CNC laser profiler speeds cabinet production

George Barker and Company has installed a high-speed automated laser cutting system from LVD to improve productivity and add greater flexibility and capacity to its manufacturing operation.

George Barker designs, manufactures and installs refrigeration units for chilled food, frozen food, specialty display and modular units.

In 2008, the company was awarded the ISO 9001:2000 quality assurance accreditation and is currently being assessed for ISO 14001 environmental standards.

The need to consistently meet high-quality standards and operate more cost effectively, coupled with a strategic group investment plan, has led work study officer, Derek Bower, in search of new sheet metal fabrication equipment.

Bower and his team first considered a CNC punch press to add capacity to existing punching equipment, but soon realised that a laser cutting system would provide greater flexibility in processing the contours for its refrigeration units.

The team researched four major equipment suppliers for six months before selecting the LVD Axel 4020 laser cutting system.

They looked for large table capacity, high-power laser and automated material load and unload.

Aside from product specifications, the team also looked for a vendor with which they could establish a long-term relationship.

The Axel 4020 laser system was selected because of its capacity to handle large sheet sizes up to 4m x 2m and to operate with reduced manpower.

LVD was chosen because of its reputation as a solution provider.

The Axel 4020 is based on a modular design; the machine is standard with integrated shuttle tables.

The shuttle table format allows one table to be loaded while the machine is cutting on the other table, maximising uptime with a changeover time of just 24 seconds.

The team chose to add an automatic load/unload unit to enhance machine productivity by eliminating manual material handling.

The load/unload device handles sheets up to 1000kg and is fully integrated and programmable.

This system option allows George Barker to reduce labour requirements, a critical consideration for Bower and his team.

The laser system also incorporates a number of features that facilitate unattended operation.

A built-in capacitive height sensor automatically maintains a constant distance between the head and the plate, automatically compensating for any uneven material without operator intervention.

The NC Focus provides programmable adjustment of the focal position, eliminating the need for the operator to adjust the focal position.

The selection of a high-power 5kW resonator gives the company the option to cut both thick and thin materials at maximum feed rates.

The high beam quality of the machine allows processing of thin material at speeds up to 40m/min and thick material up to 25mm mild steel with quality surface finishes.

The company currently processes primarily galvanized steel or mild steel in material thicknesses from 0.5mm to 3mm.

The high-speed laser machine combined with the material handling system allows a continuous, even flow of work, achieving a consistent level of throughput and a 50 per cent improvement in productivity.

In addition, the machine's large sheet handling capacity allows for better material utilisation and the nesting of parts, contributing to overall productivity.

Beyond the advantages of automated, high-speed processing, the laser has given George Barker greater flexibility in product design.

Product designs range from half-glass and full-glass frozen food units to medium-sized refrigerated display units designed to be easy to move.

The company's display units are engineered for maximum energy efficiency, display ratio (the ratio between the food display area and the total area the cabinet), modern appearance, merchandising and ergonomics.

The flexibility of the laser system means design flexibility for George Barker is virtually limitless.

Plus, high-quality parts are processed in one operation on the laser.

The quality of the laser-processed parts eliminates time-consuming grinding and finishing operations and adds to a better bottom line with more cost-effective production.

The laser source, CNC, PLC and motors are integrated and interfaced as a complete system to optimise machine performance, offering high speed and reliability, plus low operating and maintenance costs.

As Bower and his team become more familiar with the operation of the laser system, they are finding new ways to maximise the machine's capabilities.

Metal Processes invests in Bystronic laser cutters

Metal Processes, a flat bed laser-cutting sub-contractor, has ordered a Bystronic Byvention laser cutting system and a Bystronic Byspeed laser cutting system.

Bystronic advised Metal Processes to buy the Byvention because of its cutting area of 1562 x 772mm and, when equipped with the 2.2kW resonator, its ability to cut a maximum sheet thickness of 4mm for aluminium, 6mm for stainless steel and 8mm for mild steel.

The machine is operated via pre-defined programs and cutting parameters via a touch screen, making it easy to use.

It features simple and logical operation and users can operate the machine to its full capacity after a short period of training.

When equipped with the 2.2kW resonator, the Byvention requires just 6000 x 6000mm of floor space, which made it the ideal choice for Metal Processes.

John Hayward, chairman and director of Metal Processes, said: 'The production outputs we are achieving per square metre of machine space makes the Byvention a very productive laser-cutting system.

'It is very easy to set up and also very accurate, which is essential to our business.

'A standard laser beam travels all over a 3 x 1.5 metre machine bed, which can affect accuracy depending on the distance travelled by the light beam.

