Quality Reliability Design - Complete Machine Tools · Inbuilt Monitoring Camera with LCD Screen...

Quality Reliability Design


Contents

1. Machine - Highlights /Overview........................................................ 1-3

2.Technology - Fiber Laser ................................................................... 4

3. Technology - Cutting Head ................................................................ 5

4. Technology - CNC Controller ............................................................. 6-7

5. Technology - Offline Software ........................................................... 8-9

6. Components - Rack and Pinion ......................................................... 10

7. Components - Linear Guide System ............................................... 11-12

8. Components - Planetary Gear Head ................................................ 13

9. Components - High Pressure Electro Regulator ............................. 14

10. Components - Servo Motors+Drives ............................................. 15

11. Technical Specifications ................................................................. 16

Cutting Area

Laser Source Power

Position Accuracy

Repeat Position Accuracy

Maximum Position Speed

Acceleration:

1500mm*3000mm

2000mm*4000mm

500W/700W/1000W

2000W/3000W/4000W

±0.03mm/m

±0.02mm/m

100m/mm

1.5g

Cutting Area

Laser Source Power

Position Accuracy



Acceleration:

1500mm*3000mm

2000mm*4000mm

500W/700W/1000W

2000W/3000W/4000W

±0.03mm/m

±0.02mm/m

100m/mm

1.5g

01VTOP | FIBRE LASER

Inbuilt Monitoring

Camera with LCD

Screen

German Made

Linear Rails and RacksSimple to Adjust

Swiss Cutting Head

Status Light

LED

Green/Orange/Red

Large Door

Openings

and Windows

German Made Power Automation

Controller and Operating SoftwareProtective Safety

Glass

Virtually Maintenance

Free IPG Fiber Laser

Innovative

Design


LED Lights On Both

Left Hand and Right Hand

Side of Covers

Safety Light Curtains

Around the Exchange Table

Fully Enclosed

Safety Cover Centralised

Electrical Box Exhaust Fan

for Smoke

RemovalFast and Efficient

Exchange Table


Technology - Fiber Laser

Main Features

Made in U.S.A

IPG's YLR/YLS Series represents a break-through generation of diode pumped singe mode CW Ytterbium

fiber lasers of near infrared spectral range with a unique combination of high power, ideal beam quality,

fiber delivery, high wall-plug efficiency, compactness and reliability

The laser possess a reliability that is unmatched by conventional solid state or gas laser. Selectivity of

operating wavelengths, ultra-low amplitude noise, high stability and ultra-long pump diode lifetime

completes an impressive list of advantages of this modern fiber laser system. The YLR/YLS Series was

developed to meet fast growing demand of industrial, R&D and medical markets for compact, robust,

turnkey and maintenance-free solutions that can be easily integrated into an industrial manufacturing

system, scientific experiment, OEM machine or an automated production line.

700W to 4KW Output Optical Power

Over 25% Wall-Plug Efficiency

Maintenance Free Operation

Estimated Diode Lifetime > 100,000 Hrs.

Singe Mode Fiber Delivery

On Cutting applications, single mode fiber laser are utilized for precise cutting of very delicate structures

such as stents, silicon wafers, surgical knifes as well as thicker materials at the higher power levels.

Because of the high fluence, only possible with the single mode fiber lasers, combined with long standoff

distance fiber lasers are achieving speeds of heat profiles never before achieved with laser processing.

When operating in the modulated mode, these lasers are ideal for producing small holes at a rapid rate.

Compact in size, user-friendly, highly reliable and broadly versatile, IPG's diode-pumped fiber lasers bring

revolutionary solutions to multiple applicaitons.


