BP-C Complete waterjet cutting system

Transcription

1 Complete waterjet cutting system C/ Colón, GUADASSUAR ( VALENCIA) SPAIN Tel: Fax:

2 Image of a combination cutting head (plasma and waterjet)

3 TABLE OF CONTENTS /01 WATERJET TECHNOLOGY History Operation Cutting methods Applications Technological advantages 9 /02 MACHINE DESCRIPTION Cutting unit TCI BP-C Electric and control equipment TCI CNC Autonomous abrasive feeder TCI ABRALINE Abrasive regulation TCI ABRASIVE Abrasive backstop system TCI CUT CONTROL Anti-collision TCI COLLISION PROTECTION High pressure pump KMT 50 HP 4100 bar 1L High pressure installation HMI insterface TCI SMARTTOUCH V Communication system TCI ONLINE CAD/CAM Software Safety system / CE Marking 21 /03 INSTALLATION AND COMMISSIONING 22 /04 TRAINIG 24 /05 DOCUMENTATION 26 4

4 /06 TECHNICAL DATA General machine data Electricity Water connection Drainage Compressed air connection Clarification of the technical data 31 /07 BASIC OFFER 32 /08 OPTIONAL EQUIPMENT Height control system TCI SRA High pressure pump update KMT 50 HP 4100 bar 2L High pressure pump update KMT 60 HP 6200 bar Water treatment equipment TCI HIDROSYSTEM Sludge removal system TCI EXTRACTION SYSTEM Drilling system TCI DRILL Water cooling TCI CHILLER KIT TCI CUTTING 5XDD V4.0-5 Axis cutting head HD Plasma (High Definition) combined with Waterjet History Cutting methods Performance HD Plasma unit (High Definition) 130A HD Plasma unit (High Definition) 260A Software PROmanager: INDUSTRY /09 WARRANTY 46 /10 OFFER SUMMARY 48 /11 LAYOUT 50 5

5 /01 WATERJET TECHNOLOGY 6

6 /01.1 HISTORY During the first development of the waterjet technology, water was merely used for cleaning. In 1968, Dr. Norman Franz patented what would be the first intensifier used for waterjet cutting (700 bars). The subsidiary KMT (Karolin Machine Tool) developed the first intensifier to reach 4100 bars based on this patent. In 1971 the first intensifier of 4000 bars was developed. /01.2 OPERATION The operation principle starts with a primary circuit, which drives oil at a pressure of 200 bar thanks to a hydraulic pump. The oil is driven left and right in the cylinder by means of a four-way valve. This is how the movement of the piston is generated in the second circuit, the one corresponding to water. The corresponding inlet and outlet valves allow the water to fill and be expelled from the secondary circuit cylinders. A ratio of 20:1 between the surface of the hydraulic piston and the stem, achieves a water pressure of 4,000 bar. To reduce the pressures peaks when the piston changes direction, a pressure accumulator is installed. The cutting head is connected to the intensifier through rigid stainless steel tubing. Finally, a sapphire or diamond orifice is responsible for the conversion of pressure into a waterjet of great velocity (approximately 3000 km/h). The strength of the water and the abrasive is able to separate the material. The cutting head moves along the material following a series of instructions given by the control system to cut the required shape. The speed of the movement depends on a variety of factors, such as material, thickness, shape of the part, pump pressure and type of abrasive, among others. Controlling the speed of the cutting head is a crucial factor to achieve economical and efficient cutting. 7

7 /01.3 CUTTING METHODS Pure water cutting: Fabrics, elastomers, fibers, plastics, food, paper and other soft materials. Waterjet with abrasive cutting: For all the materials where pure waterjet cutting is limited, abrasive cutting is applied. The result is a jet of powerful energy, capable of cutting, separating or piercing materials of different thicknesses and density, such as metals, ceramics, natural stone or armored glass. /01.4 APPLICATIONS Waterjet cutting is the cutting technology with the most momentum in recent years, among other reasons due to the wide range of materials and thicknesses it covers. The sectors in which waterjet cutting technology is applied are: Aeronautics: alloys, insulators, carbon fiber, titanium. Food: chocolate, meat, fish, cakes. Automotive: alloys, rubber, composites, leather. Construction: rods and bars, ceramics, marble, beams. Toys: foams, synthetic fibers, polymers, polypropylene. Metallurgy: steel, stainless steel, alloy, brass. Furniture: glass, mirrors, wood, fabrics. Advertising: Plexiglas, polyethylene, PVC, vinyl 8