'The beam on the Byvention only has to travel 750 x 1500mm, which makes it accurate.

'In addition, the fact that the Byvention has only two laser mirrors reduces the cost of consumables.' Metal Processes bought a Byspeed laser-cutting centre just months after investing in the Byvention.

The Byspeed is Bystronic's fastest laser-cutting machine and can cut 600 holes per minute, with simultaneous accelerations of more than 4G.

Hayward added: 'Our two Bysprint lasers were six years old and we have had many hours of cutting out of them, having run multiple shifts.

'However, we were conscious that they were costing money to maintain each year and we felt that in this economic climate it was prudent to reduce and even eliminate our variable costs.

'We took the decision to replace both the Bysprint lasers with the single Byspeed laser-cutting centre, which provides greater productivity.

'Having a new machine, with an excellent warranty and service cover, along with a new machine purchased eight months ago (which has the majority of its warranty remaining) made economic sense, drastically reducing our variable maintenance and breakdown costs.' The Byspeed 3015 is equipped with a 4.4kW resonator.

Metal Processes has also bought a wide range of Bystronic press brake tools, which can bend various types of material in thicknesses ranging from 0.5 to 8mm.

Metal Processes has a history of buying Bystronic laser-cutting systems, dating back to 1998.

Two Bystronic Bysprint laser-cutting systems followed in 2002/03 and a Bystronic AFM EP press brake in 2007.

CNC combination machine improves productivity

Amada UK has announced that Hallmark Sheetmetal has acquired an Amada LC2012 C1 laser/punch CNC combination machine with integrated automation - the first of its kind to be installed outside of Japan.

Hallmark Sheetmetal traded-in its existing Amada X1 laser-profiling centre in exchange for the C1 combination machine.

The C1's in-line MP-C1 automated load/unload system offers Hallmark the ability to run unmanned day and night.

Furthermore, the additional punching and forming capability provides the company with the potential to complete parts on a single machine.

Paul Martin, managing director at Hallmark Sheetmetal, said: 'It's no secret that punching is faster than laser cutting when it comes to the use of standard tooling to produce repeat features.

'For this reason we now punch as many features as we can on our C1 to achieve better cost-per-part, while for aesthetic profiling we use the laser, or on apertures for which we have no tool.'
There are other benefits that Hallmark now enjoys as a result of its acquisition, such as reduced consumption of liquid nitrogen and a compact footprint.

The LC-C1 punch/laser combination machine comes with a range of features that include an energy saving single AC servo-drive motor that provides 20 tonnes of variable punching stroke.

Other benefits include: a quick-change nozzle assembly; a quick-change lens assembly; Amada's AMNC windows-based, network-ready control; and a 49-station MPT turret for flexibility and rapid set-up.

The MPT turret also allows the use of 'drop-in' style tapping tools from M2.5 up to M8 in size.

Furthermore, lift-up stations eliminate material marking due to high dies, while a floating brush table ensures punched down-forms do not catch on dies.

Martin said: 'Since it was installed in February, our C1 has been busy helping us tackle a new contract we recently secured from a blue-chip customer.

'The machine's sheet size (the C1 is available in 1270 x 1270mm and 2000 x1270mm bed sizes) and functionality, particularly the three active die stations for enhanced forming capability, have provided the opportunity to improve our margin.'.

LVD enhances Axel 4020 with load/unload system

LVD has added the option of a load/unload system to its Axel 4020 laser-cutting system, providing continuous, uninterrupted dynamic laser-processing of sheets up to 4 x 2M.

Axel 4020 combines linear drive technology, laser power and control systems for large sheet processing.

The load/unload system can be easily retrofitted at any time and handles sheets up to 1000kg.

It allows loading and unloading functions to be performed independently, with a plate-to-plate changeover time of just 29 seconds.

Integration of the load/unload system permits unattended production, freeing the operator to perform other tasks.

The Axel 4020 machine and load/unload system feature a modular design, providing maximum efficiency in material handling while minimising the required floor space.

The loading station is equipped with spreading magnets, a peeling cup to separate non-ferrous material and a sheet-thickness measurement device.

The loading mechanism moves only in a vertical direction for quick and safe loading of sheets from the loading station.

The system is controlled through a single integrated and intuitive touch-screen CNC control.

The high beam-quality of the resonator allows processing of thin material at speeds up to 40m/min and thick material up to 25mm mild steel with high-quality surface finishes.

The laser source, CNC, PLC and motors are integrated and interfaced as a complete system to optimise machine performance, offering high speed and reliability and low operating and maintenance costs.