Technology - Cutting Head

Product Features

Made in Switzerland

Compact modular design

Different optic lens options

0.05 mm of lens movement to set focus

Quick and easy access to the cover slide

High-efficiency water-cooling system

Built-in annular and lateral gas flow, easy to cut high-reflective materials and preventing

thick plate from blasting and sputtering

Guiding adjustment of optical input

Reliable sealing design

Ability to cut galvanized steel brass, copper and high reflective materials without fear of

damaging the head

Simple setting of focus via a knob

Swiss reliability and quality

Acess Lens Lock

Cover Slide Drawer

Simple and Easy to Change the Lense


Technology - CNC Controller

Made in Germany

Machine Functions For Laser CuttingInternal/external laser pointer function for teaching the start-point

Safe-Stop of NC process: During the cutting process there could be reasons why the NC-Program needs to

be interrupted. For this we have the following functions:

– Moving manually backward on contour

– Moving automatically backward on contour after stop (generated by user or error condition)

– Consideration of laser on/off delays (to avoid uncut lines)

– Automatic retract of Z-axis

– Manually move of the axes for service or maintenance reasons

– Consideration of several safety issues during stop (doors, gas ...)

– Continue automatically at last cutting position

– Switch on/off functions and selecting of the correct cut parameters again

Complex C2C (contour to contour) handling

– Selectable motion types between the contours (without stroke, square, triangle, ramp)

– Switching On/Off gas during C2C movement, to safe gas dependent of the distance.

– Special handling to reduce the nonproductive times

b ea m l o s t

M a nu a l l y m o v ingb a ck w a rd a nd s t a rt

Consumables time counting

– Beam on time, gas on time etc.

Cut single parts out of a complete nested job with flexible start

point

Nozzle change function – for fast changing of the nozzle the

software has integrated an automatic nozzle changer. The status

of the nozzles is visualized in the HMI and can be managed from

there. The structure of the nozzle changer can contain a definable

number of rows and lines.(Optional)

Marking

Film burning (burning of existing foil cover before cutting

Bypass material spot problems – different strategies to avoid

influence of spotting material to the nozzle/sensor

Advanced Functions

The package has some advanced functions which allow a fast and precise cutting process.

Laser diagnostics

– As PA CNCs are pc-based systems the laser diagnostic tools can run directly on the CNC system so that

the diagnostic is much more comfortable.

Adaptive distance regulation

– The function distance regulation allows functionality such as heights regulation above the work piece. It

keeps the distance to the sheet constant during cutting even if the sheet is not flat.

– Distance regulation needs an external analog signal from a distance or heights sensor. In its easiest form

the distance regulation can influence the position of an axis for heights control. Together with 5-axis

transformation the regulation can work in tool direction with multiple axes. The distance tool-head or

tool-tool will be regulated proportionally to the analog voltage. The characteristics can be adjusted with

parameters.

Cutter compensation look ahead

– Cutter compensation look ahead is an extension of the standard cutter compensation. Multiple blocks

(standard values: 10, 25, 100) can be looked at in advance to detect and avoid collisions. Different

adjustments are possible for reaction to the detection of a collision: e. g. generate a message but keep

executing, take a shortcut to avoid contour damage. Cutter compensation look ahead can also execute NC

programs with dummy blocks (blocks without movement information) which normally only works in special

cases.


Technology - CNC Controller..Continued

Advanced Functions

Fly/Fast-Cut

Pipe/Tube Cutting: (If the machine has this option)

– For pipe cutting PA uses barrel cam transformation by the CNC

– The barrel cam transformation has two functions:

– One function is that if the CAD/CAM gives two linear axis positions the

transformation make one linear and one round axis out of it.

– The second function is that the needed feed for the round axis which

cannot

be given by the CAD/CAM is automatically calculated by the CNC

Piercing

Fly cutNormal cut 2 31

2 31

2 31

2 31

44

4 4

2 31

2 31

2 31

2 31

44

4 4

233

11

5 5

77 6

4

Fast cut 2 31

2 31

2 31

2 31

44

4 4

PA HMI

The open user interface

The HMI for laser cutting offers you all

relevant functions for an easy and

efficient operation of your laser cutting

machine. It can be very easily and

flexibly customised and updated to

meet the needs of the user. With the

latest QT5 technology, the PA HMI is

not only graphically very attractive but

also very powerful.