8 /01.5 TECHNOLOGICAL ADVANTAGES The advantages offered by water cutting technology are: Low cutting temperatures to prevent thermal alteration and residual tension. The most versatile cutting systems on the market today, covering the full range of materials and thicknesses, even painted surfaces. Clean cut without harmful atmospheres The cut surface neither cracks nor bends. Optimal utilization of raw material with negligible material loss Eliminates subsequent finishing processes. Ability to perform different types of cutting simultaneously Very strict tolerances. 9

9 /02 MACHINE DESCRIPTION 10

10 Waterjet cutting system TCI BP-C , equipped with a TCI 2.0 cutting head. System for feeding and dosage of abrasive independent and external from the cutting table. Feeding of the high-pressure water system by means of a high-pressure pump KMT 50 HP SL-VI 4100 bar. The Waterjet system is developed to cut with an abrasive waterjet for hard materials (steel, marble, aluminum, stainless, etc.) and with pure water for soft materials. The main characteristics of the TCI Cutting waterjet cutting system are: Highly dynamic machine. Direct external precision measurement on the motor. Absolute encoder. Stiffness: transmission of forces through stable elements of the construction. Safety: Category IV systems Economical: movement by axis (axis X and axis Y). Installation, startup and training in 7 days Optimal accessibility. Additionally, you benefit from the specific TCI Cutting characteristics: The machine is protected from vibrations. Easy programming with the CAD/CAM software. Optimal protection of the operator when accessing to the cutting zone. Easy to operate software TCI SMARTTOUCH V6.0. Automatic adoption of the travel and power according to the contour Intelligent trajectory control. Reduced drive costs thanks to the modern drive system. Technical and spare parts services worldwide. Direct contact with the manufacturer. 11

11 The TCI Cutting BP-C machine includes the following elements: Structure of the machine that includes the cutting table and a bridge with a cutting head for abrasive and pure water cutting. Complete numeric control unit TCI CNC 4.0, installed in a high-quality control cabinet with a new generation multi touch screen. Automatic abrasive feeder with 200L capacity. TCI ABRALINE 1.0 Automatic abrasive quantity regulator, independent for each cutting head, controlled from the design software. TCI ABRASIVE 3.0 Abrasive backstop system TCI CUT CONTROL 3.0 High pressure pump KMT of 50 HP SL-VI 4100 bar 1L Installation of high pressure tubes. Human machine interface TCI SMARTTOUCH V6.0 Communication system to communicate between the machine and TCI CAD/CAM software and Postprocessor Machine safety system. Declaration of conformity and CE marking. 12

12 /02.1 Cutting unit TCI BP-C The cutting system XY A frame built with structural steel profiles, for a working range of 4000mm in the x axix Water tank with material supports and water level regulation, constructed from stainless steel sheets. An axis with a guided system on a bridge independent from the cutting table (X axis) consisting of a set of high precision skates and guides. This system provides a reliable linear transport, ensures a high rigidity, a minimum of frictional resistance and a high load capacity. The entire assembly is driven by a rack system / Precision reducer, which guarantees maximum performance, which is connected to a brushless AC motor. The transverse linear axis (Y axis) mounted on the linear axis X uses the same system described in the previous point. A nozzle support head (Z axis) is provided with a vertical guide system. Includes automatic adjustment of cutting height. One long lasting nozzle, with orifice and pneumatic jet control valve. Control panel integrated in the control cabinet to manage the machine. Pushbuttons for autimatic operation with emergency stop. Technical specifications Number of cutting heads 1 Effective cutting range x axis mm Effective cutting range y axis mm Z axis travel 200 mm Maximum simultaneous positioning speed 85 m/min Maximum cutting speed 20 m/min Machine tolerance according to VDI/DGQ 3441 ±0,05 mm/m Repeatability precision ±0,025 mm/m Tank volume 8 m 3 Maximum supported weight for the workpiece 790 kg/m 2 13

