FLYING SAWS
Precise cutting in motion
Flying saws are specialized solutions for cutting materials during continuous movement, without the need to stop the production line. These high-performance systems enable precise, repeatable, and time-synchronized cuts during the processing of long profiles, tubes, rods, strips, or sheet metal.
How do flying saws work?
In a flying saw system, the cutting unit – typically a motor-driven saw or milling cutter – moves synchronously with the material traveling along the conveyor line.
During cutting, the saw moves in the same direction and at the same speed as the workpiece, performs a precise cut, and then returns to its starting position for the next cycle.
This enables:
- uninterrupted production flow,
- no mechanical shocks or damage to the material,
- extremely accurate length cutting even at high speeds.
The role of servo technology and synchronization
To achieve accurate cuts, the saw must operate in perfect synchronization with the main production line. This requires:
- the use of servo motors with responsive controllers,
- real-time communication with the CNC or automation controller (e.g., via EtherCAT),
- and pre-calculated motion profiles that account for speed, length, and cut position.
Modern systems also support automatic speed adjustment based on cut length, changes in production tempo, and integration with higher-level control systems (HMI, MES).
Advantages of flying saws
- High productivity without downtime
- Precise and repeatable length cutting
- Reduced mechanical stress on machine and material
- Digital integration and automation capabilities