Database

For laser cutting

To store all necessary parameters

for the cutting process the soft-

ware package includes a sqlbased

database. In the database you can

add your parameters like material,

thickness and part number to

achieve the perfect cutting results.

That makes the operation very

easy and reliable


Technology - Offline Software

SigmaNEST TrueShape™

®

Made in U.S.A

SigmaNEST TrueShape is a step towards improving cutting and punching production through automated dynamic

nesting and superior NC programming. SigmaNEST TrueShape optimizes the cutting space and uses part-in-part

nesting to reduce or eliminate scrap.

FeaturesAutomatic part pattern recognition

Part-in-part nesting

Accurate cost and time estimators

Adaptive nesting for multi-head machines

Drag, drop, and bump features

Automatic and manual true shape nesting

Automatic NC toolpath generation and optimization

Extensive, fully customizable stand shape library

AdvantagesOne software programs all major profile cutting and

punching machines

Optimal material utilization to reduce scrap

Maximum flexibility in file conversion and importation

Custom shapes can be saved into standard part library

for future use

Streamline planning with accurate time and cost

estimates before cutting

Technical Specifications Benefits

Runs inside Windows 10, 7, Windows XP or Vista®

operating systems

Import standard industry file formats such as CDL,

AutoCAD DXF and DWG, HPGL, and IGES

ESSI, G and M codes can be user-configured

Post processors for multiple machines

Standard and customizable report generation system

Save engineering time through simplified

programming and more efficient machine output

TrueShape nesting provides maximum yield per sheet

Handle more orders in less time

Completely customizable through SigmaNEST’s open

architecture

Integrated Part Database

Multi Sheet Nesting


Technology - Offline Software..Continued

Geometry/ImportingIntegrated 2D CAD drawing package:

• Create polylines, lines, arcs, circles, fillets, chamfers, notches, bevels, layers, text, notes, and dimensions

• Duplicate, move, scale, mirror, rotate, or array copy geometry

• Trim, break, extend, auto-segment large arcs, and snap-to arcs as well as circle quadrants

• Validate the file, filter geometry, and change weld gap before creating a part

• Definable reference point and default part rotation or default to minimum rectangle rotation

• Import design from major CAD systems

Part Creation Management

Import ESSI language and existing G-code programs

Store workspaces and extracts parts from nest

Map layers to processes (for marking and cutting) or quality settings

Create multiple parts from a single file

Choose from more than 200 customizable shapes that can be saved to an integrated database with

user-defined fields

Lead-in/-outs automatically applied according to material or process type

Enable automatic internal/external contour recognition and error correction during part creation

Calculate kerf by computer or control

Estimating Part-Cost and Time

Automatically calculate part area, cut length, and pierce numbers

Calculate part costs with an integrated costing model featuring user-defined parameters for machine recovery rate,

operator costs, and other overhead and consumable materials

Calculate processing time based on the nominal feed rate, material type and thickness, machine acceleration,

part quality specs, rapid traverse, and head up/down movement on piercings

NC ProgrammingAutomatically generate lead-in/lead-outs

Toolpath is optimized according to machine and material type

“Pierce on the fly” function for machines capable of this technology

Automatically set part cut sequence from user-defined start point with manual override

Sequence options for minimum movement, reducing heat distortion, skip cutting, and block

cutting while preserving internal part sequence

Multi-process capability

Set for sequential or simultaneous multitorch line cropping

Clear NC for current or all nests, and from individual parts in a nest

Automatic NestingAutomatically nest pre-nested clusters and parts within parts

Automatic multi-torch, rectangular, and true shape nesting

Multiple sheet nesting on rectangular sheets

Nest for pre-pierce, corner loops, and bevels

Supports static nesting

Reporting

TrueShape has automatic report-generation capabilities, allowing users to create full reports in

seconds. TrueShape reports include cut time estimates, material yield, and automatic job cost

feedback.