13 /02.2 ELECTRIC AND CONTROL EQUIPEMNT TCI CNC 4.0 Electrical panel mounted in hermetic cabinet with internal ventilation system. The control and power circuits are fully protected by galvanic isolation. An industrial PC with multitouch display integrated in the control cabinet. This PC has the communication system installed with the machine control, as well as the WINDOWS 7 ULTIMATE operating system. The main characteristics of the numerical control are: Intelligent digital control of the machine axis regulation with optimized interpolation. Position limiting by software Absolute position registration Output of current value with absolute incremental position. Holding brake control integrated Automatic adaption of parameters Adjustable error handling Motor feedback for absolute position recording. Technical specifications. Connection with peripherals Ethernet Basic CNC working memory 60 MB Supply voltage 24 V RAM memory of the rack 128 MB RAM memory of the computer 4 GB Multitouch Screen 21 Processor Intel i5, 64 bits USB ports 2 14

14 /02.3 AUTONOMOUS ABRASIVE FEEDER TCI ABRALINE 1.0 This system is responsible for collecting the abrasive and storing it in its compressed air pressurizing tank, and pushes the sand to the metering hopper located in the cutting head. The abrasive transport system consists of: Collecting reservoir including sieve insert Pressure tank Control cabinet The abrasive material is poured into the collecting tank through the sieve insert and is stored in an intermediate manner. When the minimum filling level is reached, the conical seal between the collecting tank and the pressure vessel is opened for 15 seconds, controlled by the relay in the control cabinet. If the level in the collection tank drops to a minimum, a warning lamp indicates the need to add abrasive to the tank. This refilling can be done without interrupting the production in progress. Technical specifications. Net weight Length Width Height Storage deposit capacity Pressurized tank capacity Minimum working pressure Maximum working pressure Maximum compressed air consumption Maximum abrasive flow rate 80 kg 700 mm 700 mm 1400 mm 200 l 24 l 5 bar 7 bar 500 l/min gr/min 15

15 /02.4 ABRASIVE REGULATION TCI ABRASIVE 3.0 The automatic dosing of the amount of abrasive to the cutting process is done by means of a pressurizer located at the foot of the machine completely accessible by the user (see section 2.3). This pressurizer pneumatically sends the abrasive to an automatic regulation system, which is assigned a setpoint value from the design software which automatically dosages the amount of abrasive at all times through a real-time channel. This abrasive control system, together with the autonomous feeder, allows the automatic feeding of abrasive, facilitating the continuous and non-stop operation of the machine. Technical specifications. Maximum flow 600 gr/min Main voltage 24 VDC Control voltage 1.10 /02.5 ABRASIVE BACKSTOP SYSTEM. TCI CUT CONTROL 3.0 Abrasive backstop increases the autonomous operation of the machine. In case the nozzle is blocked, the system prevents water reaching the abrasive dosing system. 16

16 /02.6 ANTI-COLLISION SYSTEM TCI COLLISION PROTECTION 2.0 Electronic collision monitoring system for cutting heads. Upon detection of a determined force on the end of the cutting nozzle, the machine is stopped. The detection sensitivity regulation is programmable and easy to set up electronically. /02.7 HIGH PRESSURE PUMP KMT 50 HP 4100 bar 1L The high pressure is generated in the intensifier of the pump, actuated by an oil pump inside, and also the low water supply system. The latest generation of pumps offers the most advanced water jet technology with working pressures Up to 4100 bar The design with a single intensifier, which generates up to 4100 bar, reduces maintenance costs and offers a quieter operation and fewer spare parts. The longer and slower stroke of the ceramic plunger displaces more water in each movement and helps prolong the service life by reducing wear of the seals. The sensors, located before and after the booster pump, ensure a constant flow of water. In addition, electronic starter with frequency variation and the integrated air / oil cooler help to further reduce the fixed costs. The high-pressure pump is characterized by: Hydraulic pump of variable flow and compensated pressure High / low pressure selection that allows piercing Electrical inversion of the cutting head Noise level below 80dB Leakage detection in de high-pressure circuit Long lasting high pressure seals System to uninstall de piston without uninstalling the cylinder Air / oil heat exchanger 17

17 Technical specifications Nominal power Maximum working pressure Maximum flow Hydraulic tank capacity Pressure accumulator volume Water inlet pressure Nominal current Protection at 400 V / 50 Hz Noise level Length Width Height Weight 37 kw / 50 HP 4136 bar 4.1 L/min 211 L 1 L bar 72 A 80 A 76 db 1689 mm 1114 mm 1508 mm 1438 Kg Maximum number of nozzles for model with accumulator of 1 liter Orifice diameter Maximum number of nozzles 0,20 3 0,25 2 0,35 1 /02.8 HIGH PRESSURE INSTALLATION Complete installation of high-pressure tubing. 18

