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Digital automation platform with a 32-axis motion engine features pulse synchronised output, with error mapped systems for enhanced accuracy laser machining.

Aerotech’s A3200 Digital Automation Platform is a powerful, software only machine control system combining a high-performance, 32 axis motion engine with decentralised drives interfaced via Firewire and other machine control function modules such as HMI and soft PLC, for a completely integrated solution.

Widely used in semiconductor, data storage, laser processing, automotive, and machine tool industries, the A3200 includes a wide range of advanced motion control commands aimed at increasing and improving the finished quality and throughput performance of demanding production and test applications.

Along with an extended range of advanced commands for motion including electronic gearbox, cam profiling, high speed registration/position capture and velocity profiling, Aerotech have developed a number of commands targeted to augment application specific performance in combination with its wide range of mechanical positioning systems.

An example of such enhanced performance is that of Position Synchronised Output or PSO.

Widely used for high performance laser machining applications, PSO allows the precise, ‘on-the-fly’ synchronisation of the laser’s pulse, power level and firing pattern with the exact position of a multi-axis positioning system typically moving the work piece undergoing laser feature generation.

PSO will acquire and analyse the position of all axes of motion on the A3200 using real time encoder feedback and will process a two or three axis vector position to provide an output for laser firing control which is exactly synchronised to the 2D or 3D contoured position.

For extremely high accuracy requirements, PSO can be combined with positioning systems that have been interferometer calibrated and error mapped using Aerotech’s HALAR option, where micron level linear errors are analysed and the resulting calibration information is included as a look-up table in the A3200 motion controllers’ parameter file.

The combination of PSO and HALAR is unique to Aerotech and allows the real time encoder information to be read then error corrected before the vector position is processed, resulting in laser pulse synchronisation that achieves an unsurpassed level of accuracy.

Aerotech’s PSO provides a versatile and easy method of interfacing laser firing with high throughput positioning systems and has been broken down into a number of simple commands and parameters to allow for output modes including fixed pulse, analogue, PWM, ramping and bit pixel mapping.

Other PSO commands cover encoder position tracking input set-up, definition of distance and firing trigger, pulse sequence and pulse on/off characteristics as well as a command to define a window for absolute or incremental position window firing.

There is also provision for an array to be used to define bitmapped firing, used to fire the laser at only specific axis locations.

Interfacing with lasers that allow external control, including CO2, YAG and Excimer lasers is easily achieved.

Tracking latency varies depending upon the drive product used in conjunction with the A3200; the best performance is achieved with the Aerotech Nservo digital drive with 140 nsec for a single axis and 220 nsec for dual and triple axis tracking.

In addition to laser firing applications PSO has been successfully applied to non-destructive testing applications where its ability to provide a fixed pulse spacing along complex contours has been found ideal for ultrasonic, eddy current and X Ray inspection systems.

Aerotech’s A3200 Digital Automation Platform is a software based machine control system for IEEE-1394 (Firewire equipped PCs combining synchronised motion control for up to 32 servo axes with fully integrated modules for HMI, machine vision and soft PLC functions.

Programming and software development tools allow the Automation 3200 to be programmed in native RS274 G-code and a software development kit may be used to program with ActiveX based components as well as other languages including C, C++, VisualBasic and Labview.

The high speed Firewire interface delivers fully deterministic position and velocity motion updates to all axes with no system degradation as the number of axes increase.

A range of compatible digital servo drives with high performance, 20kHz position, velocity and current loop update rate can be supplied in stand alone or rack mounted configuration.

All drives come complete with local I/O and an optional 10/100 BaseT Ethernet interface which may be used add third party I/O and PLCs if required.

Choices of PWM or Linear power stages are available with sinusoidal commutation and onboard encoder multiplication.

The A3200 also includes extensive system commissioning tools for servo tuning and system analysis.

A range of stepper drives for open loop control systems is also available.

When compared to traditional PCI card solutions, which usually include numerous breakout modules requiring complex wiring and interfacing, the reduced cost benefit of the A3200 in terms of its simplified wiring, fewer components and Firewire based plug and play interfacing, offers OEMs and System Integrators a complete machine control solution with lower startup and lifecycle costs.

Aerotech design and manufacture a wide range of mechanical position systems and associated control and drive products for laser machining applications.