Components - Rack and Pinion

Made in Germany

Progress and Expertise from Bietigheim- Bissingen

Vtop lasers use one of Atlanta’s high end racks, the HPR( High Precision Rack ) is a class 7 quality class

and one of the highest available in today’s market. By using a class 7 rack it ensures accurate positioning

and allows for higher acceleration and positioning speeds.

As a medium-sized family company which specializes in the development, construction and production of

high quality drive systems, ATLANTA’S proved itself for over 80 years developing excellent solutions in

the field of technology. New production technologies require more complex drive systems and their

components must meet strict requirements in quality and performance. ATLANTA has repeatedly

adopted and implemented these requirements in their new and innovative products over the recent

years.

Atlanta is a dependable worldwide partner and manufacturer for many different industries, including

machine tool, wood working, material handling, robotic, food packing, special machinery and many others

trust the product “Made by ATLANTA”

Atlanta is an established manufacturer of drive technology in their three plants in Bietigheim- Bissingen

(Germany) which produce high quality products like low-backlash gear boxes, racks and gears. Constant

development guarantees complex changes in drive technology.


Components - Linear Guide System

Made in Germany

Highlights

High-Precision steel ball runner blocks BSHP have been given the patented entry zone that makes it possible to adapt to the

current operating load on an individual basis.

The technology minimizes fluctuations in frictional force and improves travel accuracy compared to conventional ball rail

systems.

Enhanced load capacities and load moments.

The same high load capacities in all four main directions of loading

Very Low noise level and best travel performance

Excellent dynamic characteristics:

Speed: Vmax to 10 m/s

Acceleration: Amax =500 m/s2

Long term lubrication over several years possible

Minimum quantity lubrication system with integrated reservoir for the oil lubrication

Limitless interchangeability; all guide rail versions can be combined with all runner block versions

Optimum system rigidity through preloaded O- arrangement

Optimum installation compensation with super ball runner block

Increase in rigidity with lift-off and lateral loading by means of additional screw connections on two drilled holes in the middle

of the ball runner block.

Integrated all-round sealing

High torque load capacity

Optimized entry-zone geometry and high number of balls per track minimizes variation in elastic deflection

Smooth, light running thanks to optimized ball recirculation and ball or ball chain guidance


Components - Linear Guide System (cont..)ComparisonConventional ball runner blocks

If the ball runner block has a conventional entry zone, this can be designed for a specific load point.

Entry zone geometry for conventional ball runner blocks

1. Ball Runner Block

2. Ball

3. Ball Guide Rail

Ball Entry

The balls are guided to the beginning of the entry zone by the ball recirculation track.

When the distance between the ball runner block [1] and the ball guide rail [3] becomes smaller than the ball diameter, the ball [2] is subjected to loading (preload) in a series of pulses.

The preload increases in the entry zone and reaches a maximum in the load-bearing zone. The ball transmits the force from the

ball runner block to the rail.

The kinematic and geometric conditions cause space to develop between the balls.

Rexroth High precision steel ball runner blocks BSHP

New entry zone geometry for high precision ball runner blocks

High-precision ball runner blocks have an innovative entry zone. The ends of the steel segments are not supported by the ball runner

block body and can therefore deflect elastically. This entry zone adjusts individually to the actual operating load of the ball runner block.

The balls enter the load-bearing zone very smoothly, i.e. without any load pulsation.

4 5 6 7

1

2

3

1. Ball Runner Block

2. Steel Segment

3. Ball Guide Rail

4-7-Balls

Ball Entry

The balls [4] are guided to the beginning of the entry zone by the ball recirculation track

The ball [5] enters the zone load-free

The ball [6] deforms the end of the steel bearing plate [2] elastically. The deflection is sum of the compliance of the ball itself and the

compliance of the unsupported end of the steel segment

If the distance between the steel bearing plate and the ball guide rail [3] gets less than the ball diameter, the ball comes under load

slowly and evenly (preload)The preload is thus smoothly increased until the ball [7] has reached its maximum preload.

