Rädlinger is taking the next step in production with the new profiBIBER from ERL Automation GmbH. A particular focus was placed on the new plasma marking function.
The successful partnership between Rädlinger Maschinenbau GmbH and ERL Automation GmbH goes back more than 15 years, with the first BIBER cutting system going into operation in 2010. Over the years, the system has proven itself to be a reliable component of weld seam preparation. But after more than a decade of continuous use, it was time for a technological fresh start.
“The BIBER never let us down,” emphasizes Simon Fischer, operations manager at Rädlinger. “But the new technical possibilities are a real quantum leap – we wanted to use them in a targeted manner.”
With the new profiBIBER, Rädlinger is not only relying on proven technology, but also on a consistently advanced automation approach. “Rädlinger is one of our longest-standing and most demanding customers,” explains Sebastian Biermeier, authorized signatory at ERL Automation. “We are delighted to be taking another step forward together – especially in the area of material testing and automated weld seam preparation.”
Focus: Safe preparation of heavy-duty components
Rädlinger manufactures up to 20,000 excavator shovels annually, around half of which are for excavators weighing over 8 tons. The components are mostly made of highly wear-resistant knife steel and are designed for heavy-duty earth and rock work. Weld seam preparation is essential here for durability and resilience.
“We need consistently high quality, even with large quantities,” says Fischer. "The new BIBER enables us to achieve a cutting length of up to 50 mm with the plasma process and up to 100 mm with the oxyfuel process.
“We need consistently high quality, even with large quantities,” says Fischer. “The new BIBER enables us to achieve a cutting length of up to 50 mm with the plasma beveling process and up to 300 mm with oxyfuel – this opens up new possibilities in design.”
How the profiBIBER works in action
The new generation of the BIBER system works with a robot that moves across the cutting table on a linear axis. The station is divided into two clearly defined areas: while cutting is taking place at one station, the other can be loaded or unloaded at the same time – the two-station operation significantly increases efficiency.
“In the past, the cutting process had to wait until the machine was reloaded,” recalls Fischer. “Now everything runs simultaneously, which saves a tremendous amount of time.”
The machine is operated via an intuitive visualization interface on an industrial PC. There, the contour of a workpiece can be called up from a *.dxf file and positioned on the digital cutting table. Bevels, dimensions, and parameters are defined, and the robot program is generated automatically – offline in work preparation if desired. Previously saved programs can be called up from a database and started directly.
The entire process is fully automated – from the start of extraction to the safety shutdown in the event of unauthorized access.
intelliplace: automatic correct positioning
One of the key features of the new BIBER is intelliplace – a system for automatic component recognition and positioning. Instead of time-consuming manual setup, the scanner detects the workpiece on the table and adjusts the cutting contour accordingly. “Intelliplace saves an enormous amount of time, especially when component geometries change frequently,” says Biermeier. “This was a clear request from Rädlinger – and a good example of how sophisticated technology and new features translate directly into efficiency.”
Light-independent line laser scanner
Another highlight is the new line laser scanner, which enables precise component detection using four measuring points – even in difficult lighting conditions. Unlike conventional scanners, this one can cope with highly fluctuating light intensities.
“A standard scanner needs constantly 200–300 lux,” explains Biermeier. “Our new scanner can cope with up to three times that deviation – ideal for real-world hall operations.”
Precise measurement detects dimensional deviations from the component and automatically performs corrections – ensuring consistent quality even with complex geometries.
Materials testing: Plasma marking as a key technology
A particular focus was placed on the new plasma marking function. This technology is used to permanently mark components during the cutting process — for example, with lines or position marks for subsequent welding work .
“The question as to whether the material is affected by plasma marking is absolutely justified – after all, we are talking about dynamically loaded components,” explains Sebastian Biermeier. “That’s why we tested it in collaboration with a crane manufacturer and TÜV: the marking penetrates a maximum of 0.2 mm into the material and has no negative effect on the material properties in most applications.”
For Rädlinger, this is a decisive advantage: the position of stiffeners or segment numbering can be applied directly to the component – securely, permanently, and in a documentable manner.
Conclusion: Technology with impact – implemented in partnership
With the new BIBER, Rädlinger has set the course for efficient and automated sheet metal processing. The combination of robust cutting technology, intelligent sensor technology, and sophisticated additional functions such as plasma marking shows what modern automation solutions can look like today – without compromising on material safety.
For ERL Automation, the implementation of this project was not only a continuation of a proven partnership, but also an outstanding example of how machine concepts can be adapted to real production requirements. “Our processes have become faster, safer, and more flexible – the new BIBER is a real step forward,” Simon Fischer concludes.
