alignment variations in real time. The result was the ASA (Automatic Cutting
System), a 6m high, 40m long machine, that automates every stage of the process, from lifting the top mat in a stack to cutting and turning sections for compact stacking.
As the mesh bends under its own weight during lifting, six grippers, each capable of independent three-axis movement, are used. These must dynamically adjust their positions to maintain even tension and prevent deformation. 18 servo drives have been specified to
coordinate this movement, with additional drives handling transportation, turning and stacking. Synchronisation between these drives, as well as with the image processing system and safety controls, is critical to ensure stability and precision. This was the reason behind Hambi deciding
utting, handling and stacking heavy reinforcing steel mesh is a labour intensive task, requiring up to six human
operators. During production, long lengths of wire are welded into large mats, which must then be cut to size and stacked for transport. But due to the weight and flexibility of themats, even small deviations in alignment can cause major issues. It was therefore considered to be a task that would be difficult to automate. Determined to overcome the challenges,
steel processor Van Merksteijn International contacted Hambi Maschinenbau, part of Terhoeven, to develop an automated solution that could detect and compensate for any
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to link every part of the system – including servo drives, safety PLCs, frequency inverters, and controllers – via CC-Link IE TSN. The high-speed, deterministic, communication provided by the open Ethernet standard allowed the team to achieve millimetre-level precision when gripping and positioning the steel mesh, even as it naturally bends and shifts during lifting. The technology’s gigabit bandwidth also allows all system components to share a single unified network. “Communication via CC-Link IE TSN
is particularly important,” explains Marc Orgassa, managing director of Orgassa, Hambi’s long-term automation partner. “It allows us to ensure that the various system components and controllers are synchronised with the drives. This is an important prerequisite, as image processing naturally requires the exact position of the grippers.”
The ASA system was commissioned at Van Merksteijn’s site in spring 2024 following two years of development. According to the company, it achieves the precision, reliability and productivity needed for large-scale reinforcing steel production. “It’s inspiring to see machine builders
like Hambi using CC-Link IE TSN to solve such complex motion control challenges,” says John Browett, general manager of the CC-Link Partner Association – Europe. “The ability to combine different tasks on the high-speed, open network demonstrates how this technology helps companies push automation performance further while keeping system design simple.”
*Visitthevideosectionofthe DesignSolutionswebsiteto watchanoverviewofMitsubishi Electric’sworktodeploythe world'sfirstfullyautomatedline forreinforcingsteelmeshsystem
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