MK Stahl- und Maschinenbau GmbH decided to modernize its production. In June of this year, the existing cutting system was replaced by an erlcut e540 gantry cutting system from Erl Automation. The new machine not only ensures better component quality for the steel processor, but also offers more processing options.
MK Stahl- und Maschinenbau GmbH, based in Regensburg, focuses on steel and engineering construction, special machine construction and contract manufacturing and was established in June 2018. The company emerged from the takeover of a business that had been located in the Haselbach industrial estate since 2001. After its closure, Matthias Kulzer, who was technical operations manager there at the time, decided to take over the company and found MK Stahl- und Maschinenbau GmbH. About a year later, the company employs more than 25 people and counts well-known companies from the forestry and construction machinery industries among its customers. The range of services offered by MK Stahl- und Maschinenbau is extremely diverse - it extends from project planning and design to flame cutting, welding, machining and surface treatment to assembly, manufacturing and repair of attachments of different excavator classes and quick coupler types.
The steel and mechanical engineering company also has a wide range of cutting tasks. Components are cut in a wide variety of sizes, sheet thicknesses and quantities. The existing second-hand system from the takeover had already been in service for almost 20 years and could no longer meet the requirements to the full extent. The outdated technology, in particular plasma technology, nesting software and control, but also the availability of spare parts increasingly posed challenges for the company, which is why Managing Director Matthias Kulzer made the decision to invest in a new cutting system with state-of-the-art technology.
In their search for a suitable cutting system, those responsible at the specialist for steel and mechanical engineering looked closely at the solutions available on the market. The user placed particular emphasis on high quality and good advice. Several manufacturers were in the running and carried out test cuts for MK Stahl- und Maschinenbau. Kulzer was impressed during the cutting demonstration at Erl Automation. "It would be surprising if other manufacturers could deliver this quality for less money,'' said the managing director of MK Stahl- und Maschinenbau. And in the end, he also decided on such a system - an erlcut type e540 to be precise.
Sheets up to 50 mm and more
The new gantry cutting system in the Regensburg company's machine park has a track width of 4,000 mm and an eleven-metre-long runway. Unlike its predecessor, the erlcut not only has a plasma cutting torch, but also an oxy-fuel cutting torch and a needle embosser.
For high-precision cuts up to 50 mm, the erlcut is equipped with a HiFocus 440i neo power source that has automatic gas control. This enables MK Stahl- und Maschinenbau to cover the majority of its cutting work. The new cutting system is a tremendous asset for the steel processor, he said. "With the erlcut including the new plasma technology, we were able to significantly reduce production times. On the one hand, the high cutting speeds were decisive. On the other hand, thanks to the precise cutting results, hardly any reworking is necessary," reports Matthias Kulzer. For thicker sheets, the steel and mechanical engineering company has an oxy-fuel cutting torch at its disposal, so that 50 - 200 mm thick sheets can also be processed.
In addition, the erlcut e540 is equipped with a powerful needle matrix embossing system. This allows long-lasting markings, be it plain text, lines or data matrix codes, to be produced on the sheet surface. The embosser works in a 150 x 100 mm marking field without machine movement, so that marking is particularly gentle on the components and nothing stands in the way of a long service life. For construction steel, a marking depth of up to 0.8 mm is possible. But the system can also be used for other materials, such as non-ferrous materials and plastics. MK Stahl- und Maschinenbau uses the needle embosser for marking its components. For example, component numbers, order numbers, etc. are embossed directly on the respective component for clean documentation and traceability.
Easy handling
With the erlcut, MK Stahl- und Maschinenbau has not only secured more machining options and better component quality, but operation has also become much more convenient and simple. The system is equipped with a control panel that can be swivelled in height and sideways, allowing an ergonomic operating position at all times. In addition, the e*volution control system features a 21-inch, non-reflective glass display, which ensures good readability and low-fatigue working. A modern touch screen enables modern operation through a virtual keyboard and various multi-touch gestures such as scrolling, pinching and swiping. Several hard keys are available on the housing for frequently required system functions. Clearly structured menus and customizable interfaces round off the intuitive operating concept.
Since the programming software previously used by the user was outdated, laborious to operate and manufacturer-specific, the company decided to invest in a new programming system as well. With the act/cut software, which was optimally adapted to erlcut cutting systems by Erl engineers, but which can also control systems from other manufacturers, the company chose an open system. It enables the import of part geometries from any CAD system, communicates with production planning and ERP systems and can be expanded by various additional modules.
Smooth project flow
Those responsible at MK Stahl- und Maschinenbau have known Erl's products for many years. The trusting cooperation was also confirmed in this project. The cutting system has been in operation since June 2019 and cuts both small and large series that are used in a wide range of industries, such as the forestry industry or the construction machinery industry.
The company is completely satisfied with the system, and according to Kulzer, the smooth project handling deserves special mention. "The short delivery time was very positive for us; in addition, existing components, such as our extraction system, could be integrated without any problems. We were always informed about the current status and the next steps, and our operating staff was also optimally prepared for operation through the training," Kulzer sums up.
