Plasmasonic J o u r n a l

Plasmasonic J o u r n a l P r e s e n t e d b y KAAST. Your Production Partner! ry o t s er Cov tting Edition 1 cu e l g n A head Insights Workpieces Te c h n o l o g y

Content Introduction Introduction Page 03 Cover story Angle cutting head Page 04 Plasmasonic CNC Plasma- and flame cutting system Cut sheets or pipes, chamfer, mark and perforate All in one with an outstanding price/performance ratio* Control Page 06 Plasmasonic series meets the highest standards of productivity, reliability and automation. Through advanced CNC control, with automatic addressing of the parameter database, various technologies, such as Plasma or flame cutting / gas cutting in conjunction with pipe cutting and weld preparation are combined. Plasma technology Page 07 Wear parts Page 09 Customer reports Page 10 Workpieces Page 11 2 Plasmasonic Journal Presented by KAAST. Your Production Partner! 3

Cover story Plasma cutting Kaast offers the five-axis-plasma cutting system Plasmasonic, one of the most compact machines in its class which has been designed for flexible chamfers for faster weld This property makes it superior to the classical three-axis and provides a distinct competitive advantage. Feasible chamfer types include Y-, V- and X-notch and bevel-square-bevel, and the adjustment of the chamfers where plates of different thicknesses join. Technical features facilitate the weld preparation via plasma cutting. Thanks to the following features the weld preparation for the user is much easier with plasma cutting: The design of the system ensures its smooth operation, even under tough conditions; A magnetic holder of the cutting head allows rapid change and in the case of collision avoids damage to the cutting head; Multiple plasma and oxy-acetylene cutting heads are optional. The preparation in steel construction. The special feature is the possibility that the cutting head can change its angle of attack within a contour, so different chamfer types can arise during the process. controller allows the use of up to 4 cutting head-carriers (plasma and oxy-acetylene cutting heads with independent height adjustment), in any combination; Dual AC-Servo motors precisely drive the bridge from both sides, which means no lag error; User-friendly control panel allows not only the motors but also the source of power, suction and filtration systems to be monitored centrally. With the plasma cutting machine equipped with precision fine beam plasma generators, it combines the highest cutting quality with maintenance. The fine-beam generators PP (Precision Plasma) ensure very fast piercing and high cutting speeds, with an unusually clean and almost perfectly square cutting edge; The technique is deemed to be future-proof and provides sufficient reserve in terms of cutting performance, in order to cover a wide range of applications. Available with four or five-axis for bevel cutting Spare and wear parts for plasma cutting system available within 24 hours. The conventional weld preparation is extremely labor intensive and is one of the biggest time devourers in the steel and metal construction, explains Benjamin Kaehlcke, the managing director of Kaast. Plasmasonic achieves a tangible time and therefore cost advantage in comparison to competitors because the investment can be amortized quickly. Another advantage which is reflected in the price-performance ratio, is the philosophy of the manufacturer: a high degree of vertical integration. Tables, motors, software, control and generators are manufactured in the same factory. The in-house with variable chamfer geometry development ensures perfectly matched components and makes them available on short call. Kaast guarantees the shipment of spare and wear parts usually within 24 hours. The positioning speed is 15.000 mm/min. The repeatability accuracy is ±0,05 mm and the positioning accuracy ±0,01 mm. Almost all plasma cutting systems are supplied with 260 Amp plasma sources. Currently 40 machines per month are leaving the production halls on which the manufacturer is giving a warranty of two years or 4000 operating hours. There also is the possibility of an optional warranty up to three years or 6000 operating hours. Almost all plasma cutting systems are supplied with 260 Amp high-definition plasma sources. These provide the optimum balance between cutting performance and power usage/costs. The technique is deemed to be future-proof and provides sufficient reserve in terms of cutting performance, in order to cover a wide range of applications. Most features are included as standard such as an automatic gas mixing console, integrated marking system, CAD/CAM unit, integrated fully automatic nesting software and effective exhaust and filter unit. The following options are available for the plasma generator: The beginner model P 100 with manual gas mixing console provides a low-budget model with cutting capacity up to 10 mm in mild steel. The two sources with either 130 or 260 ampere max cutting current are much more popular, especially the 260 because of the low option cost over the 130. Both are equipped as standard with the automatic gas mixing console which provides faster and more accurate adjusting of the system to the specific cutting job. The complicated and error-prone tuning of the individual gases to its application is totally eliminated with this solution thus the service life for wear parts in extended. The PP130 and PP260 will cut 16 mm and 30 mm respectively in low carbon steel and 12 mm or 20 mm in stainless steel. The piercing thickness is up to 35 mm and 20 mm for the PP130 and, depending to the type of steel, 65 mm or 36 mm for the PP260. For plasma cutting you can use oxygen, air, nitrogen or H35. Oxygen and propane are used by the optional oxy-fuel cutting technology for cutting thicker material. Optional are oxygen welding heads, an automatic pipe and profile cutter and multi plasma cutting heads and bridge unit. With the newly developed five-axis cutting head the user is well prepared for the modern requirements of the plasma cutting business. 4 Plasmasonic Journal Presented by KAAST. Your Production Partner! 5

