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Bystronic Releases BySmart Fiber In 4020 Format

Bystronic Releases BySmart Fiber In 4020 Format

Bystronic is now producing its BySmart Fiber laser cutting system in the 4020 format, with a capability of up to 6kW laser power and the option to add compatible automation solutions. With the larger format, users can now process sheet metal of up to 4×2 metres on the BySmart Fiber. This increases the productivity of the machine because cut parts can be nested more efficiently on large-format sheet metal and raw material waste is reduced. The larger machine format offers an ideal opportunity to rise above the competition when vying for cutting orders.

Depending on the production spectrum and customer wishes, the BySmart Fiber 4020 is available for selection with varying laser power levels of 3, 4, and 6kW. With the 6kW power level, users increase their cutting speed to the maximum. For example, up to 60 percent in thin 3mm stainless steel compared to a fibre laser power of 4kW. It boasts an even bigger performance advantage over 6kW CO2 lasers. Here, the BySmart Fiber with 6kW goes through thin 3mm stainless steel two-and-a-half times faster. In doing so, the parts output is increased up to 250 percent, depending on material and sheet thickness.

For an expanded application spectrum reaching into high material thicknesses, Bystronic offers the Power Cut Fiber function in the BySmart Fiber’s basic package starting with a laser power of 6kW. Thus, users achieve particularly fine cutting quality in material thicknesses of up to 30mm. This opens up additional possibilities for cutting orders in thick material, in which the visual appearance of cut parts plays an important role.

Bystronic is also opening the BySmart Fiber 4020 for connection to versatile automation solutions—enabling users to increase the utilisation of the laser cutting system to the maximum and reduce time-consuming material handling. Both lead to cutting orders being carried out faster and at a lower cost.

The loading and unloading solutions ByTrans Cross 4020, BySort, ByTrans 4020, ByTrans Extended 4020, and Byloader 4020 are available for selection. But automation solutions from other providers can also be connected. The Bystronic systems fully or partially automate organisation of material flow depending on the order situation, and additionally offer sufficient free space around the laser cutting system for manually processing smaller orders at any time.

 

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Sustainable Manufacturing Thanks To Fiber Lasers And Automation

Sustainable Manufacturing Thanks To Fiber Lasers And Automation

A fiber laser cutting system, a matching automation solution, and innovative software enable companies to increase their productivity while simultaneously saving energy. The Haslach Group, based in the Allgäu region in Germany, shows how this can be done.

Twice the output for the cutting process with the same electricity consumption – fiber lasers are considerably more efficient than CO2 lasers. This saves resources while simultaneously increasing output. And this is why the transition was an obvious step for the Haslach Group: “We want to be able to fulfil our customers’ increasing demand and we have found a reliable partner with Bystronic,” says Managing Director Marita Haslach-Dann.

In order to meet the growing demand while simultaneously saving resources, two ByStar Fiber 4020 fiber laser cutting systems have been in operation in the Haslach Group’s production halls since December 2018. Each equipped with a laser output of six kilowatts, they can cut metal sheets up to a size of four by two meters – ideal for Haslach, a medium-sized company well-known for its ability to process large-format metal sheets.

Wide Range Of Applications

On the outside, the ByStar Fiber 4020 stands out thanks to its attractive design. On the inside, there is patented laser technology: a cutting head developed by Bystronic that precisely adapts the focal point of the laser beam to match the sheet thickness and material. This enables the fiber laser cutting system to consistently achieve the optimal processing quality in spite of varying sheet metal thicknesses and materials.

The ByStar Fiber 4020 cuts up to 30 millimeter thick steel and guarantees clean cutting edges in a wide range of sheet metal qualities. This makes it possible to cut intricate contours in the best possible quality. Complex geometries can also be implemented with ease. Moreover, the range of applications is broader in comparison to CO2 laser cutting machines: The new systems can handle a wide variety of sheet thicknesses and an extensive range of materials, including non-ferrous metals, such as brass and copper. The Haslach Group benefits from this added flexibility, because many of its customers have very specific requirements.

Customised Automation Solution

In order to ensure the rapid loading and unloading of the fast machines, the Haslach Group uses a matching automation solution on both of its fiber laser cutting systems: the ByTrans Cross 4020. “An ideal match,” Marita Haslach-Dann explains. “The automation helps us to work more ergonomically and to increase our throughput. This enables us to produce efficiently.” In spite of the fully automated material supply, operators can manually feed in sheets whenever required.