18 /02.9 HMI INTERFACE TCI SMARTTOUCH V6.0 The TCI SMARTTOUCH V6.0 software provides the user with a user friendly graphical interface to interact with the numerical control that controls the water cutting machines. It is a multi-user and multilanguage machine control software for simple and powerful machine management. It offers all the potential of machine management: regulation of machine parameters to optimize the final quality, control of the extraction system, control of height regulation, etc. In addition, it allows to visualize the cutting program at any time, moving, adding and eliminating pieces, performing cutting simulations, monitor performance and most important, direct communication of machine to our customer support. It includes a whole list of selectable materials that facilitates the cutting process: simply select material, thickness and characteristics of the high pressure to begin to perform the cutting operations. If new materials are used, they may be created directly for use in the future. 19

19 /02.10 COMMUNICATION SYSTEM TCI ONLINE The TCI SMARTTOUCH V6.0 is linked to a remote-control system, so the machine can be tested, reprogrammed and supported from the TCI technical department at our central offices. The remote-control system and the fault tracking device of the machine allow dealing with possible machine stops, that can occur both in the first few months after commissioning and later in the maintenance service. Very useful to avoid production stops and reduce technical assistance expenses. The remote control system allows the following operations Monitoring of water jet machine parameters and detection of errors and faults Read machine error reports Monitoring and calibration of the parameters of the drives. Monitoring of the PLC program and the functions of the machine by displaying the inputs and outputs. Reading, editing and writing of cutting programs. Updating software versions. Control of the parameters during the execution of a cutting program. Control, modification and updating of machine calibration. File transfer. Control and calibration of a spare part replaced by the customer, which allows the maintenance performed by less experienced personnel. /02.11 CAD/CAM SOFTWARE 20

20 CAD / CAM software prepared to generate cutting trajectories using the TCI Cutting Postprocessor included in the software. Ideally suited for waterjet cutting. The main characteristics are TCI Postprocessor. Definition of cut geometries (qualities, lead ins, curves, joints, bevel) Different letter fonts Automatic cutting sequence generation Common cut, using the cut between pieces Continuous cut, minimizing the number of perforations Cost calculation Path optimization Technology tables for materials and thicknesses Logbook File import DXF, DWG, etc. Work order management Management of pieces, sheets and rest material Manual and semi-automatic nesting and machining of parts Hardware and software requirements Processor Intel Core i5 or i7 or AMD Phenom II X4, 3.0 GHz or better 4 GB RAM memory. Screen resolution 1280x1024 pix. Operating system: Windows 7 or later. Administrator rights for installation Internet Explorer 7.x or later /02.12 SAFETY SYSTEM / CE MARKING Conformity and certification of the machine. CE Marking Certificate for TCI Cutting System BP-C Our machines comply with the safety regulations for industrial machinery if they are installed and used with the safety equipment included in the installation of the machine. 21

21 /03 INSTALLATION AND COMMISSIONING 22

22 Installation period: During the installation period, until the end of the training of the operators, the system is available for TCI Cutting staff. Production will start after the completion of these activities. The installation of the system (according to the signed layout) and the commissioning will be carried out by the TCI Cutting staff. Included in the price are travel, accommodation and daily allowance costs for service technicians. For training and familiarization with the system, it is recommended that the machine operator and maintenance personnel of the customer are present during installation. The customer is responsible for: Unloading the machine at its location. Site preparation according to the design plan. Cranes and lifting equipment required for unloading, installation and maintenance. Provide electrical power, frequency, voltage, tolerances and fuses in accordance with the Technical Data. Provide sewage and water connections in accordance with the Technical Data Provide dry, oil-free and dust-free compressed air, in accordance with the Technical Data. Provide an adequate installation area: solid industrial floor, as free as possible from vibrations. Absence of obstacles that could impede access and restrict installation. Provide appropriate material (quality and quantity) to be cut for test purposes and during acceptance. The acceptance includes: Tests of operation of the parts of the system according to the supply. Cutting of pieces as established in the protocol of acceptance or according to the agreement in writing. 23