Laser cutting provides better gas flow

In several development steps with cutting trials, Precitec has increased the flow rate through the cutting nozzle while keeping the cutting gas pressure constant.

The KT B CON ceramic part and the nozzles now have no 'hard edges' and have a conical geometry.

Thus, the cutting gas pressure can be reduced while giving the same cutting edge quality and the input pressure directly on the processing head can be reduced.

The company said that field tests with the new design have also shown an increased working range for the focal position.

Dirt on the focussing lens and the associated focus shift can be detected with the larger process window and increase the operating life of the optics.

With CO2 cutting heads without a protective window in particular, this leads to cost advantages.

Novacel develops protective film for sheet metal

Novacel, which specialises in industrial surface protection, particularly for uncoated metal, has unveiled the 4226REN protective film for sheet metal, according to the French Technology Press Bureau.

This film is suitable for protecting metal, such as stainless steel, during laser cutting.

It will not peel off or form air bubbles during cutting and stainless steel is protected from discolouration through laser cutting.

The film can be printed with brushing or polishing directions and cutting patterns to allow the sheet metal to be laser cut in a single run.

It has an outdoor resistance of six months and peels off in one piece without tearing.

The 4226REN film reduces laser cutting time and maintains surface integrity throughout the mechanical transformation cycle on parts being cut (bending, backing, stamping and forming).

The film's material prevents any risk of suction between pieces of sheet metal during automated handling.

This film is free of harmful chemicals.

As with the entire Novacel range, 4226REN is recyclable.

The colour of the product is white and the film type is UV-resistant LDPE (low-density polyethylene).

It has a thickness of 100 microns and adhesion strength (AFERA 4001) of 140cN/cm.

The adhesive type is natural rubber and lengths of 1,000m and 500m (3,280ft and 1,640ft) are available.

Custom printing samples are available on request.

LVD has introduced Sirius, an automation-ready flying optics laser-cutting system

Sirius provides efficient processing of parts at optimal speeds and accelerations to suit the part geometry, offering reliable cutting performance at an affordable price-performance ratio.

Sirius is offered in a standard and a 'Plus' model.

Sirius provides quick and precise positioning and consistently accurate laser processing.

The combination of a dynamic machine with an excellent laser-beam quality allows high-speed laser cutting.

Quick positioning is achieved with axis speeds up to 120m/min.

Sirius is designed with a modular construction, permitting the user to select the configuration that works best for their application and budget.

As a standard unit, the laser-cutting system features 3 x 1.5m integrated shuttle tables, which maximise uptime by allowing one table to be loaded while the machine is cutting on the other table.

Table change time is a mere 25s.

Sirius Plus is engineered as automation-ready and can be expanded with the addition of various components to form an automated load/unload system.

An optional compact tower-system creates a productive and flexible manufacturing cell that can be operated 'lights out'.

The tower system, working with the material-handling unit, provides full capabilities for loading and unloading and includes a shelving unit for storing raw material and finished parts.

Sirius is equipped with a laser cutting-head that accommodates a five or 7.5in quick-change lens for fast changeover and minimal set-up.

These water-cooled lenses can be exchanged easily, using a self-centring system.

Lens calibration is programmable and quick to achieve.

The Sirius Plus model offers NC Focus for programmable adjustment of the focal position without operator intervention.

This model also provides process control for piercing and cutting and an automatic shut down feature.

Sirius is equipped with a high-pressure cutting head that produces exceptionally clean cuts.

A crash-protection system protects the head from damage after collision with the workpiece.

A total power-control feature automatically adjusts the laser power in relation to the cutting speed, ensuring an optimal cut at every contour width and minimising the heat-affected zone.

The machine's edge-function feature processes sharp corners cleanly, particularly in thicker materials.

Like all LVD laser-cutting systems, the Sirius series employs the Fanuc GE RF excited fast axial flow CO2 laser.

Sirius is available with a powerful 2.5 or 4kW CO2 laser.

The laser, CNC control, drives and motors are fully integrated, providing superior processing speed, high reliability and low operating and maintenance costs.

The integrated Fanuc GE PC-based control provides perfect reproduction of programmed contours, producing acute angles at high speed.

The laser power is matched to the vectorial speeds to achieve a constant cut-width and a small heat-affected zone.

All parameters, diagnostic and start-up procedures are conveniently displayed on the screen.

The 32-bit control features powerful mathematical capabilities and an extensive material library.

Optional Cadman-L 3D offline programming software provides a comprehensive laser-cutting CAM package.