These include the new VasculatheTM, single machine platform for the production of cardiovascular stents.

All Aerotech systems are supplied complete with motor power and encoder cables, all performance and calibration related documents and a CD with complete interconnection drawings to help integrators with their own system documentation.

In addition, all motor parameter set-up data for the software configuration file is included; with full technical support and product training always on hand, system commissioning is straightforward requiring little more than connecting cables and applying power before programming application software.

These features are built into every Aerotech product ensuring that the true cost of ownership is extremely competitive.

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Among a range of 2D and 3D laser cutting, welding and drilling machines being introduced to the UK is a machine that combines laser cutting and high speed milling in one unit.

The Lasertec-Series for precision 2D and 3D cutting, welding and drilling combines the respective talents of DMG and Sauer to create a range of machines that are both flexible and highly dynamic.

As well as dedicated machines for drilling and filigree cutting, the product programme includes laser cutting and high speed milling on a single combination machine.

The user can also choose the best laser source to suit the application, Nd: YAG or CO2 and the optimum power from 15W to 1kW.

Designed for high precision cutting and drilling of sheet metal between 0.1mm and 3mm thick, the Lasertec 80 Series is characterised by its accuracy of 10 micron, high positioning speeds up to 120m/min and acceleration of up to 2G.

The massive, vibration-damping machine bed with 3-point support, linear drives and solid X-Y compound table enhance the performance of this machine.

Working area is 800 x 500 x 700mm.

Control of all machine functions is provided by the Siemens 840D powerline, accessed via the DMG ControlPanel with 17in TFT screen.

The overall footprint of the machine is just 3 x 3.5m and to facilitate servicing, a walk-on panel is provided for fast access to the laser.

The modular concept of this machine with 3, 4 and even 5 CNC axes makes the Lasertec 80 ideal for fine 2D and 3D cutting and for a broad spectrum of laser drilling and welding applications.

This flexibility allows it to be configured for specific needs in the automotive, electronic and aerospace industries.

Typical applications for the Lasertec 80 FineCutting model include the production of electronic circuits, surgical instruments, prototype car parts and hydraulic valves.

Its dedicated counterpart for drilling, Lasertec 80 PowerDrill is best suited to hypodermic needle, micro tool, oil filter and turbine blade manufacture.

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Laser cutting/engraving machine offers power, precision and flexibility, yet is as simple to set up as a printer and is affordable for industrial and educational users.

The new Legend 36EXT laser cutting/engraving machine is setting new standards in accuracy, performance and throughput according to Unimatic Engineers of London.

Yet it is as simple to set up as a printer and offered at a price that is affordable for both industrial and educational users.

The Legend 36EXT offers high energy optics that enhance the natural characteristics of its CO2 laser beam, software that precisely coordinates the firing of the laser with the position of the work piece carriage and a large work area.

Combined with the precision and repeatability of linear encoders and a vacuum table with an integrated vector grid that permits cutting of materials from paper to wood without the risk of under-side burning of the work piece, these features ensure users can achieve high levels of throughput worked to the tightest of tolerances (1200 DPI).

Unimatic’s ‘Radiance’ high energy optics system has been developed to shape and refine the laser beam to create the best possible beam profile for engraving and cutting applications to ensure both high accuracy and maximum productivity on work pieces up to 355mm thick.

Indeed, to handle the higher volume of gases resulting for the increased throughput, Unimatic has installed a twin exhaust facility.

‘HyperDrive’, Unimatic’s own motion control software, provides the total harmonisation between laser beam firing and work piece positioning.

This facilitates process operation whilst ensuring quality of output.

With its work area of 914 x 609mm, the Legend 36 EXT can handle the largest of engraving/cutting work jobs.

It also permits multiple task working; either straight forward step and repeat jobs or quantities of one-offs.

Other features include ‘NeverWear’ stainless steel bearings, advanced B-stile Kevlar precision drive belts and high speed, continuous loop DC servomotor system.

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Laser system delivered to EBTEC has the capability to drill a wide range and size of parts and products range from sheet metal combustors to nozzle guide vanes.

Prima North America has announced that Laserdyne Systems, the world leader in precision multi-axis laser machining systems, delivered a Laserdyne 790XL BeamDirector Nd:YAG drilling system to EBTEC Corporation, Agawam, Massachusetts.