23 /04 TRAINING 24

24 The training is for: technicians and machine operators. TCI Cutting offers the following training for the end user: In the training center of TCI Cutting and prior to the installation of the waterjet cutting machine CAD/CAM training High pressure and maintenance training Machine operation and software operation for TCI SMARTTOUCH V6.0 On site at the customer Machine operation and software operation for TCI SMARTTOUCH V6.0 Operation and control of the high-pressure pump Machine maintenance 25

25 /05 DOCUMENTATION 26

26 The following documentation is supplied with the machine: Two copies of the Machine Manual CE conformity declaration Delivery protocol Installation plans Electrical schematics Operating manual for the machine and HMI software TCI SMARTTOUCH V6.0 Operating manual for the CAD/CAM software Preventive maintenance plan Suppliers documentation 27

27 /06 TECHNICAL DATA 28

28 /06.1 GENERAL MACHINE DATA Maximum load of the material 790 Kg/m 2 Number of cutting heads 1 Working area Machine tolerance according to VDI/DGQ 3441 Repeatability Minimum speed 4000 x 2000 mm ± 0.05 mm/m ± mm m/min X axis Y axis Z axis Useful travel Maximum positioning speed Useful travel Maximum positioning speed Useful travel Maximum positioning speed 4000 mm 60 m/min 2000 mm 60 m/min 200 mm 15 m/min Maximum material thickness Steel Stainless Steel Aluminium Glass PVC 200 mm 150 mm 120 mm 100 mm 150 mm 29

29 /06.2 ELECTRICITY Machine Connection Nominal power consumption of the pump Nominal power consumption of the motors Nominal power consumption of the chiller (optional) Nominal power consumption of the plasma (optional) Total nominal power consumption Protection at 400 V / 50 Hz Ground resistance Line protection switch with ma and time regulation Connection Internet/Ethernet 3 x 400 V + PE 37 kw 10 kw 6,6 kw 19,5 (130 A) kw // 45,5 (260 A) kw According to configuration 100 A 4 Ohms Magneto-thermal with adjustable RJ45 The electrical installation of the machine must be performed by an authorized installer fulfilling the national, regional or local regulations. The operating voltage and the maximum amperage must meet the requirements of the specific machine model (section technical data) and the electrical circuit that supplies must be serparate, equipped with magnetic protection and Industrial differential (adjustable sensitivity and time 300mA and 0.5s). The cable section of the circuit must be able to withstand the maximum permissible current according to low voltage electrotechnical regulations. Voltage fluctuations +/- 10% over the nominal voltage can cause damage to the machine and therefore void the warranty. /06.3 WATER CONNECTION PUMP KMT 50 HP 4100 bar 1L Inlet connection Inlet pressure Minimum flow 1/2 inch NPT bar 16.5 L/min All water connections should be where they are indicated in layout. All water connections should have their own water tap, installed by the client. If there is no chiller, it s necessary to install a water tap (by the client), to cool with tap water and to connect the outlet to the drainage. 30

30 /06.4 DRAINAGE It should be created using drainage pipes with 110 mm diameter or more (the general drainage pipe), also it should have accessible points in order to clean it when necessary. Installation should be done by the client and according to the layout. Pump zone, connections ½ inch, 22 mm diameter pipe. Machine drainage connection 1 ½ inch, 40mm diameter pipe. (see layout). Hidrosystem zone, connections ½ inch, 22 mm diameter pipe. /06.5 COMPRESSED AIR CONNECTION Compressed air installation should have atmosphere filters. Compressed air should be humidity free, and compressor should have a dryer system Characteristics Technical data of machine/pump Minimum inlet pressure 6 bar Connection ½ inch Minimum consumption 500 l/min Compressed air temperature 5ºC 40ºC Ambient temperature 2ºC 40ºC /06.6 CLARIFICATION OF THE TECHNICAL DATA The technical data described in this offer are PRELIMINAIRY and STANDARD for the TCI BP-C The final configuration created by the customer, as well as the distribution and implementation design of the machine for the installation of the machine on site at the customer can change this data. The final and definitive TECHNICAL DATA the customer needs to use for the installation will be provided after the purchase of the machine by the engineering department of TCI cutting. 31

31 /07 BASIC OFFER 32

32 BP-C Cutting machine with: 1 Table XY with 1 cutting head 4000x2000 mm working area 1 Long lasting nozzle 1 Computerized Numerical Control: TCI CNC Autonomous abrasive feeder. TCI ABRALINE Automatic abrasive regulation. TCI ABRASIVE Abrasive backstop system TCI CUT CONTROL High pressure pump KMT 50 HP SL-VI 4100 bar. 1L 1 High pressure tubing installation 1 HMI Software TCI SMARTTOUCH V6.0 1 Communication system TCI ONLINE 1 CAD/CAM software and postprocessor for the toolpath generation Cutting technology software Machine sparepart software Safety system and CE marking 33

