FAQ

Automating a laser cutting machine enables full use of production capacity by eliminating downtime that occurs during material supply and during loading and unloading material onto the machine table. A laser cutting machine automation system increases production flexibility by providing access to multiple types of sheet metal stored near the processing area. Automating the transport of material to the laser cutting machine, its loading and unloading, and material storage significantly improves the safety and ergonomics of the production process by eliminating manual operations and the use of less efficient transport equipment such as forklifts. A laser cutting machine automation system combined with a storage system organizes the entire process while making full use of the available space.

Yes, the automation system can operate 24/7 without interruption.

The floor space occupied by an automation system depends on several factors, including storage capacity, the number of access points, and the operating direction of the automatic sheet loading and unloading system relative to the laser table. For the loading and unloading system alone of a laser cutting machine for cutting sheet metal of 3 x 1.5 m, the required space is approximately 16 m² (4 x 4 m). If we add an automatic sheet storage rack with two storage columns, about 80 m² is required.

• exchange tables that provide access to the entire cutting table outside the processing machine,
• electrical signal exchange enabling collision-free movement of the laser cutting machine systems (exchange tables) and the automation system,
• connection of the laser cutting machine safety signal to the safety system of the automation system,
• data exchange between the laser cutting machine control and the automation system in order to execute orders automatically.

Yes, due to the change in how laser cutting machines are operated, a change in work organization is necessary. Many tasks become automated, making it possible to run laser cutting machines without the constant presence of an operator, e.g. on night shifts or weekends. As a result, employees responsible for operating the cutter can be assigned to other duties.

For each of our automation systems, we provide access to the laser cutting machine table, which can be used, for example, to clean the cutting table grate, manually remove cut parts, or place a sheet on the table.

Yes, it is possible. The reference point must be positioned in the same place and the laser cutting machines must be arranged in the correct order within the system. In every case, installing laser cutting machines with different table dimensions requires individual consultation with our specialists.

Baumalog offers several types of access points:

• Single access point – the simplest access station for sorting cut parts and loading sheet metal directly on a pallet,
• Two-level access point – a station expanded with a second level, allowing each level to be assigned to a specific laser program or material type,
• Buffer access point – a point offering the greatest sorting possibilities, enabling the creation of several buffer zones to which a shelf with cut material is delivered,
• Belt conveyor – a module enabling ongoing sorting of cut parts delivered from the cutting zone.

Yes, this is possible. The key factors are matching the dimensions of the laser cutting machine grate and the ability to exchange data with the automation system. Our specialists provide detailed information on integrating a new laser cutting machine with the automation system.

Using micro-joints is not always necessary. It depends on many factors, such as the shape, thickness and geometry of the cut parts, as well as their position on the laser cutting machine table.

Cut parts can be sorted on an ongoing basis, or they can return to the storage system – for this purpose we use universal shelves that allow raw material and cut parts to be stored. For cut parts, the operator must equip the shelf with a sheet of metal that serves as the base and properly mark the shelf in the system.

The advantages of choosing an independent automation supplier are:

1. The possibility of implementing a custom automation system layout,
2. The possibility of integrating several laser cutting machines from different manufacturers within one system,
3. The possibility of integrating CAD/CAM software from multiple vendors,
4. The possibility of integrating ERP software from multiple manufacturers,
5. The possibility of replacing the laser cutting machine (e.g. after several years of use) with a machine of another brand.

Our automation systems have been integrated with many laser cutting machine manufacturers and software vendors.

Baumalog automation systems communicate with CAD/CAM software from global suppliers such as CADMAN, Lantek, Metalix and SigmaNEST.

Baumalog is responsible for coordinating the integration. The laser cutting machine interface should enable data exchange and digital signal exchange with the automation system. The participation of the laser cutting machine manufacturer and the CAD/CAM system manufacturer or supplier is required in the integration process.

It is possible to integrate the automation system with the laser cutting machine in two operating modes – when the laser cutting machine operates as the „Master” and the automation system as the „Slave”, and vice versa. The choice of the appropriate operating mode depends on many factors and is selected individually.

Yes, this is possible. The system can be equipped with 2 independent stations or 1 station traveling to both sides of the rack. In such a case, we determine the direction and operating mode of the stations.

The maximum load capacity of a shelf in Baumalog automatic systems is 5 tons.

Yes, it is possible to store different sheet formats in an automatic storage system. When planning storage of sheets in different sizes, shelves with the appropriate dimensions should be used.

Yes, it is possible to create dedicated locations in the automatic warehouse for storing different sheet metal assortments, e.g. stainless steel and black steel.

Yes, all shelves for storing sheet metal are universal. Each shelf can be used to store raw sheet material or cut parts. When storing cut parts, the bottom of the shelf should be fitted with a sheet of metal of appropriate thickness.

Shelves on which stainless steel sheets are stored are fitted with special ABS plastic overlays, so the sheets do not come into contact with the shelf itself and no damage occurs.