Dr Paolo Cigna, president and CEO of PRIMA North America, announced the shipment saying the delivery was made to EBTEC to expand their capacity for laser drilling with the latest system technology.

“We are pleased to have the opportunity to provide this system to EBTEC, a pioneer in high energy beam processing.” stated Dr Cigna.

“EBTEC has over 40 years of experience providing parts for the aerospace, medical, defense, power generation and commercial industries.

We are grateful for their positive evaluation of our system technology and the Convergent P50L laser, another product of Prima North America.

Laserdyne products are in use in aerospace and turbine engine manufacturing sites around the world.” stated Dr Cigna.

EBTEC Corporation is owned by Aquasium Technology, Cambridge, England, and has been a supplier of electron beam welding and laser processing services to North American industry since 1963.

As an early user of these processes it has developed an expertise in the supply of difficult to weld and drill components.

According to John Leveille, president of EBTEC Corporation, the Laserdyne 790XL system was purchased as the first new laser system outlined in an equipment phase replacement plan.

The 790XL was chosen over other systems primarily for overall processing versatility.

The 790XL system is a 6-axis system with a 2m x 1m x 1m (40in x 40in x 40in) work envelope with a 25in diameter high accuracy rotary table and Laserdyne’s latest software features including Optical Focus Control (OFC) and BreakThrough Detection.

OFC complements the 790 BeamDirector’s patented Automatic Focus Control (AFC) and BreakThrough Detection has been shown to not only produce parts with a shorter cycle time but with a better flow consistency.

This will enhance EBTEC’s capability to provide precision drilling of cooling holes in thermal barrier coated turbine engine components.

An additional feature of the EBTEC system is the ability to drill parts programmed for Laserdyne’s new 450 systems on the 790 as a result of the Part Surface Coordinate, or PSC, programming feature of the Laserdyne control.

Laserdyne products have become the technology standard for the aerospace industry and are used in turbine engine manufacturing facilities across North America, Europe and Asia.

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A laser galvo head control has been added to a software based motion and machine control platform to produce a single integrated development platform for laser applications.

Aerotech’s PC based A3200 software machine control system combines 1 to 32 axes of Firewire distributed motion control with HMI, PLC and vision control modules and is now available with the Nmark galvo control package for vector and graphics based laser marking applications.

OEMs and machine builders of laser marking systems are able to significantly reduce application development time and cost by controlling industry standard XY2-100 protocol galvo scanning heads and additional axes of servo based linear and rotary motion with other machine control functions within a single, integrated programming environment.

Two versions of Nmark are available - the Nmark VCT (vector) suits vector laser marking applications where lines, arcs and circles define the marking path, and the Nmark GRC (graphic) is available for raster-scan based marking.

Both versions are supported with a comprehensive range of programming commands and parameters that are used in conjunction with the A3200 Digital Automation Platforms’ powerful software to achieve complete control of multi-axis laser machining applications including marking ‘on-the-fly’ for continuous web processes and Z-focus height control for 3D processing.

All Nmark galvo motion and functional parameters can be controlled in synchronisation with motion and machine control commands directly from within the Automation 3200 program space, providing a single integrated program development environment for the complete application.

Galvo based laser marking provides a fast and convenient means of coding and identification, and is used extensively in the aerospace, automotive, industrial, and medical industries.

Galvo’s can also be applied to other medium accuracy marking and machining applications such as micro-hole drilling and decorative work on a range of thin metal and non-metal substrates.

Aerotech’s Nmark products use the industry standard XY2-100 serial protocol to communicate with galvo scanning heads from a wide range of manufacturers.

Aimed at laser marking, cutting, welding, sealing and ablation applications, the Nmark VCT is programmed from the A3200 in the industry standard RS-274 G-code language with Aerotech’s own AeroBASIC command extensions for laser and I/O control.

As all major CAD/CAM suppliers support RS-274 output, a direct conversion path from CAD to galvo motion is available.

The Nmark VCT is used in conjunction with a PCI interface board and via a Windows DLL, is able to access all commands, status and diagnostic information from the galvo head in real time.

The Nmark GRC is targeted at applications such as barcoding, engraving, serialisation, and character scribing.

Laser marking projects are created using a simple Windows tool that is used to import and manipulate bitmaps, graphics and barcode images and store the resulting marking profile in a project file.

