design package that contains detailed information about the building’s structure. This includes specifications for the type and quantity of steel profiles needed, hole locations for joining, and the required dimensions. The design package can export this data into a DSTV-NC1 file format that is compatible with the X-Calibre offline programming software.
While the data provided by this file reflects an ideal profile, the reality is that the dimensions of steel profiles can vary within acceptable standards and specifications. These variations must be considered during the cutting process to ensure accurate alignment of the steel structures during assembly. “The X-Calibre reads the actual material dimensions using precise laser measurement,” explained Jan Pristavok, General Manager of Kraftech. “Based on this, the robot’s path is adjusted to account for discrepancies between the drawing and the material, ensuring precisely cut structural steel profiles. We recalibrate our systems during manufacturing to ensure accuracy.”
Once the NC1 file is loaded into the built-in nesting software, robot paths are generated in minutes. After the steel profile is placed on the infeed conveyor, the X-Calibre measures all sides of the profile and performs the cuts and markings according to the design specifications. The system also alerts the operator if the steel profile or length deviates from the program parameters, reducing the risk of human error and minimising potential additional costs.
Ensuring unmatched accuracy
The Kraftech X-Calibre has advanced lasers and sensors, allowing it to adapt seamlessly to real-world conditions. The cutting software generates programs in just minutes, while the system scans steel profiles to assess their position, size, and orientation. This enables precise adjustments to the cutting programs, ensuring exceptional accuracy
“As opposed to a manual operator, who would take hours to complete this process, the X-Calibre can accomplish it in minutes, resulting in significant time savings,” said Pristavok. “Additionally, the machine maximises tonnage processing capacity, further enhancing return on investment.”
The choice of control system
It was clear from the outset that X-Calibre would need to support a wide range of communication options and programming facilities, so that it could interface with the cutting equipment used. “Different pieces of cutting equipment have their own communication protocol, and we need to be able to handle this seamlessly”, explained Andrew Michael, Engineering Manager at Kraftech. “Beckhoff supports everything we needed, from EtherCAT with safety, EtherNet/IP, down to serial interfaces, which allow us to develop drivers inhouse.”
Beckhoff’s Automation philosophy of having a single, centralised industrial controller minimises hardware and alleviates the need for additional PCs. Reducing components not only makes the whole system more reliable but also more economical.
Safety considerations
The machine has a safety-interlocked front door with a viewing window, safety scanners at the infeed and outfeed, and sensors surrounding the robot’s working area— all designed to meet stringent safety standards. Additionally, four cameras are installed within the cell, with footage displayed on the HMI for continuous monitoring and remote diagnostics.
“The process of cutting and welding steel can be dangerous, not just in a physical, operational sense, but also in terms of the heat generated, intensity of light, fumes and more. So, our safety considerations need to be multifaceted,” added Andrew Michael.
Service and maintenance
The Kraftech team is dedicated to delivering high-quality industrial equipment that is reliable, durable, and designed to increase business productivity. With expert installation, training, and ongoing support from their skilled technicians, customers can maximise the full potential of their equipment.