This includes an integrated 3D design and unfolding module, which allows easy importing of 2D and 3D designs and automatic unfolding and generation of flat patterns from 2D or 3D files.

Cadman-L 3D also incorporates automatic, semi-automatic or manual nesting and optimises cutting and machine parameters to maximise sheet utilisation.

Advanced features include cutting-path optimisation, common line cutting and high-speed communications via Windows, networking or DNC link to maximise machine productivity.

ESAB launches CNC plasma-arc cutting power source

ESAB Cutting Systems has launched a CNC plasma-arc cutting power source that provides high-speed cutting of materials from 0.5mm to 100mm.

The three-phase 440A 50Hz machine, with IP 22 protection, operates from a 400V supply.

The power source also produces high-quality cuts, has low running costs and is ideal for production line applications, steel producers and sub-contract profilers.

High-speed cutting can be achieved on conductive materials including mild steel from 0.5 to 80mm, stainless steel from 1mm up to 100mm including up to 70mm dross-free, and aluminium.

Quality cutting can be achieved with all thicknesses and piercing of material up to 50mm thickness can also be carried out.

Plasma gases include air, oxygen, nitrogen/hydrogen, argon/hydrogen with argon as a marking gas.

Cutting and marking operations can be carried out with the same consumables.

The power source can be used in conjunction with the full range of ESAB CNC plasma-arc cutting tables.

Friedman Industries

Friedman Industries located its steel coil processing plant adjacent to a steel mill to increase productivity and lower operating costs.

Friedman Industries Inc. recently opened a new steel coil processing plant located in Decatur, Ala. The facility converts hotrolled coils received from the adjacent Nucor Steel Co. mill into hotrolled sheet and plate relieved of distortions commonly associated with coiled steel through the use of temper-passing and leveling equipment.

Temperpassing and leveling result in significantly flatter and more consistent steels, with the improvements becoming even more pronounced in higher-strength alloys. The cost- and timesaving benefits of Friedman temper-passing and leveling capabilities have become increasingly important where higherstrength materials and tighter tolerances are best handled using today’s more precise, more expensive plasma and laser cutting CNC equipment.

http://www.americanmachinist.com/304/Issue/Article/False/84594/Issue

Massive oxy-acetylene gantry profiler doubles throughput for large parts

Spain's Oxyser has dramatically increased the throughput of its oxy-acetylene steel cutting machinery, and automated the process, by developing a new twin-head machine controlled by NUM's Axium CNC platform. In total, the CNC controls 16 motor axes to manage the motion of a gantry with two positioning heads - each fitted with mobile oxy-acetylene cutting torches.

The machine has just been commissioned at Grupo Ros Casares' plant in Aviles, Spain – the company is the Spanish leader in industrial distribution and logistics, steel service centres and structural steelwork.

The new machine is used initially to produce steel plate sections required to construct wind turbine generator towers. The shaped plates are generally cut with bevelled edges so that they can be welded together easily on site.

The parallel worktables - one for each tool head - are 26 metres long, and eight metres wide. The gantry supports two cutting tool heads, with one slave tool following the motion of the master tool. The 4.2 cm thick steel plates being cut for the current wind turbine application typically weigh around eight tonnes each, measure around 10 x 2 metres, and have bevelled edges. To meet the end user's production requirements, the machine currently operates for 16 hours a day. During this period it cuts up to 32 steel plates. The high degree of automation of the cutting process supported by Oxyser's machine means that just one operator is needed, both to run the machine and remove offcuts. The new machine more than doubles throughput.

Believed to be the first of its kind, the machine introduces automatic programmed control of shape cutting in an application sector that is use to much simpler machines: traditionally, only three CNC-controlled axes are employed and the initial positioning of the oxy-acetylene tool for linear cuts is performed manually.

Oxyser developed the new-generation cutting machine to improve productivity for Grupo Ros Casares, and although the cutting capability of the machine's oxy-acetylene torch heads were conceived with the versatility needed to produce bevelled edges for the cladding of wind turbine structures, the machine will cut virtually any complex shape defined by a CAD program.

A specialisist in producing plasma and oxy cutting machines, up to now Oxyser has typically produced smaller systems with up to five axes of control. This project marks the company's entry into the high-end cutting market.

The key technical requirement to meet the demands of this application was a much more powerful CNC. NUM provided a solution in the form of its Axium platform, which offered the computational power to control the 16 axes of motion required. NUM was also able to provide all of the ancillary automation components required for the application including drives, motors, I/O and HMI panel.


http://www.machinery.co.uk/article/19149/Massive-oxy-acetylene-gantry-profiler-doubles-throughput-for-large-parts.aspx