Straightforward AeroBASIC commands within the A3200 are used to download the file at run time and additional commands are available to manipulate the properties of objects such as text strings or barcode values during the marking process for serialisation applications.

Commands are also available to scale, rotate and change the orientation of the object.

Aerotech’s A3200 Digital Automation Platform is a powerful PC based, software-only machine control system combining a high-performance, 1 to 32 axis motion engine with decentralised drives interfaced via Firewire with other machine control function modules such as HMI, Vision and soft PLC.

A 10/100 Base-T Ethernet interface is also available to add third party I/O and PLCs for a completely integrated solution.

Typically used with Aerotech’s extensive range of high performance direct-drive, linear and rotary positioning stages and digital servo drives, the A3200 based motion and machine control system includes a wide range of advanced motion and machine control commands aimed at increasing and improving the finished quality and throughput performance for demanding applications.

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Direct-drive, brushless linear and rotary motion platform that includes automated workpiece handing and tooling platforms is intended for cylindrical laser machining applications.

Aerotech’s LaserTurn combines high performance, direct-drive brushless linear and rotary positioning stages with automated workpiece handling and provision for customised tooling - for a completely integrated motion solution for high-throughput cylindrical laser machining applications.

The new LaserTurn series is the result of Aerotech’s dedicated research and extensive experience to provide improved productivity, industry-specific motion sub-systems, for high-throughput manufacture and test applications.

The LaserTurn series features direct-drive brushless linear and rotary stages with non contact encoders for high speed, zero backlash performance with micron level precision and repeatability.

The integrated linear and rotary design allows a low machine centre of gravity that reduces the potential for dynamic pitch error under rapid acceleration and reversal conditions - offering a vast performance improvement over separate linear and rotary stages.

Other benefits include superior productivity, higher rigidity, smoother motion with faster settling times, and consistently improved high quality of the laser machined part.

Available in two sizes for workpiece diameters up to 30 mm with a choice of 200mm or 300mm linear travel, the smaller LaserTurn 2 has an ER16 collet supporting tube and bars from 0.5mm to 10mm diameter.

The LaserTurn 5 has a larger width footprint and is available with options of an ER25 or ER40 collet for 0.5 to 16mm and 16mm to 30mm workpiece diameters respectively.

In addition the larger model may be fitted with a three-jaw gripper.

All workpiece handling may be pneumatically automated and includes a clear aperture for product feed through.

The linear stage includes a hard top design with side seals for full protection and the complete assembly is fully protected against laser machining debris.

As well as motor power and encoder wiring, pneumatics and customer specific cabling is routed through an e-chain cable management system with interfacing connectors provided.

This greatly simplifies machine design and commissioning time and ensures high reliability and a long maintenance-free life.

For custom fixtures such as workpiece alignment supports and automated material advance, the LaserTurn’s front facing end-plate provides a tooling platform with a matrix of M6 holes on a 25mm square pattern.

As this tooling interface is an integral part of the linear stage, a common reference is guaranteed for maximum system stiffness.

An optional rear tooling platform may also be specified and customised mounting patterns or additional fixtures may be provided upon request.

With a choice of linear encoders, overall accuracy of +/-5 micron is achievable, alternatively a ‘Halar’ calibrated option provides for +/-1 micron accuracy over the full travel range.

Positional repeatability is within +/-0.5 micron and straightness and flatness is within a total deviation of +/-1 micron.

Maximum linear speeds are up to 2m/s.

For both models, rotary stage accuracy is +/-15 arc-sec with repeatability at +/-3 arc-sec for the smaller LaserTurn 2 and +/-6 arc-sec for the LaserTurn 5.

Axial and radial runout and wobble specifications correspond with the overall high precision of these assemblies and rated speeds for the smaller and larger models are 2000 rev/min and 600 rev/min respectively.

Complementing the performance capability of LaserTurn laser machining systems, Aerotech’s A3200 Digital Automation Platform is a powerful PC based, software-only, machine control system combining a high-performance, 1 to 32 axis motion engine with decentralised digital servo drives interfaced via a high-speed Firewire network.

The A3200 has integrated machine control function modules such as HMI, Vision, soft PLC and a 10/100 Base-T Ethernet interface for third party I/O and PLCs.

It includes a wide range of advanced motion and machine control commands aimed at increasing and improving the finished quality and throughput performance for demanding applications.