33 /08 OPTIONAL EQUIPMENT 34

34 /08.1 HEIGHT CONTROL SYSTEM TCI SRA 3.0 Electronic height adjustment system for the cutting head, which guarantees the constant distance between the nozzle and the cutting material, offering the possibility of cutting materials with uneven surfaces. The system has several configuration options for the regulation: by distance, drilling, time or continuous. /08.2 HIGH PRESSURE PUMP UPDATE KMT 50 HP 4100 bar 2L Technical specifications Nominal power Maximum working pressure Maximum flow Hydraulic tank capacity Accumulator capacity Water inlet pressure Nominal current Circuit breaker at 400 V / 50 Hz Noise level Length Width Height Weight 37 kw / 50 HP 4136 bar 4.1 L/min 211 L 2 L bar 72 A 80 A 76 db 1689 mm 1114 mm 1508 mm 1438 Kg 35

35 Maximum number of nozzles for model with accumulator of 2 liter Orifice diameter Maximum number of nozzles 0,20 3 0,23 2 0,33 1 /08.3 HIGH PRESSURE PUMP UPDATE KMT 60 HP 6200 bar The latest generation of pumps offers the most advanced waterjet technology with working pressures up to 6200 bar. The design with a single intensifier, which generates up to 6200 bar, reduces maintenance costs and offers a quieter operation and fewer spare parts. The longer and slower stroke of the ceramic plunger displaces more water in each movement and helps prolong the service life by reducing wear of the seals. The sensors located before and after the booster pump ensure that the water flow is constant and adequate. A particularly important precaution to protect, above all, the components of the high-pressure section. 36

36 Technical specifications Nominal power Working pressure Maximum flow at maximum pressure Nominal current at 400V/50Hz Protection at 400 V/ 50 Hz Water inlet pressure Hydraulic tank capacity Length Width Height Weight 60 HP / 45 kw bar 2,8 l/min 66 A 80 A 2,4-5,5 bar 211 l mm mm mm kg /08.4 WATER TREATMENT EQUIPMENT TCI HIDROSYSTEM 2.0 This unit will condition the incoming water to the intensifier, removing lime from the water. It is highly recommended to install it to ensure filtration and decalcification of the water used for cutting, prolonging the life of all the high-pressure components. /08.5 SLUDGE REMOVAL SYSTEM TCI EXTRACTION SYSTEM 2.0 This system removes the residual sludge from the used abrasive found in the bottom of the tank, separating it from the water and recirculating the water to the tank to maintain the constant level. It allows the customer to keep the cutting machine in operation and prevents machine stops for cleaning the tank. This system guarantees the extraction without moving parts inside the tank. It includes the extraction system and a collection container, which filters the elements and ensures the proper operation of the system The sludge removal system will be controlled from the cutting machine control panel. 37

37 /08.6 DRILLING SYSTEM TCI DRILL 2.0 Equipment developed to realize mechanical drilling in fragile materials and multi laminated composits. Different drill diameters can be mounted. It is also possible to mount another tool such as a countersink, a threading screw, etc. Technical specifications Maximum speed in rpm Speed in rpm at maximum power Maximum torque Nm Startup torque Nm Power Drill size 930 rpm 430 rpm 6,3 N m 12,6 N m 285 W 0-8 mm /08.7 WATER COOLING TCI CHILLER The hydraulic oil cooling system for intensifier pumps with a closed water circuit is optimal for warm regions, as it allows to maintain the correct operating temperature even in the summer months. It also eliminates the cost of cooling water since it is a closed circuit which, cools the water with a gas and recirculates constantly. 38

38 /08.8 KIT TCI CUTTING 5XDD V4.0 5 AXIS CUTTING HEAD The 3D cutter head has five axes, 3 linear and 2 rotating. It has been designed for both pure 3D cut and 2D 1/2 cut (flat cut with bevel), without losing 2D (flat) cut functionality. Its design features offer great work possibilities. Especially its infinite rotation in the C axis, which avoids the need to rewind with a consequent reduction in working times and a lower risk of reducing the cut quality. On the rotating frame of the C-axis, it is possible to connect the height adjustment and anti-collision control module. Due to the configuration of the axes, it is possible to reach any position and / or orientation of the nozzle keeping the focal point constant, which allows the cutting of parts in 3D. The orientation of the spindle is software limited from -60º to 60º, a limitation that can be extended up to -90º and 90º, as long as an adequate user protection system is ensured in compliance with current machine safety regulations. 39