In the case of a station moving along the long side, the mass of the automatic rack structure increases because of the greater spacing between the columns. This is the main reason for the higher price compared with a rack equipped with a station moving along the short side.

This is possible, but any future expansion should be taken into account at the design stage of the system.

Yes, it is possible for the Customer to make the shelves themselves. For this purpose, we provide execution drawings of the shelves and consult their manufacture at the technological level. Based on our experience, we recommend entrusting the production and delivery of the shelves to our company.

The enclosure of an automatic warehouse cannot be attached to the rack’s load-bearing structure. It is necessary to use an independent steel structure, to which e.g. sandwich panels can be attached.

Yes, this is possible. To do so, the shelves are equipped with movable separators that allow compartments to be created.

Yes, shelves in an automatic warehouse for storing long items can have different heights. The height of the shelves and their number are selected individually after consultation with the Customer.

The automatic storage system is controlled via a touchscreen control panel located next to each station. This panel runs the Smart WMS application on the Windows operating system.

Yes, thanks to our software supplied together with the automation system, the Customer gains access to many reports such as production order status, warehouse stock levels, operation history, and the history of manufactured parts. In addition, thanks to the SQL database used in our system, the Customer can create their own reports tailored to their individual needs.

The delivery of our automation systems is carried out in several stages. All subassemblies are transported to the installation site according to the agreed schedule, which forms an integral part of the contract.

Baumalog is responsible for organizing the necessary equipment for the installation of our systems. During the installation process, we use a scissor lift, a forklift, and in special cases a telescopic loader or a truck-mounted crane.

No, the Baumalog installation team works independently. We do not involve the Customer’s employees, nor do we use the Customer’s tools or equipment for installation. From unloading structural components from truck trailers, through transport to the installation site, to final assembly and commissioning, everything is carried out by us.

The floor should meet the appropriate load-bearing requirements to carry the system load. Together with the offer for the system, we provide the Customer with a load transfer sketch showing the location of the column grid (mm), pressures (MPa) and forces (kN) under each column of our structure, the anchoring method, and the required floor flatness tolerance. The Customer is responsible for designing and making the floor with the appropriate strength parameters.

Yes, the structures of Baumalog automation systems are anchored to the floor. For each project, we provide a load transfer sketch (pressures in MPa, force in the column in kN) and the column grid.

We can use two types of tracks – installed in the floor or on its surface. The choice depends on where the tracks are located in the hall. Tracks built into the floor do not protrude above its surface, so they do not create an obstacle for pedestrians or vehicles moving around the hall.

We do not handle the construction part of projects. The Customer is responsible for all construction work such as cutting channels for the tracks or making openings in the wall. To facilitate construction work, before installation begins we provide all necessary drawings and guidelines: a complete system diagram taking into account the building plan, the location of the tracks, the connection points for electrical power, compressed air and the internet network. Each project also includes a load transfer sketch.

To ensure trouble-free installation of our systems, 200 mm of free space must be maintained between the highest point of the storage system and the hall roof.

In the case of installing an automation system for a single laser cutting machine, two scenarios are possible. If the laser cutting machine is already installed, the automation system is installed next. If the laser cutting machine is not yet present, the automation system is installed first and the laser cutting machine is installed in the next step.

If the laser cutting machine is positioned within the automation system area, it cannot be used during installation. In special cases, it is possible to use the machine outside our installation team’s working hours. If the laser cutting machine is positioned outside the automation system, it can be used, as there is no collision between the Baumalog installation team and the laser cutting machine operators.

Based on our previous experience, integrating laser cutting machines with the Baumalog automation system takes about one week.

During installation and commissioning, installers, mechanics, electricians and automation technicians are present. The IT integration aspects, i.e. the production scenarios to be implemented, the scope and method of data exchange between the laser cutting machine and the automation system, are addressed during system manufacturing, before the installation team begins work, together with the Customer’s IT team and Baumalog specialists. The integration test is carried out during system installation in accordance with the agreed schedule, which forms an integral part of the contract.

The automation system can operate without the constant presence of an operator. If raw material stock is available in the storage system, there are still free unloading spaces for cut parts (shelves or access points), and the laser cutting machine and automation system are fully integrated, then the entire system can run without an operator. As a result, our customers use our cutting machines during night shifts and weekends. The laser and automation system communicate directly throughout the entire laser cutting process, so an operator may only be needed in emergency situations.

The sheet metal depalletizing process (separating the pallet from the sheet pack) takes a little over a minute and consists of several stages:

1. A forklift with a pack of sheet metal on a pallet drives up to the storage system loading station
2. Next, the depalletizer pins are raised (controlled from the operator panel)
3. The forklift forks with the palletized pack of sheet metal are lowered onto the unloading station
4. The forklift withdraws, causing the pallet separated from the sheet metal to drop onto the shelf
5. The forklift drives up again and lifts the pack of sheet metal positioned on the depalletizer pins
6. After the sheets are removed from the station, the pallet can be taken away by the operator
7. After the pallet is removed, the forklift places the pack of sheet metal back onto the raised depalletizer pins
8. The depalletizer pins with the sheet pack are lowered, and the sheet is thus loaded onto the shelf without the pallet.

