At Rädlinger Maschinenbau in Cham/Oberpfalz things are really moving, for example excavator buckets and wheel loader shovels of all sizes, which are utilized along the entire production chain. There is also a lot going on in terms of production logistics and process optimization. "We are gearing up for the future," explains Simon Fischer, Plant Manager Cham at Rädlinger Maschinenbau. "We are investing heavily in preparing our production for 2033 - a ten-year project since 2023. This includes several relocations, adapted hall layouts, modern warehouse technology and improved production processes," says Fischer, outlining the individual projects. "Our goals are clear: greater efficiency, greater safety, and even more flexibility with a view to producing more economically. To this end, we are investing large sums of money and shaking things up," says the Operations Manager.
The family business has grown organically over time. "At some point, it became clear that we needed new structures here at the Cham site, and that we had to rethink our processes." Fischer and his team took a year to reorganize the material flow. This also includes the setup of a new hall with a new flame cutting machine and a new sheet metal storage unit, the Stopa Compact storage center. A key question was how these two process stations could best be linked. "We were looking for a perfectly fitting link between the cutting machine and the warehouse for sheet metal handling," reports Fischer. On this occasion, full automation was not an option on account of the sheet thicknesses, dimensions, and weights. This is how the electropermanent magnetic cross beam from SCHUNK came into play.
Growth requires an adapted material flow
For several years, the toolholding and workholding, gripping technology and automation technology has served Rädlinger as a cooperative partner, with clamping devices from SCHUNK have naturally been part of the lathe operating equipment at the Cham plant. "We have been working with SCHUNK for many years," says Martin Grassl, Project Manager at Rädlinger Maschinenbau. "With SCHUNK, we have a partner-like advisor at our side, especially when it comes to the magnetic clamping technology on our milling machine. High quality, fast assistance at all times and absolute reliability – this what we know SCHUNK will provide," assures martin Grassl. Based on this positive experience, the Rädlinger team also brought SCHUNK in on the new lifting technology project. "Because SCHUNK stands out due to its magnetic clamping technology," emphasizes Grassl. This led to the decision in favor of the TRETEL electropermanent magnetic module cross beam for handling metal sheets between the flame-cutting machine and the sheet storage system. Commissioning took place at the beginning of January 2025. "After a week of familiarization, it was clear that we had done the right thing," says the project manager. "With the flat magnets we have seen a noticeable increase in safety, ergonomics and process efficiency, while at the same time the process paths, set-up times and space requirements have noticeable shrunk," points out Grassl.
Optimum machine utilization and process acceleration
Prior to the realignment, Rädlinger removed the four-by-two-meter sheet from the cantilever racking of the raw material warehouse using a forklift, placed it on the cutting table using a crane, and transported the components away again with the forklift after the cutting process. "This traditional method of metal sheet handling was fairly tedious and was not without its dangers," points out Martin Grassl. "The flat magnet now offers the advantage that we can de-stack the sheets from the raw materials warehouse, place them on the cutting table in a line and lift the workpieces complete with the residual grid back off again after the cutting process, with one stroke. On the one hand, this significantly reduces the workload for the operator, who no longer has to climb onto the table for each individual part, but can work at ground level at the side of the machine. On the other hand, it results in a significant process acceleration, since the cutting unit has a high rate of operating hours without standing idle." Without the flat magnets, the productivity of the flame cutting machine would be cut to around 50 percent. Now, however, Rädlinger can utilize the full performance of the Microstep MG. This machine was chosen because it also cuts thick and long sheets. So while the Microstep continues working, the cut parts are separated in front of the cutting machine and the residual grid sheet is set aside separately. Thanks to the magnetic cross beam, workpieces are handled outside the cutting system in parallel while machining continues. "This boosts our productivity," comments Simon Fischer, "and this will quickly pay for itself."
Employee protection and a significant ergonomic improvement
The new lifting technology has been well received in the factories: "Acceptance among employees is very high - they are enthusiastic about the advantages offered by the new processes," states Grassl. One worker operates the magnetic traverse and a second worker provides support with the sorting of the cut components alongside the machine, which now no longer have to be collected from the table with a magnet. "In addition to faster machine loading and unloading, convincing arguments in favor of the magnetic traverse included an improvement in the areas of occupational safety and ergonomics," explains Grassl. "Given the shortage of skilled workers, we want to provide the employees we have with the best possible support and offer them a pleasant working environment." IN this way, the new solution contributes to an improved working environment for employees, as well as an overall increase in production output. The control of the magnetic traverse also benefits the operator in terms of safety and simple operation; it is realized with the system idling, by means of two-hand operation at the control panel of the traverse, and by means of remote control during the lifting and transport phase. SCHUNK has designed all operating elements to be of high quality, clearly arranged and labeled, which the user greatly appreciates.