An example is the acclaimed Position Synchronised Output or PSO command that maintains precise, ‘on-the-fly’ synchronisation of the laser’s pulse, power level and firing pattern with the exact position of the multi-axis positioning system typically moving the work piece undergoing laser feature generation.

Aerotech are able to meet and often exceed a customers’ performance requirements by providing engineered systems with fully tested and calibrated mechanical stages and associated control and drive equipment.

This reduces the overall cost of ownership when compared to individual design, purchase and assembly of motion control components.

Typical systems include all motor power and encoder cables plus performance and calibration related documents to help integrators with their own system documentation.

All motor parameter set-up data for system configuration is included, making commissioning straightforward.

These features are standard for every Aerotech product and with full product training and comprehensive on-line technical support, the true cost of ownership is extremely competitive.

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Laser engraver performs deep engraving direct from 3D CAD models on workpieces up to 500mm3, including cutting complete tool cavities, adding fine detail, textures, logos or producing electrodes.

To accommodate the first ever UK exhibition for the FOBA Laser Engraving machine Kaye-Dee have had to move to the larger C52 stand Hall 3 at the forthcoming PDM show.

Centrepiece will be the G5 Laser Engraver demonstrating its capability of deep engraving direct from 3D CAD models.

You can engrave work pieces up to 500mm3 and applications include cutting complete tool cavities, adding fine detail, textures, logos or producing electrodes in copper or graphite.

Kaye-Dee invites you to come and see how you can totally transform your mould and tool manufacture with this equipment.

In addition to the G5 there will also be a second FOBA laser showing you its expertise of marking a wide range of materials using fibre laser technology.

As the market leaders in the pad printing industry we will also be displaying the exceptional Teca-Print pad printing machines.

On show will be the TP printer series designed with the operator in mind, equipped with sealed ink pot system and extended pad stroke to allow mouldings to be printed in either a fixed jig position or whilst being indexed on a production line.

Also on show will be the TPX 100 Open Ink Well System with Touch Screen control panel, easy learn logic and an extremely user friendly programming menu.

Next to this state of the art machine will be a working 30 year old TC70 unit highlighting the quality and value for money you get from this precision Swiss manufactured equipment.

To ensure you get the best print on your product we can also advise on pad and screen printing inks from the extensive Ruco ink range.

This includes the new T40 ink with excellent opacity and no harmful cyclohexanone or hydrocarbonates.

Another addition to our collection of marking equipment and on show is the new range of Hot Foil machines.

With an extensive model range manufactured to the height of British excellence, automation and a wide range of accessories, foils and dies Kaye-Dee can accommodate your every hot foil requirement.

We look forward to you visiting our stand so we can help make your marking requirements simple, reliable, cost effective and most importantly allow you to achieve the ultimate marking perfection! Written invitations will follow for your personal attention shortly.

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A 400W laser power source for a major OEM manufacturer of medical equipment and features a 60A constant current source and can drive up to 35W CW laser diodes.

UK Power supply specialist, Ferrus Power, has demonstrated its extensive design capability by developing a new 400W laser power source for a major OEM manufacturer of medical equipment.

Featuring a 60A constant current source and nominal voltage of 2V DC the product can drive up to 35W CW laser diodes.

In addition a TEC output rated at 250W/25V DC is provided with reversible polarity for driving external peltier devices for diode cooling or heating.

Laser and TEC current is controlled via 0-10V DC external programming in each case.

Current monitoring for both laser and TEC is provided in 0-10V DC format with voltage monitoring proportional to output.

For safety purposes a further laser interlock control offers beam attenuation and shuts down the laser output to meet the requirements of 21 CFR 1040.10.

Signal and control connections are via 16W IDC whilst laser and TEC are via high current screw terminal block.

The need for an external power supply to drive ancillary microprocessor control circuitry is removed as the product also features low voltage outputs of +5V DC,+/-15V DC and 24V DC via six-way 0.156in header.

The product is suitable for worldwide applications and offers universal mains input operation of 90 - 264V AC with active power factor correction to meet the line harmonic distortion requirements of EN61000-3-2 class D.

The product is currently undergoing medical approvals testing to EN60601-1.

Ferrus has the capability to design and manufacture similar products to suit the laser and opto-electronics industry and would welcome enquiries.