Innovative solutions from Rexroth:

The load-dependent entry zone

The crucial factor is the functionality of the entry zone. The steel segments are manufactured with such

precision that they deflect to the right degree in response to the actual load. This results in especially

smooth ball entry behavior. A ball deflects the precision- manufactured steel segment only as far as

necessary to allow the following ball to enter load-free. The ball is no longer guided into the load-bearing

zone in pulses by a rigid entry channel but by a very smooth flexing curve, which ideally transitions

tangentially into the load-bearing zone. The extremely smooth ball entry behavior and the continuous

adjustment of the entry zone in response to the actual load are the great advantages of these high precision

ball runner blocks.

Characteristic features

1. Highest travel accuracy

2. Minimal frictional drag variation

3. The conflicting aims are resolved


Components - Planetary Gear Head

alpha Made in Germany

Drives, controls and positional accuracy are areas that require maximum precision. Products manufactured by

WITTENSTEIN alpha GmbH are setting bench marks worldwide in the fields of mechanical engineering and drive

technology. From low backlash planetary gear heads, servo right-angle gearheads and complete drive units

to the comprehensive cymex® engineering software package and expert technical consultation: WITTENSTEIN

alpha GmbH has redefined the meaning of precision.

TP+ / TP+ HIGH TORQUE – Compact Precision

Compact top performers with output flange. The standard version

is ideally suited for high positioning accuracy and high dynamic

cyclic operation.

The TP+ / TP+ HIGH TORQUE are particularly well suited for

high-precision applications in which high torsional rigidity is

required.

WITTENSTEIN alpha GmbH are setting bench marks worldwide in the fields of mechanical engineering and drive

technology. From low backlash planetary gear heads, servo right-angle gearheads and complete drive units

engineering software package and expert technical consultation: WITTENSTEIN

Compact Precision

Compact top performers with output flange. The standard version

is ideally suited for high positioning accuracy and high dynamic

HIGH TORQUE are particularly well suited for

high-precision applications in which high torsional rigidity is

Planetary Gear Head

alpha Value

alpha Basic

alpha Advanced

alpha Premium

alpha Value

alpha Basic

alpha Advanced

alpha PremiumRP+

alpheno®

TP+

SP+

NP

CP

NPSNPL

NPTNPR

RP+

T

LP+ NPLLP+

Axes with very high precision, dynamics and power density requirements

Axes with mid-range precision, dynamics and power density requirements

Performance

Value

Used on VTop Lasers

High-End Low Backlash Planetary Gear Head

150% more moving force

100% higher power density

50% higher system rigidity

50% less labor required for installation

15% more accurate positioning


Components - High Pressure Electro Regulatoromponents - High Pressure Electro Regulator

Made in Japan

SMC Corporation is a global organization that supports customers in every industrialized country and is based in Japan.

Since its establishment, SMC has been a leader in pneumatic technology, providing industry with technology and products to

support automation based on the guiding principle of “contributing to automation labor savings in industry.” Over the past

50+ years, SMC's products have become established as a recognized international brand through sales, technical, supply

and after sale services in world markets. Sales have grown to achieve a 30% global market share.

Subsidiaries and joint ventures have been setup in a total of 53 countries. Production facilities are located in 29 countries.

In addition, a sales network extends throughout 81 countries, with local services in 400 locations. SMC offers technology

accumulated through the years, engineers that bring it to life in new products, production capacity which can deliver a variety

of products in a short time, and an extensive sales network ithroughout the world.

With its goal of ever more advanced automation, and using its many achievements as a base, SMC is developing high quality,

high reliable products to contribute to automation in industry, as well as in familiar areas of everyday life

Working Principle

When the input signal rises, the air supply solenoid valve ① turns

ON, and the exhaust solenoid valve ②turns OFF. Therefore,

supply pressure regulated by a built-in regulator ③passes through

the air supply solenoid valve ① and is applied to the pilot chamber

④. The pressure in the pilot chamber ④increases and operates on

the upper surface of the diaphragm ⑤.

As a result, the air supply valve ⑥ linked to the diaphragm ⑤

opens, and a portion of the supply pressure becomes output

pressure.

