IMA Schelling Precision Develops Saw with XXL Rotary Table

Ergonomic and Safe Handling of 1,500 Kilograms

When plastic panels reach the weight of a small car, the demands on material flow and handling increase significantly. IMA Schelling Precision has developed an fk 6 panel saw with an XXL rotary table for this application: 5,800 x 2,200 mm, laterally movable, and designed for panels weighing up to 1,500 kg. The core of the solution is a newly developed support system combined with an air-cushion table featuring dual blowers. This ensures that the height and flatness of the table system remain stable in all positions, while heavy panels can be moved almost friction-free.

The system enables continuous and controlled handling of large-format plastic panels. Uniform air distribution lifts the material and reduces friction during rotation and positioning. The surface remains protected, and the transition to the saw is seamless. The XXL rotary table is designed to accommodate high loads while still enabling ergonomic operation. Just two control commands are sufficient to position panels as required.

Technical Basis: fk 6 with Extended Rotary Table System

The fk 6 from IMA Schelling Precision is designed for cutting plastic and composite panels up to 120 mm thick. For this application, it was configured with a cutting length of 6,300 mm. The rotary table measures 5,800 × 2,200 mm, can move laterally, and features a Bakelite surface. The integrated air-cushion system ensures even support and allows gentle movement of the panels across the entire table area.

Stability Under Load Through Intelligent Support System

Calculations and tests showed that conventional table constructions can lose flatness under high loads. This is critical for air-cushion systems, which require a perfectly level surface. “We deliberately provoked the situation during testing,” reports Dieter Zucalli, Product Manager Precision at IMA Schelling. “Under load, we could clearly see the point at which flatness measurably changed. That formed the basis for the new support concept.” Zucalli adds: “The starting point for the development of the XXL rotary table system was a specific customer requirement: to safely and ergonomically handle large, heavy plastic panels. These materials are easy to machine but come with considerable weight – which pushes conventional air-cushion systems to their limits. That is exactly where we focused our efforts.”

The developed system uses laterally integrated supports controlled via a rocker-lever mechanism. During table movement, the supports remain retracted; in the end positions, they engage beneath the frame and restore the original height. “The supports only engage once the table has reached its position,” explains Zucalli. “This keeps the movement smooth, while ensuring correct height and flatness in the end positions.”

 

Air Cushion with Double Blower Capacity and Precise Transition to the Saw

To stabilize the air film, a second blower was integrated. This provides a higher air volume, ensuring consistent floating performance even with slightly uneven panels. As a result, the operating forces required are significantly reduced, and control over the material is improved throughout the entire movement process.

The interaction between the air cushion, Bakelite surface, and support system ensures a seamless transition between the rotary table and the machine table. Panels can be positioned without manual guidance. Scratches on the underside are avoided, as are uncontrolled movements when rotating heavy workpieces.

Application in High-Performance Cutting

The fk 6 with XXL rotary table is designed for industrial cutting of large-format plastic panels. The system supports both safe handling and precise cutting across the entire working length. “We wanted a solution that runs as smoothly under full load as it does without weight,” says Zucalli. He continues: “With the support system and the second blower, we achieve exactly that condition. In real continuous operation under full load, the added value of the solution becomes evident: despite the high weights, the movement of the workpieces remains smooth and precisely controllable. This significantly reduces the operator’s physical effort while simultaneously ensuring a stable and safe process – even in continuous operation.”

Conclusion and Technical Details at a Glance

The XXL rotary table in combination with the fk 6 significantly expands the possibilities for handling heavy plastic panels. The combination of air-cushion technology, stabilizing support system, and generously dimensioned table surface enables a controlled, ergonomic, and material-friendly process. “The key outcome of this development,” summarizes IMA Schelling Product Manager Dieter Zucalli, “is that even very large and heavy workpieces can be handled safely and ergonomically without unnecessarily over-dimensioning the system. We demonstrate that high loads and precise handling can be efficiently combined through a well-thought-out overall concept.”

 

  • fk 6 panel cutting saw with 6,300 mm cutting length
  • Rotary table 5,800 × 2,200 mm, laterally movable
  • Bakelite surface, air-cushion system with dual blower technology
  • Additional side supports with rocker-lever mechanism
  • Load capacity for panels up to 1,500 kg
  • Cutting of plastic and composite panels up to 120 mm thick
  • Main drive 27 kW, chip-free cutting quality up to 99.5 %