39 It is also possible to eliminate the taper of the pieces, by means of a TCI JET CONTROL1.0 with a tangential cutting function using the 5-axis, that has been programmed in the CNC. Technical specifications Maximum material load 790 Kg/m 2 Number of cutting heads 1 Working area Z axis travel 4000 x 2000 mm 200 mm 5 axis cutting head C axis Effective range Infinite Max positioning speed 300 min -1 A axis Effective range ± 60º Max positioning speed 500 min -1 Clarification on the sound level reached with the use of this cutting head The noise level generated by the machine has been set at 85 db at a distance of one meter during cutting 10 mm material with one cutting head with a nozzle diameter of 0.30 mm and submerged cutting. Note: This level can vary considerably and exceed the set level (85 db) depending on the cutting conditions and the shape of the pieces when cutting. Therefore, it is necessary that the client / user equips workstations around the machine with the necessary equipment (protective cells, ear protection for operators...) depending on the actual noise. 40

40 /08.9 HD Plasma (High Definition) combined with Waterjet The combination of HD plasma (high definition) with waterjet technology, makes it possible to combine speed and cutting quality, essential requirements to be competitive. / History During the initial developmental stageof this technology, the United States defence industry discovered a new welding technique whilst researching better ways of joining metals together. This process, usually referred to as TIG or GTAW welding, involves feeding an inert gas through an electric arc. From 1941, when it was discovered, up to the present day, technology has continued to advance with the development of submerged plasma cutting, thus expanding the cutting performance or enabling cutting without dross, whilst at the same time continuing to increase cutting performance. / Cutting methods Transferred arco / Non-transferred arc: This is generally the most utilised method as the pre-heating of the material facilitates the fusion process. Dry method: various options: - Without supply gas: a single gas is used to heat and melt the work piece - With protective gas: this is injected around the nozzle of the conventional manner, crating an area which restricts the projection of ionized gas and also keeps it clean - Air as plasma gas: this promotes oxidation of the material and an exothermic reaction which also generally favors the process. With water: - Water protected arc, instead of using the protective gas on the outside of the nozzle, water injected under pressure is used which favors cooling of the nozzle, a part that suffers quite a lot during the process due to the high temperatures. The water also ensures that this area is clean by raising the quality of the cut, and restricts the temperature in the cutting area improving the speed. - Submerged arc: this reduces the noise level and the ultraviolet radiation and prevents the formation of fumes and gases. The speed is redued by 10%. There is a danger of small explosions: these are caused by the hydrogen generated when the work piece is totally submerged when it can become dissociated from the water, the oxygen escapes through the melted material and the hydrogen is then deposited mainly under the sheet. To avoid this, the water must be kept in constant agitation. 41

41 High definition The aim of the process is to produce a very high energy density. The energy density reflects the intensity of the current per square centimetre and the objective of the process is for the density to become much greater than when using any other conventional type of plasma cutting technique. This process can achieve a density three times greater, in the order of 6000 or 9000 amps per square centimetre, thus accelerating the cutting speed. This process competes with that of the laser for cutting relatively reduced thicknesses, both in terms of speed and cutting quality. / Performance This process is also thermally based and for this reason, when the objective is fusion of the material, the aim is to reach the ideal temperature to enable it to melt and by means of the generated gas flow to heat the work piece; the melted material is then expelled, thus cutting and advancing. Many technical references, refer to plasma as the fourth stage of matter; however, plasma is simply an ionized gas; in other words, it conducts electricity and is therefore capable of reaching a very high temperature, to a degree high enough to melt a work piece when projected onto it. Electrode Plasma gas ELECTRICITY Pression gas Ionize gas Plasma arc Nozzle NOZZLE MELTING Ionize gas (V (300 m/s) + + T ( ºC) Metal to cut CAST METAL EXPULSION / HD Plasma unit (high definition) 130A The plasma generator and the automatic console have a continuous amperage rating of 130 A. It consists of: A gas inlet and distribution console and wiring to the machine. Water cooled torch in closed circuit with a working pressure of 8.3 bar, marking of the part with the same torch. 42