Technology CNC control Plasmasonic Your Production Partner! Machining sizes of 1,5 x 3 m, 3 x 12 m, 4 x 16 m or 5 x 12 m are standard sizes Industrial PC, USB port, CD drive, 80 GB hard drive, TFT Screen Easy integration into existing network through integrated network card CNC files can be imported in the following formats: ISO ESSI, G codes, DXF Extensive cutting parameter library Automatic setting of process parameters by the CNC (Included: gas mixture, gas pressure, regulation of cutting current, selection of feed rates, indication of nozzle / cap combination) Fast switching of the cutting process from plasma to oxy-fuel cutting and back An NC program can be stopped at any point and then resumed from that point Override function during processing, in both automatic as well as manual mode Part rotation Automatic workpiece orientation Automatic adjustment of the cutting gap All relevant machine data and statuses are displayed at one glance Integrated standard parts library Editing and designing parts in the integrated CAD / CAM program Automatic nesting software High-speed operation Automatic look-ahead and feed regulation for tight radii Autonest program is included in the standard software package for optimal sheet usage Programmable microwebs ISO 9013 Range 3 ISO 9013 Range 4 ISO 9013 Range 5 10 mm Angle: 2.86 10 mm Angle: 5.71 10 mm Angle: 8.81 12 mm Angle: 2.48 12 mm Angle: 4.95 12 mm Angle: 7.68 20 mm Angle: 1.71 20 mm Angle: 3.43 20 mm Angle: 5.42 Standard configuration: 4 Solid, welded, high quality steel frame 4 Automatic gas and air pressure adjustment for plasma and oxy-fuel cutting is done in a control unit (only for PP130 and РР260) 4 Hand operating unit (allows parameter changes while cutting) 4 Automatic height control of plasma and oxy 4 Exhaust and particulate filter unit 4 Automatic marking for marking of workpieces (PP130 plasma source РР260) 4 Ergonomic control panel for the central control of all machine components or areas 4 Robust, stand-alone table with sectional extraction 30 1.71 30 30 3.43 5.42 28.8 27.6 26.2 4 Import of DIN / ISO G, DXF, ESSI files possible 4 Integrated CAD program to create geometric part contours directly in the system 4 Integrated fully automatic nesting software 4 Recovery function to restore cutting operation from the point of interruption after a power failure or deliberate shutdown of the system 4 Function for automatic process shutdown in case of electrode and nozzle break 4 Look-ahead function to control the dynamics in cutting tight radii and corners 4 Manual 20 Cylinder Pipe on flat surface Two pipes elbow Right angle connection Technical Specifications Plasmasonic 3015 4020 6020 12030 Table length 3000 mm 4000 mm 6000 mm 12000 mm Table width 2000 mm 2000 mm 2000 mm 3000 mm Cutting speed 7500 mm/min 9800 mm/min Positioning speed 15000 mm/min Repeatability accuracy ±0.05 mm Positioning accuracy ±0.1 mm Y shape Multiple pipes Different angle Cone connection elbow with offset Axial pipes Radial pipe Expert connection connections Connections Technical Specification of the Plasma generators P100 P200 PP130 PP260 Low-carbon steels Cutting thickness 10 mm 20 mm 16 mm 30 mm Max. piercing thickness 15 mm 25 mm 25 mm 36 mm Max. thickness (non-piercing) 20 mm 45 mm 35 mm 65 mm Stainless steels Cutting thickness 8 mm 15 mm 12 mm 20 mm Max. piercing thickness 12 mm 20 mm 20 mm 36 mm Max. thickness (non-piercing) 15 mm 38 mm 25 mm 65 mm Control of gas pressure during cutting Semi-automatic Semi-automatic Automatic Automatic Gases used (plasma cutting) Air Air Oxygen, air, nitrogen, Oxygen, air, nitrogen, F5, H35 F5, H35 Gases used (oxy-fuel) Oxygen, propane Oxygen, propane Oxygen, propane Oxygen, propane 6 Plasmasonic Journal Presented by KAAST. Your Production Partner! 7

