The ironworker gets automated

"On the punching side of it, we’re seeing more and more calls to automate," said Mike Albrecht, national sales manager of Scotchman Industries. For example, Scotchman has added punch station automation to its DO 85 ironworker. Photo courtesy of Scotchman.

Long dubbed the Swiss army knife of the fabricating world, the ironworker offers flexibility and functionality all in one machine. Although these workhorses have been a staple on the shop floor for decades, they have resisted calls for major tech upgrades. However, more and more, manufacturers are looking to incorporate automation to help make these versatile machines even more efficient.

"We are definitely seeing more calls for automation across the board," said Mike Albrecht, national sales manager, Scotchman Industries, Philip, S.D. "Everybody wants a machine to do a little bit more than they did before. Ironworkers are basic, manually run machines. The operators punch holes, shear angle iron or plate. Those are the main functions. On the punching side of it, we’re seeing more and more calls to automate."

Basic Automation

When most people think of automation, they often go straight to robotics. However, for the ironworker, a simple or semi-automated operation is a great first step. There are a number of challenges when it comes to incorporating automation. One of the biggest challenges for OEMs is placement. With a machine that performs many different operations, it can be difficult to place a highly automated system without impeding the surrounding operations. However, in a manual system, adding even the simplest of automation can make all the difference.

"Automation continues to get a little more sophisticated," said Angus Catterson, president, KAAST Machine Tools Inc., Aldan, Pa. "On the basic machines, an electronic sensor is included. So for bar stock, angle iron, channel, and flat plate, the operator could manually set this sensor, and then as soon as the material hits that sensor the ironworker cuts. So it’s a very quick and easy way of making many repeat, uniform cuts."

Albrecht added that completely automating an ironworker is probably a stretch. But one area where it can be added is material positioning. When an operator is punching holes in heavy material, making a mistake can be costly. If the operator has to measure by hand and then mark the hole location, especially with a range of hole placements, human error can occur and the operation time-consuming.

"In order to deal with this challenge, adding a programmable measuring system to line up the one axis can make a huge difference," said Albrecht.

Semi-automated Operations

Beyond basic automation, moving away from manual operations to semi-automated operations that fit a shop’s needs is another step to maximizing the ironworker’s utility.

"Having a cut list programmed into the system is a great way to automate the ironworker," said Albrecht. "Operators can put the punch list into the system so the hole locations can be indexed without having to do any material marking and the machine can move the material to the proper position. This is a big step in helping customers speed up the punching process."

Catterson agreed that the next step up from simple automation would be to incorporate automation that would allow for a single axis to cut, punch, or notch at various lengths. Being able to program in many different lengths is a great option for shops that are producing many different parts. Catterson noted that a system like this is typically limited to one axis.

Expanding Automation

Beyond simple automation, an ironworker can include a full CNC. The operator can program in the operations and the ironworker works in multiple axes for punching, shearing, notching, and more.

"The majority of machines we’re still selling with a simple electronic sensor," said Angus Catterson, president of KAAST Machine Tools. This KAAST PS 85 DP ironworker includes electric trigger switch up to 1,000 mm for quick work flow of repetitive work. Photo courtesy of KAAST.

"We have just built a big system where we put a 20-ft. measuring system on the punch of an ironworker," said Albrecht. "With this, the operator can put a full cut list in and program the series of holes. The operator manually positions the Y axis, but then the X axis pusher could push the angle iron through to the hole location and automatically punch the hole. This helps speed up the operation tremendously."

For punching a significant number of holes, adding a full CNC and automated system can significantly increase speed and accuracy.

"For example, if an operator is punching a series of holes, the system allows the machine to move the material quickly without the need for measurement, which in turn reduces scrap," said Catterson. "As long as the program is correct, there shouldn’t really be any errors. With a system like this, the shop gets faster processing and fewer mistakes."

Market Interest

Both Catterson and Albrecht agreed that customers are very comfortable incorporating basic automation like sensors and semi-automatic operations. However, only a few shops are interested in exploring big automated systems.

"The majority of machines we’re still selling with a simple electronic sensor," said Catterson. "There’s definitely some interest in the fully automated system, but at this time the simpler machines still [generate] by far the highest sales volume."

Catterson believes that this is partially due to operator availability. The ironworker is a fairly simple machine to operate, but when it becomes a full CNC machine, it has to be programmed.

"I think that’s definitely one of the reasons why, if only at the moment, there is less interest in CNC than basic automation," said Catterson. "The more sophisticated the automation, the greater the increase in productivity and reduced scrap. However, finding an operator either with the skills or training the operator to meet the machine’s requirements can be challenging. Before investing, a shop has to ask itself, ‘Who is going to operate this machine?’"

Challenges

An ironworker is known for its flexibility to complete a number of different tasks. Besides finding skilled workers to operate advanced CNC ironworkers, another challenge with these automated systems is that their flexibility is reduced.

Albrecht explained that automation can be a great thing, but shops need to be aware that even fully automatic systems have restrictions. He gave the example of an automated angle line that is designed to cut 4-in. angle to length then automatically punch holes in it. An automated ironworker may not be able to handle 1½-in. angle in the same capacity. An ironworker still has that ability to work with a larger range of material, but in a semi-automatic mode.

"It’s important to know these limitations, and in many ways, we can overcome the challenges and find a solution to the customer’s requirements," said Albrecht. "Certainly, though, customers are always wanting their ironworker to do more. That’s the struggle. It’s almost always easy to make a machine do one, two, or three functions. The trick is making a manual ironworker that has been time-tested for over 50 years go a couple of steps farther. That’s why there are different levels of automation available for the ironworker to really meet the needs of all shops."