The inflow and outflow of materials is connected to a high-bay warehouse. The Haslach Group had specified an automated warehouse system, but only one supplier was able to meet their specific demands: “Bystronic rapidly implemented a customised solution for us,” Marita Haslach-Dann says. It was the overall package of cutting systems, automation, software, and service that convinced her.

Software Brings Transparency To Manufacturing

Cutting plans are created using the Bystronic BySoft 7 software, where programmers work in a 3D CAD environment. The 3D models provide a tangible idea of the parts that are to be produced. The BySoft 7 software automatically selects the best possible cutting technology and helps optimise cutting processes. It also ensures optimal use of the raw sheets based on the highly sophisticated nesting of parts.

Thanks to the touch screen, operators always maintain an overview: Production and machine data are retrieved in real time. Operation is so user-friendly that one employee can supervise several machines at the same time. “With the previous systems, we had one operator for every machine,” says Marita Haslach-Dann. The staff have been assigned to new tasks because the high cutting speed of the ByStar Fiber 4020 results in the output of more cut parts that require sorting.

In order to ensure all employees have an overview of the production process, the Haslach Group also relies on planning software from Bystronic, the Plant Manager. The programmer is enthusiastic: “We can always see at what capacity the machines are running,” he explains. “This allows us to flexibly coordinate individual steps of the workflow to accommodate short-term change requests.” Virtually real-time access to all the relevant production and machine data makes it possible to adapt production processes to be able to accept last-minute customer orders.

Doubled Productivity

Programming and planning software has transformed production into a digitally networked manufacturing landscape. Employees can constantly monitor the flow of information and quickly implement plans. “Our path from the incoming order to the end product has become faster and more efficient,” Marita Haslach-Dann explains. The Haslach Group’s head of the cutting department confirms this: “We have successfully increased productivity by 50 to 60 percent when processing thin sheet metal.” The results are impressive: The perfect cutting edges satisfy even the most demanding customers.

 

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Bystronic Releases Entry Level Solution For Bending

Bystronic Releases Entry Level Solution For Bending

Bystronic’s entry level Xpress press brake offers concentrated bending technology at an attractive price point, enabling users without prior experience achieve professional results.

For many companies, a high-quality press brake is prohibitively expensive. Hence, small workshops and beginners often revert to second-hand machines or low-budget models. But the low purchase price is often offset by poor quality. Bystronic’s new entry-level model, on the other hand, is a much more sustainable investment. With its attractive price-performance ratio, the Xpress sets a new quality benchmark in the lower price segment.

With the Xpress, Bystronic’s innovative bending technology is now accessible to a new segment of customers—small job shops, family businesses, and medium-sized enterprises no longer have to accept compromises in terms of quality. Entry-level users can rely on high-quality equipment. And for those companies whose core competencies previously did not include bending, the Xpress allows parts to be manufactured in-house instead of having to be subcontracted at high cost.

Xpress enables a quick entry into bending technology. Featuring the ByVision Bending software, all the process steps are on a single screen, enabling users to design parts with just a few swipes of the finger. The software provides valuable support for the programming of bending sequences. ByVision Bending determines the suitable tools and the ideal bending process for every material thickness and bending angle.

The ByMotion drive control, a Bystronic in-house development, ensures that the upper beam and backgauges of the Xpress are accelerated with high precision. The press force required at any given time is distributed with high precision over the entire bending length, both when coining and when air bending—ensuring bending results with a high degree of repetition accuracy.

The closed O-frame design of the Xpress guarantees high machine rigidity and offers sufficient space for applications along the entire bending length. In addition, the modular design ensures a high degree of flexibility. Different tool clamping and backgauge systems allow individual customisation to adapt to the production environment. Compatibility with all other Bystronic bending systems also makes it easy to expand production.

 

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Modular Power Package For Demanding Benders

Modular Power Package For Demanding Benders

With the Xpert Pro, Bystronic presents a high-end press brake that sheet metal processing companies can adapt to their requirements on a modular basis. The new model in the Xpert series of machines meets the highest demands in terms of process speed and flexibility.

Modular design has long since established itself in the automotive industry. Manufacturers offer a model in various editions and in addition to the standard specifications, customers can choose from a wide range of optional features. Bystronic was inspired by this principle when developing the new Xpert Pro: Customers can choose between three editions and customise them with optional extras.