Technology Proven 1000 times! Plasmasonic Technology that convinces all over the world for years Plasma cutting machines which are equipped with fine beam plasma generators are in use by hundreds of customers every day tough production conditions. They guarantee very fast piercing and high cutting speeds with an unusually clean and near perfectly perpendicular cutting edge. Our machines are delivered with an automatic CNC controlled gas mixing console, cutting table with sectional suction, suction unit and particulate filter system. Options for pipe cutting system and oxy-fuel are available. In addition, the flat bed machines can be combined with a pipe cutting system available with 4 axes or with a bevel cutting unit to provide up to 5 axes. Proven technology from one of the market leader! Thousands of installations worldwide! Unbeatable price/ performance ratio! Rigid and stable bridge construction for permanent use under tough production conditions! Driven both sides to avoid lag errors. Low consumable prices with proven long life Plasma torch Nozzle Electrode Stärke-Geschwindigkeits-Diagramm Main Body 17 Motorised turnable and manual swivable plasma torch for bevel cuts up to 45 Pipe cutting system Shield 6000 Cap Schneidgeschwindigkeit mm/min. 7200 6800 6400 5600 5200 4800 4400 4000 3600 No. 3200 Part name 1 2800 Shield cap 2400 2 Shield 2000 3 1600 Gas ring 4 1200 Nozzle 800 5 Swirl ring 400 6 Elektrod 0 7 Water tube 8 Nozzle body 9 Main body Shield Gas Ring No. Part name 10 Main water tube 11 Water return 12 Ohmic contact tip 13 Plasma gas 14 Nozzle contact tip 15 Shield gas 16 Aluminium pipe Stärke 17 mm Screening / Normalstahl holder Gas Diffusor 130 Ampere 260 Ampere 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 10 11 12 13 14 15 16 7 6 5 4 A 965 1030 Thickness-Speed-Diagram 9 3 2 Plasma generator 260 7200 6800 6400 6000 130 ampere 8 1 Maximum open circuit voltage (OCV) Maximum output current Maximum output voltage Maximum power 310 VDC 260 Ampere 200 VDC 52 kw Power factor (cosφ) 0.85 Cooling type Weight Compressed air 530 kg 1700 1960 Cutting speed mm/min. 5600 5200 4800 4400 4000 3600 3200 2800 2400 2000 1600 1200 800 400 0 260 ampere 0 5 10 15 20 25 30 35 40 45 50 55 60 65 70 75 80 PIERCING NUMBER 2000 1500 1000 500 F:2100 mm/min. Sheet Thickness: 20 mm ISO 9013 RANGE 4 RANGE 3 260 REQUIRED CUTTING QUALITY F:2100 mm/min. Sheet Thickness: 20 mm 260 Ampere 300 900 CUTTING LENGTH (m) 100 200 300 400 500 600 700 800 900 CUTTING LENGTH (m) 860 930 Thickness mm / mild steel PP260 Electrode and Nozzle Required Life Time Chart 8 Plasmasonic Journal Presented by KAAST. Your Production Partner! 9