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Laser cutting technology is no longer costly for mainstream sheetmetal fabrication due to rapid developments in speed, cutting quality and manufacturing. The laser beam is now efficient enough and has been quantified as a universal tool for cutting, welding, surface treatment and coating.

Not only does it enhance OH&S standards by operating silently and without wear and tear; laser cutting technology produces burr-free edges with narrow kerfs and minimal heat-effected zones. Its advantages include minimal heat input, low distortion and high feed rates.

Integrateability has been a key factor in laser cutters crossing into the realm of mainstream cost effectiveness. With the worldwide increase in versatility of turret punch presses, fabrication companies at all levels have greater possibilities to add laser cutting manufacturing solutions for their applications.

Laser cutting machine specialist, Maxitec , says that in the upper market segment, both ultra-fast flying optics laser cutting machines and punch-laser combinations have been gaining ground.

The company’s marketing director, Andrew Bentrup, said that now the integration of several work stages in the punching unit, the manufacturing of sophisticated components becomes possible at a lower cost/component ratio.

The share of ultra fast laser cutting systems, featuring linear drive technology is increasing due to fabricators’ demand for faster part processing time combined with enhanced accuracy and reduced setup times. Today, many manufacturers are looking closer at lasers to meet low run, high part number needs because of a disappearing need for higher volumes of the same part numbers and it is important to understand how the features of the present technology will last into the future.

Anticipating what the best features of a laser cutting system is important, but more vital is the evaluation of which features will become ‘obsolete’ and costly in the years to come. The basics of laser cutting have not changed for the past 20 years. There is an energy source (the laser) that removes material by thermally vaporising it. The mechanism to do this is controlled by five major elements: power, feed rate, focus, assist gas pressure, and type of assist gas.

Feed rate controls either the material or the laser movement at a speed that will allow the laser to consistently vaporise the material. Focus places intensity of the laser beam either on the surface, above, or into the material to achieve the desired cutting condition. The type of assist gas and pressure will remove the molten material and achieve the desired edge quality.

Recent Developments: According to Bentrup, high technology machine tools are what most manufacturers are looking for.

Lower set up times, high part quality and accuracy have been a natural benefit of laser cutting systems. Fast cycle times on lasers have always been related to geometry. Large radius parts cut on a laser have always outperformed other manufacturing methods.

With the latest in new linear drive technologies, the cycle time margin on traditional sheet metal systems is narrowing. A completely new type of laser design needs to be provided to accept the speed of acceleration that the new drive technology offers.

This new speed of process combined with the existing trend of the laser industry towards automation make the future of this manufacturing technology bright. Technologies like DpM and DpMplus are examples and make it easy to understand how fabricators can benefit from those new developments.

Control of axis movement has improved over the early systems, especially over stationary beam style lasers. Yet, most machine tool manufacturers still embrace either ball screw or rack and pinion drives.

Focus point is automatically changed through a cutting database or technology table. Assist gas change and pressure are system controlled as well. In fact, most of the internal functions of laser cutting have been automated. The NC cutting database has taken over almost all of the operational commands, leaving simple functions like nozzle or focus lens alignment or change to the operator.

Higher laser powers have advanced the technology as well. Thicker capacities of metals can now be processed, but the real advantage of higher power (3,000W and above) has been the increased feed rates on thin metals.

By using an inert gas, cutting speeds of metal are almost three times faster than earlier wattage systems. However, in efforts better to maximise speed of cutting more and more attention has been paid to nozzle design and beam collimation.

Punch-Laser Combination Machines: The development of laser cutting systems in recent years and the benefits associated with laser fabrication have increased interest in the use of laser cutting in many sectors of industry. Laser technology, in combination with punch press machines, has been used in the industry since 1980s.

Product designers are able to consider the opportunities of punch presses with the ‘four-in-one’ solutions, i.e. using forming, tapping, punching and laser cutting in one system to have different manufacturing methods available within one fabricating cell. However, various sheet metal components can be made using different machines, but also with one common manufacturing tool – laser cutting.