The three editions of the Xpert Pro will appeal to a wide variety of users: The Classic Edition is ideal for job shops with small batch sizes or for prototype builders. With the Performance Edition, medium-sized companies can produce larger series quickly and reliably. And the Dynamic Edition with bending speeds of up to 20 millimeters per second is ideal for companies that need even more speed to efficiently handle batch sizes of 1000 pieces and more.

Maximum Flexibility

The Xpert Pro’s press capacity can also be adapted to a wide range of requirements. The spectrum ranges from 100 to 320 tons. This enables sheets up to a thickness of 15 millimeters to be bent effortlessly. In terms of bending length, there is a choice of three or four meters. Companies that require even more flexibility can connect two machines together to process extra-long parts.

The modular concept enables the press brake to be adapted very specifically to the requirements of the production environment – and in this respect Bystronic goes one step further than the car manufacturers: If the requirements change, the configuration can be flexibly adapted. The exchange of individual modules, for example of the backgauge, is straightforward and all optional equipment can be easily retrofitted.

The Xpert Pro is also flexible with regard to the use of bending tools, because this press brake eliminates the usual compatibility problems. The developers designed the tool clamping system to be so open that, in addition to the large selection of Bystronic equipment, tools from other suppliers can also be used. This provides users with more freedom for the bending of a wide variety of parts.

Precise And Convenient Bending

Precision is the most important performance factor of every production environment. Thanks to the tried-and-tested dynamic crowning, the Xpert Pro achieves precise and consistent bending results from the very first part. Bystronic’s patented compensation system automatically adjusts the curvature of the lower beam during the bending process. For even higher process reliability, the LAMS angle measuring system is available as an option. In addition to sheet thickness fluctuations, this system also compensates for springback and rolling direction variations.

Thus, the Xpert Pro reduces the need for tedious manual corrections while also reducing the operators’ workload during programming: The ByVision Bending software solution determines the ideal bending process for every material thickness and bending angle. Thus, the high-end press brake leaves nothing to be desired in terms of convenience. Bending has never been faster and more precise than with the new Xpert Pro from Bystronic.

 

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Competence Days 2019: New Technologies, New Solutions

Competence Days 2019: New technologies, New Solutions

Bystronic presented its innovations for the sheet metal processing industry at its largest in-house exhibition in Niederönz (Switzerland). A perfect opportunity to chat about new approaches in the fields of laser cutting, bending, automation, and software.

Over a period of two weeks, Bystronic welcomed 1200 guests from more than 50 countries to the Competence Days at its Swiss headquarters in Niederönz. The motto for the event was “World Class Manufacturing”. The event provided an answer to the question of what sheet metal processing could look like in the future. Visitors experienced the most important trends and innovations in the fields of laser cutting, bending, automation, and software up close during live demonstrations and guided tours of Bystronic’s Swiss production halls for laser cutting and automation technologies.

For many customers, looking ahead to the future of their own sheet metal processing operations means: Being able to adapt to decreasing batch sizes and fluctuating order situations. Mastering cost and time pressure by applying the most efficient processes and systems available. And positioning themselves on the competitive global or local markets with leading technologies and manufacturing solutions.

Hardware And Software Open Up New Paths

Thanks to new technologies, metal and sheet metal products can now be manufactured more versatile and profitably than ever before. In addition to the suitable hardware, software solutions are playing an increasingly important role in the sheet metal processing sector. In future, it will not be just the machines, but also the correct software that will determine competitive success. Software packages and digital process solutions help customers to make increasingly complex production processes transparent and profitable. This allows the costs, processing times, and quality of production processes to be optimised to achieve previously unattainable levels.

In a conversation that took place during the event, Bystronic CEO Alex Waser said: “Events such as the Competence Days are an important platform for our visitors to exchange ideas with Bystronic. This allows new ideas to be developed and existing visions to be refined. We talk to our guests about what is bothering them, what solutions Bystronic can develop for them, and what the next step for their production processes could be.”

For job shops, for example, the next step could be a powerful fiber laser with an automated loading and unloading solution to increase productivity. Or a fully automated material and data flow to enable virtually autonomous operation in multiple shifts. “Advanced users and large metal processing companies also think in other dimensions. Here we are talking about end-to-end solutions that cover cutting, bending, material handling, as well as process and data management.