This output pressure feeds back to the control circuit ⑧ via the

pressure sensor ⑦. Here, a correct operation functions until the

output pressure is proportional to the input signal, making it

possible to always obtain output pressure proportional to the

input signal.

Working Principle Diagram

Air supply valve

Diaphragm

SUP OUT

EXH

Pilot chamber

P

Output signal

Built-in regulatorEXH

Solenoid valveEXH

Pressuredisplay

Pressure sensor

Exhaust solenoid valve

Air supply solenoid valve Built-in regulator

Input signalPower supply Control

circuit⑧

① ③

⑤

⑥

⑦④

②Laser Beam Machine

O2

Air

Highpressure N2


Components - Servo Motors+Drivesomponents - Servo Motors+Drives

Made in Japan

Yaskawa has packed 25 years of innovation and five generations of servo expertise into the tuning features of a Sigma

Series servo system. The complete package of tuning features work together to deliver higher speed, greater precision and

faster throughput than any servo on the market.

TUNING-LESS MODE

Every Sigma Series SERVOPACK is equipped with a tuning-less function that is enabled from the moment you pull it out of

the box. This function allows the amplifier to detect load inertia and automatically adjust servo gains at the update rate of

the position loop (a lightning fast 62.5 microseconds). You may never need to tune a Yaskawa servo; not at installation and

never again over years of precise, productive operation.

VIBRATION SUPPRESSION

Sigma series SERVOPACKs neutralize vibration, both from

the motor’s motion artifacts and from resonances within

the machine. It detects actual vibration frequencies and

cancels them out of the motion command, creating a new

machine cycle that is quicker, quieter and more efficient.

Without Vibration

Supression

With Vibration

Supression

FIGHT FRICTION, RESONANCE, RIPPLES

Every Sigma-7 SERVOPACK is equipped with a complete set

of compensation algorithms that virtually eliminate

mechanical impediments which rob a servo of speed,

accuracy and smoothness of movement

Anti-resonance compensation counteracts the effects of a machine’s natural mechanical resonances

Ripple compensation eliminates the oscillations caused by motor cogging and other motor-based vibration effects

Friction model compensation automatically corrects for

changes in machine operation caused by component

wear and other effects of friction over time

FRICTION COMPENSATION

Yaskawa’s exclusive friction compensation software delivers consistently smooth machine starts and transitions, even with the stress of machining operations and gradual long-term wear of machine components. The Yaskawa algorithms compensate for both coulomb friction between dry surfaces and viscosity friction between dry and wet surfaces.

MORE TORQUE IN LESS SPACE,FOR AN EASIER FIT IN YOUR TIGHTEST APPLICATION

Yaskawa's segmented stator core

design and automated winding

techniques pack nearly twice the

copper into the stator gap, for much

more torque output from every

square millimeter of space

REDUCE DOWNTIMEBy eliminating gear reduction and creating a

direct coupling to the machine load, direct drive

motors simplify your machine's design.

Eliminating couplings and other components in

the machine’s mechanical transmission will

ultimately lead to fewer breakdowns and

long-term reliability you can trust.

INCREASE PERFORMANCEDirect drive motors eliminate the

inefficiencies that develop as mechanical

transmission components wear over time.

Say goodbye to mechanical backlash as well.

As compliance is reduced, the

responsiveness of the servo system can be

dramatically improved.


Technical Specifications

Cutting Area

Laser Source Power

Position Accuracy



Acceleration

1500mm*3000mm

2000mm*4000mm

700W/1000W

2000W/3000W/4000W

±0.03mm/m

±0.02mm

1700mm/Sec

1.5g

Cutting Thickness Limit

Material

Carbon Steel

Stainless Steel

Aluminum

Brass

Copper

Galvanized Steel



[email protected]

123 Bluestone Circuit

Seventeen Mile Rocks

QLD 4073

Tel: (07) 3279 3344

Quality Reliability Design - Complete Machine Tools · Inbuilt Monitoring Camera with LCD Screen...

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