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CASE STUDY

Melt Room Cut-off Saw Systems

Turn-Key PLC-Controlled Cut-off Saw Systems for a Precious Metals Minting Facility

The Challenge

A precious metals minting facility needed to replace overseas-built cut-off saw equipment that created parts sourcing risk and lacked modern PLC-based automation.

• Overseas-manufactured saw with limited parts availability — sourcing replacement components required long lead times and significant effort, exposing the melt room to extended downtime risk
• No variable speed or programmable feed control — the existing saw lacked the flexibility to optimize cut parameters across different metal alloys, stock dimensions, or production speeds
• Fixed, non-adjustable operating configuration — no ability to tune feed rates, blade speed, or clamping sequences through a control interface
• No PLC-based automation — saw operation depended on manual sequences without interlocks, position feedback, or automated cycle control
• Footprint and installation constraints — the melt room environment required a compact machine installable quickly without extensive site modifications

The Solution

Logic Control Systems designed and built two domestically manufactured, turn-key PLC-controlled cut-off saw systems — each featuring an Allen-Bradley MicroLogix 1500 PLC, hydraulic and pneumatic motion control, integrated lubrication, and variable blade speed.

Machine Design

Each saw system was built around a 14" blade capacity with hydraulic lift/drop for blade positioning, pneumatic vise clamping, pneumatic eject ram, and a pneumatic slide for stock positioning. A PPT hydraulic power unit drives the blade lift/drop circuit. An integrated lube system delivers coolant to all nozzle points throughout the cutting cycle, extending blade life and maintaining cut quality.

Control System

An Allen-Bradley MicroLogix 1500 PLC controls the full cutting cycle — blade speed selection, hydraulic sequencing, pneumatic vise and eject functions, and slide positioning. Two blade speed options allow operators to optimize cut parameters for different metal alloys and stock dimensions. All control wiring, panel components, and PLC program files were delivered with complete AutoCAD electrical schematics.

Commissioning

LCS performed full factory acceptance testing and on-site commissioning:

• Electrical I/O checkout — all control wiring, sensors, solenoids, and panel components verified against the AutoCAD schematics
• PLC program testing — full cycle verification including blade speed selection, hydraulic lift/drop sequencing, pneumatic vise clamping, eject ram, and slide functions
• Hydraulic system testing — PPT hydraulic circuit checkout, pressure verification, and lift/drop cycle timing confirmation
• Pneumatic system testing — vise, eject, and slide functions tested across the full operating cycle with correct pressure and timing verified
• Lube system checkout — flow confirmation to all nozzle points across the cutting cycle
• Two hours of operational training delivered to client melt room operators covering normal operation, speed and feed selection, alarm response, and routine maintenance checks

Domestic manufacture eliminates the parts sourcing delays that created downtime risk with the legacy overseas-built equipment — replacement components are readily available through standard supply channels.

Technology at a Glance

Results & Impact

• Domestic manufacture eliminates the parts sourcing delays that created downtime risk with the legacy overseas-built equipment — replacement components are readily available through standard supply channels
• PLC-based cycle control replaces manual sequencing with consistent, repeatable automation — reducing operator-to-operator variation and cycle time variability
• Variable feed rates and multiple blade speed options give operators the flexibility to optimize cut parameters for different metal alloys and stock dimensions without mechanical adjustments
• Integrated lube system extends blade life and maintains consistent cut quality, directly reducing consumable costs in a precious metals processing environment
• Turn-key delivery and simple installation requirements minimized facility downtime during cutover — the system was operational within hours of delivery
• One-year parts and workmanship warranty provides the client with covered maintenance support through the initial production period
• AutoCAD electrical schematics and all PLC program files delivered in electronic format give the client a complete technical record for long-term maintenance and future modifications

About Logic Control Systems

Logic Control Systems (LCS) is a Texas-based industrial automation integrator specializing in PLC programming, SCADA/HMI development, process control, electrical panel fabrication, commissioning, and remote automation maintenance. LCS serves clients across the U.S. in industries including food processing, fabrication, chemical, oil and gas, pharmaceutical, and water/wastewater.

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