In future, in its role as a supplier of integrated solutions, Bystronic will support users with the planning and implementation of such production landscapes,” Alex Waser explained. “With our experts in the Bystronic Solution Center and with a wide range of technologies, we meet our customers at their current level and help them take the next step.”

Seize Opportunities And Invest

The framework conditions of today’s sheet metal processing companies vary around the globe. And yet it became clear that the international visitors to the Competence Days 2019 also had things in common. Users in Europe, America, and Asia are currently facing the challenge of successfully aligning their manufacturing environments to demanding and unpredictable markets.

“Many of our customers face the question: Wait and see how things develop or invest right now,” Alex Waser explained. “We understand the obstacles. But we also see the opportunities for our customers. Companies that invest in new technologies now and that enhance their production processes can rely on powerful equipment when the next upward trend begins.” And that this upward trend will come is guaranteed. This was the wide consensus among the guests at Bystronic’s Competence Days.

 

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Bystronic Expands Portfolio Of XXL Laser Cutting System

Bystronic Expands Portfolio Of XXL Laser Cutting System

Bystronic is increasing the productivity of fibre laser cutting and the diversity of cutting applications with the new extra-large 6225 and 8025 formats for the ByStar Fiber laser cutting system. The machines can be equipped with laser outputs from 3kW to 10kW, depending on the users’ requirements.

With the new extra-large formats, users can process metal sheets on the ByStar Fiber with a working area of up to 8m by 2.5m. This increases the machine’s productivity, because large metal sheets allow the parts that are to be cut to be nested more efficiently and thus significantly reduce undesirable raw material offcuts. The BySoft 7 software supports users with smart nesting procedures that enable optimal cutting plans to be created for large formats.

With ByStar Fiber’s new 6225 and 8025 formats, large-format metal sheets allow large parts to be cut in addition to diverse small parts, without requiring the machine to interrupt the laser cutting process during long cutting paths.

In addition to cutting applications with extra-large metal sheets, it is also possible to process several smaller format sheets in one go. The various metal sheets can be positioned on the ByStar Fiber’s cutting table as required. This enables users to increase the level of machine utilisation by reducing non-productive times and allowing the laser cutting system to operate for longer in an uninterrupted cutting cycle.

As standard, all ByStar Fiber machines, including the new extra-large formats, are equipped with the latest generation Bystronic cutting head. Additional options, such as a second operating terminal with touch screen, ensure an optimal overview when operating the extra-long machines.

 

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The Carefree Package For The Entry Into Bending

The Carefree Package For The Entry Into Bending

Bystronic is advancing into a new customer segment. The Xpress offers concentrated bending technology at an attractive price-level. Thanks to the newly developed press brake, even users without prior experience achieve professional results.

For many companies, a high-quality press brake is prohibitively expensive. Hence, small workshops and beginners often revert to second-hand machines or low-budget models. But the low purchase price is often offset by poor quality. Bystronic’s new entry-level model, on the other hand, is a much more sustainable investment. With its attractive price-performance ratio, the Xpress sets a new quality benchmark in the lower price segment.

With the Xpress, Bystronic’s innovative bending technology is now accessible to a new segment of customers. Small job shops, family businesses, and medium-sized enterprises no longer have to accept compromises in terms of quality. Entry-level users can rely on high-quality equipment. And for those companies whose core competencies previously did not include bending, the Xpress allows parts to be manufactured in-house instead of having to be subcontracted at high cost.


Simple operation, high precision

The intuitive operation of the Xpress enables a quick entry into bending technology. All the process steps on a single screen – this is the idea behind the ByVision Bending software. The 22-inch touch screen enables users to design parts with just a few swipes of the finger. The software provides valuable support for the programming of bending sequences. ByVision Bending determines the suitable tools and the ideal bending process for every material thickness and bending angle.

Precision is the most important performance benchmark of a press brake. Hence, the ByMotion drive control, a Bystronic in-house development, ensures that the upper beam and backgauges of the Xpress are accelerated with high precision. The press force required at any given time is distributed with high precision over the entire bending length, both when coining and when air bending. This ensures bending results with a high degree of repetition accuracy.

Modular design offers high degree of flexibility

The closed O-frame design of the Xpress guarantees high machine rigidity and offers sufficient space for applications along the entire bending length. In addition, the modular design ensures a high degree of flexibility. Different tool clamping and backgauge systems allow individual customization to adapt to the production environment. Compatibility with all other Bystronic bending systems makes it easy to expand production.