42 Main features and cutting capabilities: Material Maximum thickness high quality Maximum thickness for cutting Steel 25 mm 38 mm Stainless 20 mm 25 mm Aluminum 20 mm 25 mm Material Steel Stainless steel up to 10 mm Acero Inoxidable > 10 mm Aluminum up to 6 mm Aluminum > 6 mm Gases to use Oxygen and compressed air F5 and nitrogen H35 and nitrogen Air - air H35 and nitrogen Specifications HyPerformance plasma HPR130XD Auto Gas Maximum Open Circuit Voltage Maximum Output Current Output Voltage 311 V DC 130 A V DC Nominal duty cycle 100% with 19,5 kw and 40 ºC Ambient temperature range for work cycle Between -10 ºC and +40 ºC Power Factor 0.88 with 130 A of DC output Cooling Forced air (Class F) Isolation Dimensions Weight Class H 1080 x 968 x 567 mm ca. 317,5 kg / HD Plasma unit (high definition) 260A The plasma generator and the automatic console have a continuous amperage rating of 260 A. It consists of: A gas inlet and distribution console and wiring to the machine. Water cooled torch in closed circuit with a working pressure of 8.3 bar, marking of the part with the same torch. 43

43 Main features and cutting capabilities: Material Maximum thickness high quality Maximum thickness for cutting Steel 34 mm 64 mm Stainless 32 mm 50 mm Aluminum 25 mm 50 mm Material Steel Stainless steel up to 10 mm Stainless steel > 10 mm Aluminum up to 20 mm Aluminum > 20 mm Gases to use Oxygen and compressed air F5 and nitrogen H35 and nitrogen Air - air H35 and nitrogen Specifications HyPerformance plasma HPR260XD Auto Gas Maximum Open Circuit Voltage Maximum Output Current Output Voltage 311 DC 260 A V DC Nominal duty cycle 100% with 45,5 kw and 40 ºC Ambient temperature range for work cycle Between -10 ºC and +40 ºC Power Factor 0.98 with 260 A of DC output Cooling Forced air (Class F) Isolation Dimensions Weight Class H 1181 x 1143 x 803 mm ca. 554,7 kg 44

44 BP-C /08.10 Software PROmanager: INDUSTRY 4.0 PROmanager, the ERP from TCI Cutting. TCI Cutting in its process of innovation and optimization, has created PROmanager. A powerful software that makes INDUSTRY 4.0 a reality. PROmanager brings together all the information a company needs, from employees to processing of materials, stock and shipping. PROmanager digitally connect with all the elements of the company, collecting and sending data and information with a single purpose, the control and optimization of each process. Thus reaching a greater profitability of the company. 45

45 Headquarters: C/ Colón, GUADASSUAR (VALENCIA) SPAIN Telf: Fax: Cutting.com

46 TÄGLICH AKTUALISIERTE LAGERLISTE UNTER Vertrauen Sie auf über 70 Jahre Erfahrung! Die Firma HESSE+CO wurde 1947 als Hersteller von Blechbearbeitungsmaschinen gegründet. Seit 1980 sind wir auf den Handel mit neuen sowie gebrauchten Blechbearbeitungs- und Werkzeugmaschinen spezialisiert. Wir haben ständig etwa 300 Maschinen in unserer m² großen Ausstellungshalle, die nur 20 Minuten vom internationalen Flughafen Wien entfernt ist. Trust in more than 70 years of experience! HESSE+CO was established in 1947 as a manufacturer of sheet metal working machines. Since 1980 we are specialized in dealing with new and second hand sheet metal processing machines and machine tools. We always have approximately 300 machines available in our m² showroom, which is located only 20 minutes from the Vienna International Airport, waiting for your inspection. Ihr Partner seit 1947 Öffnungszeiten: Mo - Do Fr 8:00-16:30 Uhr 8:00-14:30 Uhr HESSE+CO Maschinenfabrik GmbH Industriezentrum NÖ-Süd Straße 4 - Objekt 8 A-2351 Wiener Neudorf AUSTRIA Technische Änderungen, Irrtum und Druckfehler vorbehalten. Gültig bis auf Widerruf. Tel.: +43/2236/ Fax: +43/2236/ office@hesse-maschinen.com