Automation Case Study: Bandsaw Machines

CUSTOMER PROFILE

A leading metal-cutting machine manufacturer based in India, recognized for its innovation and reliability, produces a comprehensive range of horizontal and vertical bandsaw machines catering to industries such as automotive, forging, and machinery manufacturing. The company’s products are known for their precision, productivity, and performance, serving customers both domestically and globally.

THE CHALLENGE

The customer aimed to upgrade its double-column, fully automatic bandsaw machine to deliver greater automation, accuracy, and process reliability — while maintaining a competitive cost structure suitable for the economical market segment.

The key challenges included:

• Achieving cutting accuracy within ±200 microns..
• Ensuring reliable performance and consistent quality across various operations.
• Developing a flexible and scalable control solution supporting multiple operational modes — manual, semi-automatic, and automatic.
• Ensuring faster commissioning and on-site support availability from a local engineering partner.

THE SOLUTION

After a detailed evaluation of leading automation brands, the customer selected Inovance Technology for its combination of performance, customization, and responsive support.

Inovance provided a tailored automation system comprising:

• Easy302 PLC (24DI/16DO) – Compact, robust controller for basic to mid-range automation with built in RS232 & RS485 communication.
• IT7070T HMI – intuitive and user-friendly interface for monitoring and operation.
• MD310 AC Drive – efficient motor control for optimized cutting performance and saw speed regulation.
• GL20 DI/DO - Expansion module with ultra-fast response, compact design and wiring without tools
• GE20-232/485 module - Enhanced PLC-HMI communication delivers seamless and high-speed response.

The control architecture was developed using Autoshop Application and InoTouchPad platforms, enabling seamless integration and high configurability.

Key Functional Features:

• Standard & Interrupt Homing functions
• Manual, Semi-Auto, and Auto modes
• Intelligent alarm and diagnostics system
• Batch processing for up to 10 user-defined batches (customizable cut lengths, quantities, and loop settings)
• Multi-indexing function for cuts exceeding the shuttle stroke (390 mm)
• Pulse Feed Control for adjustable cutting feed rate
• Dual feed cylinder modes for flexible operation:
  • Linear Magnetic Scale Mode – precise stroke measurement for accurate length control
  • Sensor-Based Mode – fallback system for uninterrupted operation

Communication was established via RS485, supported by GL20 DI/DO modules for expanded input-output control.

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THE BENEFITS

By adopting Inovance’s automation solution, the customer achieved a highly reliable and efficient cutting process, with noticeable gains in machine precision and productivity.

Key benefits included:

• High cutting precision (±200 microns)
• Improved operational efficiency and reduced downtime
• Simplified user interface for operators
• Seamless multi-mode operation with batch flexibility
• Enhanced reliability through intelligent control and diagnostics
• Energy-efficient performance with stable speed and feed regulation

The project was successfully implemented within a tight timeline, with smooth installation and commissioning. The customer appreciated Inovance’s technical expertise, responsiveness, and commitment to quality throughout the project lifecycle.

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