Manufacturing Benefits of Punch/Laser Combination: In recent years, machine tool builders have managed to economically integrate different manufacturing methods in a system through punch/laser combination systems. Fast axial flow CO2 lasers up to – 3,000 Watt laser power play the dominant role as an additional tool in the turret punch press. The integration of a diffusion cooled 2,500 Watt SLAB CO2 laser with its outstanding beam quality equals even 3,750 Watt laser power in comparison with conventional fast axial flow CO2 lasers. The heart of the machine is the robust O-frame of welded construction. The rigid construction of machine frame and the coordinate table permit the use of high axis speed and acceleration.

The punching operation can be generated either with a hydraulic system, with the possibility for more than 1,000 hits on 1mm axis movement, or by a servo-motor-driven mechanism. Its principle is made possible by a combination of electrical servo technology and mechanical power transmission.

Further enhancements also include linear drive motor technology allowing the punch/laser combination to become not only as fast as the 3-axis high speed laser systems but making the new combination machine the most universal sheet metal fabrication centre in the market, capable of punching, forming, contouring, marking, and tapping in one single set up without releasing the sheet metal fro the work holder.

More Integrated Work Stages – More Automation: Besides punching, nibbling, forming, marking, even bending and tapping operations are possible. For outside part contouring and special inner contours, in order to avoid nibbling marks, sharp edges or buying special tools the laser is used to increase part quality in one operation with no additional material handling.

Additional increases of productivity for punch laser systems are modular extensions in the overall system, like loading/unloading, part sorting or stacking.

The laser cut parts will be guided outside the working area via trap doors and conveyor systems. From this point or even straight from the cutting position a sorting and stacking robot transfers the part to its programmed sorting address.

High-Speed Laser Cutting Systems:

Flat bed laser cutting systems have been established technology in the sheet metal industry for more than a decade. The flexibility of the laser cutting process in producing components with various contours, with varying thickness and materials, has led to the world-wide use of these systems.

High speed laser cutting has been accepted by sheet metal manufacturing shops throughout the years as several studies of institutes have shown the possibility of cutting materials such as 1mm aluminium at 50 m/min or even faster.

Many sheet metal applications have been solved with punch presses due to manufacturing costs for the component. With the integration of linear drive technology, new and rigid machines had to be developed to achieve positioning speed up to 300 m/min and acceleration of more than 20 m/s2. In addition to this, the laser cutting speed could be set up to 25 m/min for 1mm mild steel without a negative influence to path accuracy. In aluminium even 50m/min cutting speed is a standard parameter in the system cutting data base.

The high-speed laser cutting system can be designed also for flexibility. With the use of, for example, 4,000 Watt laser power mild steel can be cut up to 25mm.

Higher cutting speed for thin material and the repositioning speed from one cutting point to the next contour have led to higher productivity in comparison with conventional flat bed laser cutting systems.

The laser cutting process is a complex one, which is why a more sophisticated and user-friendly operator interface for the CNC control was developed for the system. All necessary parameters are available, and functions from the system can be activated through a Windows-based touch screen operator panel.

The process time for a complete sheet has been drastically reduced. Also more and more material handling devices like loading and unloading from the sheet are installed in high-speed laser cutting systems.

A further step towards more sophisticated material and component handling is Finn-Power’s laser cutting centre LC6. This automation for laser cut components helps the customer integrate laser operation and part handling for fabricating high-quality components within one system.

The LC6 Laser Centre utilises a fixed laser beam system, combining the unique C-series turret punch press drive concept with the latest generation of diffusion cooled CO2 SLAB laser.

Laser Automation: The biggest trend towards laser cutting over the last 10 years has been one towards automation. This trend promises to continue. The reasons are varied and this trend promises to continue.

Bentrup says that the consistency of operation of an automated cell, especially with a laser at the heart of it, offers complete flexibility to the manufacturer. Reaction time to the customer’s demands is minimal.

There is no costly tooling inventory to manage, nor need pallets be chased down to be prepared for processing.

More and more companies are implementing lean manufacturing strategies to minimise wasted movement and overproduction of parts and thus reducing inventories. An automated laser cell is the suitable tool to achieve these goals.

Developments in laser power control and technology tables have reduced cycle time and set up. The new developments in linear drive technology are causing manufacturers to rethink the basic design of laser cutting equipment.

Laser automation and the new advancements in laser processing are likely to bring the production cost-per-part lower than ever before, with less set up and higher throughput.

The future of any technology depends on how that technology best serves its end user, the customer. With this thought in mind, the future of the laser technology is moving in the right direction.
Maxitec Website

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