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.