During the separation process, it is important to keep the sheet metal oil contamination level low. With high oil contamination, the risk of sheets sticking together and the system picking up more than one sheet increases. The correct picking of a single sheet is ensured by a mechanical caliper, which in automatic mode checks the sheet thickness, so the system can be sure that the sheets have not stuck together.

The thickness measurement accuracy is 0.2 mm.

The maximum thickness of sheet metal handled by the forks of the unloading module of the laser cutting machine table is 25 mm.

Service requests are divided into failures and faults. In the event of a failure, it is not possible to retrieve material from the storage system, whereas in the event of a fault, which accounts for most service requests, access to the stored material is maintained with certain limitations, e.g. reduced speed of the lift transporting the shelves, which results in a longer waiting time for the material.

If the automation system is out of service, the laser cutting machines can be operated manually or by forklift. A detailed description of the possibilities for operating laser cutting machines when the automation system is unavailable is provided in the operating manual for each system.

Yes, this is possible. The Smart WMS Production control software enables various material flow scenarios to be implemented.

The maximum speed of the warehouse crane along the track is 2 m/s. The selection of crane speed depends on many factors, including shelf load capacity and system size. In the crane drive systems, we use Demag wheel sets and A75 crane rails.

The shelf guides are made of self-lubricating PA6 polyamide, which ensures long and reliable operation thanks to the very good lubricating properties and high wear resistance of this material. It can be assumed that the service life of the guides is several decades.

In all chain drives we use high-quality pre-tensioned chains.

The track system located outside the building requires cleanliness and proper rainwater drainage. If possible, heating should be used so that snow or ice does not remain on the track.

Smart WMS software has a PC version. Both versions of the application – on the operator panel and on the computer – work on the same SQL database. This means that access to warehouse data is also possible from a computer.

Production optimization in short cutting programs is possible thanks to quick access to many sheet metal assortments provided by the duo station (automatic two-level storage system station), optimization of the order queue based on information received from the ERP system via Smart WMS software, and the possibility of picking single sheets on the shelf according to the order sequence. It is also possible to arrange the shelves in the storage system in such a way as to transport them faster to the duo station, which, thanks to two independently operating levels, ensures quick access to many sheet metal assortments. In the case of several laser cutting machines in one system, we enable the appropriate program to be assigned to each laser cutting machine.

Yes, production order planning is possible from Smart WMS with the Planner Lite module or Smart WMS Production. After analyzing the Customer’s production process, we select the appropriate control software for the automation system, taking into account, among other things, the number and brands of laser cutting machines and the functionality of the CAD/CAM system.

Yes, this is possible. However, each installation must be considered individually with regard to system relocation plans.

In the event of a failure of our systems, technical support is provided by the Baumalog service department.

Technical support is provided by phone or email on business days from 8:00 to 16:00. We also offer the option of concluding an individual service agreement providing 24/7 technical support from Monday to Saturday.

Yes, all our systems are connected to the internet. Remote access is provided via TeamViewer. We resolve more than 70% of service requests remotely, without the need for an on-site visit from a Baumalog service employee.

We include technical documentation with each system, containing recommendations on the frequency and scope of routine maintenance tasks. The recommended tasks are: cleaning safety curtains or barriers, cleaning optical and inductive sensors, and cleaning dirty external machine components that do not require work at height, etc. In the case of more complex service tasks or tasks requiring work at height, maintenance and service work is carried out by Baumalog service employees.

The inspection takes no longer than one business day. The exact duration depends on the size and complexity of the system and is agreed individually.

Most faults are caused, for example, by incorrect placement of material on the shelf or – in the case of automation – contamination of the laser cutting machine grate or oily sheet metal that the vacuum suction cups cannot pick up.

The warranty period for Baumalog automatic systems is 24 months, provided that an inspection is carried out after 12 months of commissioning.

Baumalog has been operating since 2011.

Baumalog’s main headquarters is located in Duchnice (Ożarów Mazowiecki commune). The warehouse and assembly area is located directly next to the office. Our headquarters is about 15 kilometers from the very center of Warsaw, in the immediate vicinity of the A2 motorway and the S8 expressway.

Yes, Baumalog has its own production plant where the structures of our systems are made: automatic warehouses, laser cutting machine automation systems and warehouse cranes.

The entire process – design, construction, control and manufacturing together with assembly, commissioning and service of our systems, including warehouse cranes – is carried out by Baumalog.

In our systems we use components from reputable manufacturers to ensure long and trouble-free operation. Our suppliers include:

• Nord for gear motors and frequency inverters,
• Schmalz for vacuum technology,
• Beckhoff for PLC controllers,
• Sick for safety systems and automation components,
• Siemens and Eaton for electrical components,
• Tsubaki for chains,
• Festo for pneumatic systems,
• INA/FAG for bearings,
• Igus for cable carriers.