Twin Circular Saw for DOW Chemical

Scope of Project

Cut a material in varying diameters to a specific length. Having to both ends of the material simultaneously and having the end result of the cut being the 2 ends were parallel within +/-.002. Have the ability to run in automatic with a robot loading and unloading or be able to run manually by an operator.


  • Cross talk and communicate with 3rd party robot
  • Handle diameter range of 6” to 9”
  • Cycle time 1 minute or less from load to unload
  • Remove all dust and debris accumulating inside the enclosure
  • Automatic run side separate from the manual run side
  • Safety interlocks on doors and unable to open until zero movement is detected
  • Use of HMI control with integrated diagnostics for ease of programming and trouble shooting.
  • Used customer specific approved vendors and components

Final Configuration

We designed a saw that has 2 identical saw blades mounted in a vertical position. The blades adjust for the width of cut by moving in unison from the center point. Between the blades is a vise and beam. The vise moves horizontally back and forth between the blades. A V-shaped saddle holds the material from rolling and a top clamp arm holds the material firmly in place by pressing down from the top. This vise has a load/unload area that is outside the enclosure. Doors automatically open and close allowing for unloading and loading. This is the robotic side of the machine where it faces a robotic cell that handles the material coming off a conveyor belt, load/unload the saw, and back onto a conveyor for down line operations.

When a part is loaded the doors close and the vise travels through the blades in a very controlled manner. Once the cut is made the blades move slightly to make the gap a little larger then the cut piece so as to not rub on the part as it travels back through to be unloaded.

The manual side of the machine has a gull wing door. When placed in manual mode the vise load/unload area is right inside the Gull wing door. The operator places the material in the vise saddle and closes the door. The cycle consists of the vise moving through the blades to the back of the machine, the blades move to their position and the vise travels forward through the blades and stopping at the Gull wing door. The doors can not open until all movement has stopped.

The cut ends of the material are either sucked up by the vacuum attached to the dust hoods around the blades or the larger pieces fall to the bottom where the pieces are sent through a grinder that chops it up into smaller pieces and is then sucked away by the vacuum.