Service Service plus at KAAST Reliable service and satisfied customers At KAAST the result of our commitment to service is our long-term customer loyalty. To realize this, it is not enogh to offer a good and reliable service. According to managing xdirector Benjamin Kaehlcke it needs more. The company has to pay full attention to the customer and his needs. specialized at building construction and scaffolding. The company, located in Breese, attaches great importance to flexibility and quality. The company offers their customers everything from one source and accepts responsibility for the planning, drawing, delivery, installation and final inspection. Both companies praise the fast service of KAAST. If a technical problem occurs, a service technician is coming from Neumünster the next day and clarifies all questions. Interested companies can visit these or other reference customers, to see for themselves the capabilities of these machines. 60 mm St37 steel Sample tube cutting unit with standard cutting software Employees of KAAST visit their customers regularly. This is important to demonstrate to the customer that KAAST is not going to sell a machine and forget them, but is working on an intensive and long-term partnership from which both parties profit. This also provides us with valuable customer feedback which allow us to react to market trends. The company Eurostahl Prignitz is a medium-sized company in the steel construction industry and is The payback-period was just 1 year! assures Jens-Peter Gorski. Since 2010 Eurostahl Prignitz has utalized a Plasmasonic from KAAST and is a strong reference customer of plasma cutting machines in Germany. The managing director, Jens-Peter Gorski, is very satisfied with the machine. It was the best investment his company has made since its founding. The payback-period was just 1 year, assures Jens-Peter Gorski. And he is enthusiastic about the durability of the consumables. This is another advantage of the Plasmasonic series, in addition to continuously good cutting results. High Precision drilling in 4 mm St37 steel Various patterns 0.8 mm stainless steel Bevel in 12 mm St37 steel The Plasmasonic in action at the company Eurostahl Prignitz. Since 2010 Eurostahl Prignitz is in possession of a Plasmasonic from KAAST. And also is a reference customer of the Plasma cutting system in Germany. KAAST worldwide sales network Technical manager Klaube (left) und KAAST managing director Benjamin Kaehlcke (right) check the cutting results. Company Gosag in Klostermansfeld, Germany The company Gosag in Klostermannsfeld is focused on steel and plant construction, enameling and sand blasting systems, residential and functional buildings, and deburring technology. Gosag also uses a cutting system from the Plasmasonic series and is an official reference customer. Mr. Klaube, technical manager of Gosag, is very satisfied.the Plasmasonic with a working area of 4x2 has been in production at the company in Klostermannsfeld for one year. KAAST Headquarters in Neumünster, Germany 10 Plasmasonic Journal Presented by KAAST. Your Production Partner! 11

Plasmasonic CNC Plasma- and flame cutting system b y K A A S T The Innovation in Plasma cutting Technical specifications Table length Table width Cutting speed Positioning speed Repeatability accuracy Positioning accuracy bis zu 40.000 mm bis zu 4.000 mm bis zu 9800 mm/min 15.000 mm/min ±0.05 mm ±0.1 mm already from 49.000, * * All shown prices are on EXW KAAST stock basis without VAT. Product offers are not binding. The above specifications are subject to change without prior notice, no liability for mistakes. Machines may be shown with optional equipment. KAAST Werkzeugmaschinen GmbH Gadelander Straße 172 24539 Neumünster Phone: +49 (0) 4321-25 20 03-0 Fax: +49 (0) 4321-25 20 03-90 E-Mail: info@kaast.de www.kaast.de