FOCUS ON AUTOMATION
SEE IT, SORT IT
Remmert analyses various ergonomic, semi-automated and fully automated solutions to address the automatic sorting of laser-cut sheet metal parts.
“ Users are advised to prioritise flexibility when selecting an automation solution, so that they can integrate future generations of machines or be free to change suppliers.”
By
Remmert GmbH
A
fully automated sorting system typically costs between 400,000 and one million euros. This is a sum that rightly catches the attention of sheet metal processing companies.
In many automated laser cutting centres, sheet change at the laser cutting machine is automated( ideally in combination with a sheet storage system) but subsequent sheet metal part sorting is still firmly in human hands. Manual sorting is a physically demanding, monotonous and dirty activity with a considerable risk of injury. Cut sheet metal parts must be separated from the scrap skeleton, sorted and stacked. Impact and cutting tools are often used.
The personnel requirements are also considerable: the more complex the cutting plans and the larger and heavier the sheet metal parts, the more time and muscle power are required. In companies with two or more laser machines, this often means that one operator is responsible for two lasers cutting machines whilst one or two other people per shift are exclusively occupied with sorting and material movement.
Gantry robots for automated parts sorting.
Ergonomic and semiautomated approaches
Before taking the step to full automation, there are various methods that manufacturers can adopt to make manual sorting easier and more efficient.
■ Belt conveyor systems: One of the most popular options is the use of a belt conveyor system. The laser automation places the cut sheet metal panel onto the conveyor belt and the operator cycles the parts in piece by piece. The working height can be adjusted so that the operator does not have to lean far forward. This advantage is particularly noticeable with small parts that are connected to each other via micro joints, as several hand movements are required to separate them anyway, and it helps if the parts are conveyed close to the operator.
■ Decentralised sorting stations and AGVs: Another option is the spatial separation of cutting machine and sorting. A sufficiently dimensioned sheetmetal warehouse, in which cut sheets can be temporarily stored alongside the raw sheets, is suitable as a central distribution centre.
A separate station in the sheet metal store facilitates access to the sheet metal from all sides. This also makes it possible to run night shifts with few personnel. Manual sorting can be concentrated on the day shift and the productive times of the lasers can be maximised. As a result, laser cutting and sorting can be decoupled in terms of space and time. Alternatively, forklift trucks or even AGVs can transport the cut sheets flexibly through the hall- the operator is then completely free to choose the sorting location.
■ Semi-automated removal of large parts: Semi-automated sorting offers a middle way. For example, our LaserFLEX automation system loads and unloads full sheets at the laser and can be used to remove heavy and unwieldy sheets from the cutting plan. These can be stored again as residual sheets or palletised directly. No additional investment is required as the existing automation is also used and manual sorting is limited to smaller parts.
However, viewing manual sorting solely as a cost factor would be short-sighted. Manual visual inspection adds real value, especially when processing high-quality materials such as stainless steel, because the cut and material surfaces can be assessed directly. To fully automate sorting, the quality assurance aspect must be included in the overall process.
Fully automatic sorting
Almost all major manufacturers of lasercutting machines and independent specialists now offer solutions for parts automation. Cartesian robots( or gantry robots) have established themselves in this application.
Using linear axes, one to four tool heads move over the cut sheet metal and pick one sheet metal part after another from the cutting
38 | ismr. net | ISMR May 2026