FOCUS ON AUTOMATION
plan using vacuum or magnetic end effectors. Multiple heads enable faster sorting of small parts on the one hand and support the picking of large and heavy parts through“ group work” in which several heads are synchronised on the other. Single-head systems use a single head with a suction matrix. Others use up to 2 x 2 heads, each of which can pick up individual small parts or synchronised larger parts.
The parts can be removed directly from the shuttle table of the laser machine or from a separate sorting station. The sorted parts are typically placed on Euro pallets according to order or identical parts, which can then be temporarily stored directly in the sheet metal warehouse if required.
Specialised software plays a central role. It analyses the cutting plan, transfers the coordinates to the robotics and calculates the optimal placement of the pick-up tool and the best storage location for each part. As a rule, nesting must also be adapted to the requirements of the automatic pick-up( even design specifications for individual parts can become relevant). For example, it may be useful to round off corners so that the parts are easier to remove from the metal sheets.
Hybrid sorting strategy.
Points to consider
The selection of a suitable sorting system is complex. The relevant criteria can be divided into three areas:
1. Technical criteria: The range of parts is the central starting point. The size and weight of the parts influence the choice of robotics, the number and design of the heads and the type of tools. The available area for suction cup placement is also crucial, as many hole cuts can make automatic pick-up considerably more difficult. It is generally advisable to have cutting plans analysed for feasibility by the supplier of the automation solution before purchasing.
2. Overall process view: The integration of the sorting robot into the overall process requires careful planning. How fast does the laser machine work and must the robotics absorb at the same speed without delaying the plate change? Are the cutting plans suitable for automatic sorting or do they need to be re-clustered if necessary? All these material flow issues need to be considered in advance. The quantity and position of the load carriers provided is also crucial for the overall setup, as the robot only has a limited radius of action for depositing the parts.
3. Commercial consideration: The investment for a fully automated sorting solution can be offset by the savings in personnel costs. The better starting point for higher machine utilisation through multi-shift operation with lights-out shifts is also an argument for the investment.
Fully automated systems significantly reduce personnel requirements, but do not replace them completely. There may be issues( technological challenges, parts that tilt or tilt on the shuttle table etc.) that require manual intervention. This is an important factor when calculating profitability.
Looking to the future
The market for laser cutting machines and automation solutions is highly dynamic. The supply of inexpensive laser-cutting machines has opened the door for small and mediumsized companies to enter the prefabrication field with their own laser machines.
Internet portals, such as Laserhub, expand access to the market for suppliers and customers. This increases competitive pressure on contract manufacturers who must expand their range, offer competitive prices and provide short delivery times and highquality products.
At the same time, competition is driving innovation. High-power lasers with 20 or 30 kilowatts( kW) of power are being used more frequently to cut sheet metal. This puts downstream processes under time pressure. Sorting directly from the shuttle table could create a bottleneck that limits the potential of fast lasers. More flexible concepts with a separate sorting station offer a solution.
Laser cutting machines with bevel cut technology offer several design advantages, including the reduction of downstream processing steps. However, phase cuts can be an obstacle to automated parts sorting.
This is where concepts from high-tech manufacturers come into play. These concepts involve the mechanical removal of the skeleton before sorting. Then, the sorting of the sheet metal parts is no longer based on the cutting plan’ s coordinates and robotics are guided by 3D vision.
The prospect of humanoid robots is particularly exciting. In two to three years,
A humanoid robot example.
humanoid systems could represent a real alternative to permanently installed gantry robots for SMEs in this sector. For example, when combined with laser automation for removing large parts, they could possibly pick up smaller sheet metal parts.
In conclusion
Automatically sorting sheet metal parts remains one of the most complex challenges in sheet metal processing. There is no onesize-fits-all solution because the requirements vary greatly depending on the range of parts, machinery and operating strategy. A sensible starting point is often a well-thought-out material flow, ergonomic improvements or semi-automated solutions. Those who take the step towards full automation should carefully consider the technical, process-related and commercial criteria involved.
In most cases, the laser machine is replaced before the surrounding automation. Therefore, users are well advised to prioritise flexibility when selecting their automation solution, so that they can integrate future generations of machines or take advantage of the freedom to change suppliers. n
EDITOR
’ S NOTE
New AI / vision-assisted robot systems have already been demonstrated by machine manufacturers for the automated sorting of laser-cut parts from a sheet metal skeleton.
About Remmert
Remmert GmbH offers automated storage systems, automation and software solutions. It specialises in intelligent automation and intralogistics solutions, as well as long-product and sheet-metal storage systems.
www. remmert. de / en /
ISMR May 2026 | ismr. net | 39