DERATECH
GSS Systems Co., Ltd. is a high-tech enterprise specializing in grain drying, bulk material conveying, intelligent warehousing, and smart IoT. The company provides one-stop solutions encompassing product R&D, manufacturing, turnkey engineering, and technical consulting for industries such as agriculture, grain and oil, feed, and bioenergy.
In November 2025, Derateck entered into a strategic partnership with Suzhou GSS. Leveraging the intelligent laser cutting and bending unit of GSS’s Phase II Smart Factory as the carrier, the two companies jointly promote the intelligent upgrading of grain equipment manufacturing.
Project Background & Production Requirements
To align with the Phase II Smart Factory’s goals of large-scale, flexible, and digital development, Suzhou GSS needed to address several pain points: low processing efficiency for multi-variety large sheet metal parts, inconsistent quality, weak digital foundation, and insufficient production flexibility. Derateck therefore introduced a customized integrated intelligent production line featuring an “Intelligent Vertical Storage Warehouse + Automated Laser Cutting Loading/Unloading & Sorting + Automated Bending” solution.
Overall Solution
01 — Automated Laser Cutting & Unloading Unit
The unit is built around two FuturA 4020 6kW fiber laser cutting machines, paired with an 8-tier vertical raw material warehouse, a gantry-type automated loading/unloading system, an intelligent sorting system, and a full set of auxiliary equipment, enabling fully automated material flow from storage to finished cut parts.
(1) Core Cutting Capabilities
The system handles carbon steel, wear-resistant steel, stainless steel, galvanized steel, and other materials with thickness ranging from 2 to 10 mm. The cutting area is 4000 x 2000 mm, with a maximum single-part weight of 300 kg. Positioning accuracy reaches ±0.03 mm/m. Equipped with Chuangxin laser sources, Bochu CNC system, and intelligent cutting heads, it supports common-edge cutting and intelligent nesting to maximize material utilization.
(2) Automated Logistics & Sorting
The vertical warehouse operates with coordinated scheduling, enabling automatic sheet retrieval and storage as well as automatic return of remnant materials. A suction cup + fork composite mechanism handles automated loading and unloading, with a sheet-separation detection device to prevent double-sheet feeding. Intelligent sorting is based on nesting coordinates combined with automatic edge-seeking positioning, achieving a sorting success rate of ≥99% for workpieces ≥300 x 300 mm. The system supports mixed production of two work orders simultaneously, with manual processing stations reserved for small or irregular parts.
(3) Digitalization & Interfaces
The system comes pre-installed with Bochu CypNest professional nesting software, supporting automatic layout optimization to improve material utilization. Three core data categories — OEE, material utilization rate, and production traceability — are openly accessible free of charge. Standard interfaces include Modbus TCP and API, with capability reserved for MES system integration and MQTT IoT connectivity.
02 — Automated Bending Unit
The bending unit adopts a flexible combination of an “automated bending cell + manual bending stations,” comprising two TAM-300/4100S CNC bending machines that cover the full range of product specifications, balancing mass production efficiency with the flexibility required for complex parts.
(1) Closed-Loop High-Precision Automated Bending Unidade
The 7+1 axis fully closed-loop bending machine delivers a nominal force of 3000 kN. It is equipped with a Data-m laser angle detection system (measurement accuracy ±0.3°), ensuring finished bending angle accuracy stable at ≤±0.5°. Paired with a FANUC R-2000iC/270F robot on a long-stroke floor track, three sets of quick-change grippers, a gravity positioning table, and a turnover frame, the cell achieves fully unmanned operation from loading to bending to stacking. Offline programming software reduces changeover and commissioning time by over 50%.
(2) Manual Bending Station
One 6+1 axis CNC bending machine is configured with a bending support cart rated at 380 kg payload. This station handles narrow-edge small parts, complex process parts, and urgent order catch-up production, complementing the automated bending cell to maximize overall line utilization.
(3) Workpiece Adaptability Range
Supported workpiece dimensions: length 142–3122 mm, thickness 2–10 mm, single weight < 130 kg, bending angle range 40°–170°.
03 — Intelligent Line Integration & Safety Protection
The entire production line is controlled by a unified upper-level management system, communicating via Ethernet and standard industrial protocols to enable centralized task distribution, aggregated data collection, and full-process production monitoring. Full-enclosure safety fencing, safety light curtains, emergency stop interlocks, and anomaly alarms are installed. Dust treatment and equipment noise levels comply with all applicable national environmental and safety standards.
Core Value of the Solution
High Flexibility — Supports mixed-line processing of multiple material types and specifications with efficient changeover, matching the multi-variety, variable-batch production characteristics of grain machinery.
Efficiency Improvement & Cost Reduction — Core processes are fully automated, reducing manual labor intensity and dependency on operators, resulting in significantly improved overall production capacity.
Consistent Quality — Full-process precision closed-loop control for both cutting and bending ensures strong product consistency, high yield rate in mass production, and reduced rework and material loss.
Digital Empowerment — Full production data traceability across all processes, native support for MES system integration, enabling refined management and long-term digital upgrading for the enterprise.
Reliable Assurance — All core components are sourced from leading brands, complemented by comprehensive spare parts inventory and responsive after-sales service, ensuring stable and continuous production line operation.
The commissioning of the sheet metal automated production line at Suzhou GSS’s Phase II Smart Factory is not only a landmark achievement in the deepening strategic cooperation between Derateck and Suzhou GSS, but also a deep practice and validation of intelligent sheet metal manufacturing solutions in the grain machinery segment. Leveraging their respective technical expertise in equipment manufacturing and grain machinery, the two parties precisely targeted core pain points such as multi-variety mixed-line production, large workpiece processing, and digital production line upgrading. Through full-process collaboration spanning solution customization, equipment delivery, and installation and commissioning, the project has not only helped GSS achieve capacity upgrades and quality improvements in sheet metal processes, but also provided a replicable benchmark for intelligent transformation in the grain equipment industry.
您好！Por favor, assine