Electro-permanent lifting technology for complete safety in every operating phase
The electro-permanent magnetic plates require only a short current pulse for magnetization (MAG) and/or demagnetization (DEMAG) – continuous current is not required as with electromagnets. In Pick-Up mode, the operator lifts the sheet a few centimeters clear with 75 percent power and checks that the load is centrically attached and that the air gap behavior is acceptable. If this were not the case, a controlled tear-off would occur once lifted just a few centimeters and the load would remain on the ground. With this partial load function in the Pick-Up phase, the safety of people and machines are guaranteed at all times and in every status. Full magnetization then occurs with one hundred percent power for the actual lifting and transport process. A central safety lamp on the traverse clearly indicates the switching status: White light means power supply present and operational readiness, the blue lamp lights up during a switching cycle, yellow light indicates the pick-up status in partial load and the green lamp signals full magnetic voltage and complete safety. In this phase, the permanent magnet technology works without a power supply and holds the load absolutely reliably. Even if shear forces act in transport mode, shearing of the load is ruled out; triple safety is naturally provided in the design, taking into account operational conditions such as material, surface quality, and roughness.
Controlling the load lifter by radio remote control ensures a safe distance from the operator and helps to prevent accidents. Demagnetization – and the subsequent release of the holding force – is only possible when the load has been set down and the load on the chain sling has been relieved. Two redundant safety load eyelet switches mounted diagonally at the chain sling fixing points on the traverse monitor this; they prevent the load from falling during the lifting phases as a result of unintentional actuation or operator error. As such, complete safety is guaranteed in the event of a power outage or overvoltage, e.g. due to a lightning strike. Any incorrect operation on the cross beam or via radio remote control is also ruled out.
Maximum flexibility in the sheet metal handling process
At Rädlinger, the surface magnet handles all sheet metal panels in all grades, sizes, and thicknesses up to five metric tons in weight. In many instances, high-alloyed steels such as HARDOX are used; here it is a requirement that the sheets are completely demagnetized again and can be used without any problem in subsequent processes, for instance when welding. "The load traverse handles all the materials we work with by magnetizing them and also completely demagnetizes them again," explains Martin Grassl. Quality losses due to any residual magnetization on the material are excluded. "We can adjust the holding force in four stages and lift individual sheets with a thickness starting from five millimeters in a defined manner. This provides us with a unique flexibility when handling sheet metal." This way the metal sheets can be individually fed to the flame cutting machine with the magnetic lifter and, after cutting, it can be raised in one operation, along with the workpieces, residual grid and cutting waste. The feeding of the sheets to the seven-meter-high Stopa sheet metal warehouse can take place individually or in sheet metal packages – for this purpose, SCHUNK has specifically integrated transport hooks and chains into the load traverse, as special equipment.
The manufacture of construction machine equipment at Rädlinger benefits from the optimization boost during handling and from the future viability of the system, as the load lifter can be expanded with additional magnetic modules as required. "We found a great solution together," says project manager Grassl. SCHUNK clearly presented the advantages and special features for the use of the MAGNOS magnetic technology at Rädlinger, which was an important factor in the decision in favor of the TRETEL traverse. "Added to this was the fulfillment of our individual requests and requirements – for example the transport hooks and the entire system being produced in our desired color – as well as the clean commissioning," adds Grassl. "SCHUNK dedicated a lot of time to us and worked intensively to ensure that we ultimately received the best result."
Electropermanent magnetic cross beam closes the loop
"This material flow solution with the TRETEL electro-permanent magnetic module traverse represents a quantum leap forward for us," sums up Simon Fischer. "It completes the circuit between the flame cutting machine and the warehouse with an optimally structured process." The Operations Manager summarizes the advantages offered: "Reduced space requirement, optimal machine utilization during the cutting process, forklift-free operation, improved worker protection and ergonomics, as well as a massive reduction in handling times, set-up times and distances to be covered for each product," lists Fischer. "The lifting technology adapts flexibly to different sheet sizes, thanks to the integration with the ERP system we have acquired transparency and trace-ability, and we can more or less eliminate search times during order-related production. What's more, the electro-permanent system is environmentally-friendly because we use less energy. This cuts costs and makes us more economical. As such we are well equipped to face the future."