This makes the Xpress predestined for small businesses that want to grow. The versatile bending technology lays the foundation for a high quality standard upon which a successful business can be built. Bystronic’s comprehensive know-how and customer-oriented services make the Xpress a carefree package for future bending experts.

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Fiber Laser Cutting With 12 Kilowatts

Fiber Laser Cutting With 12 Kilowatts

The ByStar Fiber from Bystronic is being enhanced with a 12 kilowatt laser and the new “BeamShaper” function. Besides offering higher speed and an expanded cutting spectrum, a newly designed cutting head ensures consistent cutting quality up to a sheet thickness of 30 millimeters.

To compete for cutting jobs, sheet metal workers need to manufacture quickly, flexibly, and cost-effectively. The best cost per cut part and short delivery times are decisive for achieving good production utilisation. A laser cutting system with its specific components must therefore enable high processing speeds, a reliable cutting process, and low maintenance costs. Those who position themselves this way are awarded jobs and gradually increase productivity. That builds the foundation for growth.

In order to optimally support sheet metal workers amid growing competition, Bystronic is now launching the next level of power in fiber laser cutting: The ByStar Fiber with 12 kilowatts. The high-end fiber laser represents precise Bystronic technology, a stable cutting process up to the highest laser power, and a broad spectrum of applications. It is an enormous technological leap from the three to 10 kilowatt levels, available up until now, to the new 12 kilowatt level.

With the 12 kilowatt laser, the ByStar Fiber’s cutting speeds increase up to 20 percent on average (when laser cutting with nitrogen) compared to the previously available 10 kilowatt laser source. This increases productivity throughout the range of sheet thicknesses from three to 30 millimeters.

Stefan Sanson, Bystronic Product Manager for Laser Cutting explained: “This laser power is of interest to companies that want to achieve higher cutting speeds with material thicknesses starting at three millimeters in order to increase their productivity per unit of time. The result is Swiss quality with lower costs per part.”

New Cutting Head Design For Process Stability

The cutting head is the core element for a stable cutting process and constantly high parts quality. This applies all the more with increasing laser power, which must be brought to the cutting material precisely and reliably. To enable this, Bystronic has consistently continued to develop the ByStar Fiber cutting head.

A slimmer design for the new cutting head increases security in the cutting process. Bystronic is also reducing the number of different components and accommodating important technical functions in the interior of the cutting head. This decreases the danger of collisions with protruding cut parts. The new design also decreases maintenance and operating costs because the integrated technology is better protected from contamination occurring from cutting dust, for example.

Optimal cooling in the cutting head ensures constantly precise cutting performance, particularly for long-lasting cutting operation with high laser power. Bystronic thus protects the lenses and cutting nozzle from high thermal stresses.

High Cutting Quality Up To 30 Millimeters

For sheet metal workers who want to expand their job volumes into the highest material thicknesses, Bystronic has developed a further innovation. The new “BeamShaper” function enables exceptional cutting quality for steel up to a sheet thickness of 30 millimeters. This function can be selected with a new purchase of a 12 kilowatt ByStar Fiber or retrofitted at a later date. “BeamShaper” allows for an ideal adjustment of the laser beam form to greater sheet thicknesses and variable sheet metal qualities. In strengths of 20 to 30 millimeters, the new function thus raises the quality of cutting edges and increases the cutting speed by up to 20 percent.

Automation Optimises The Material Flow

In order to provide an optimal material flow to the high speeds of laser cutting, Bystronic has a broad selection of automation solutions available for the ByStar Fiber. The offer includes loading and unloading systems, sorting solutions, and individually configurable storage systems. Based upon the existing manufacturing environment and available space, a seamlessly integrated automated laser cutting process is developed.

ByTrans Cross is the newest loading and unloading solution on offer from Bystronic. The automation can be flexibly adapted to changing order situations and production rhythms in the laser cutting. Various utilisation scenarios are possible.

As an automation bridge, ByTrans Cross can be integrated between a laser cutting system and material storage in order to direct the material flow. ByTrans Cross can also be used equally well as a stand-alone solution without a storage connection, to provide the laser cutting system with raw sheet metal of differing strengths and materials. In its basic version, ByTrans Cross has two loading carriages that serve as material storage for stand-alone utilisation.

ByTrans Cross becomes even more versatile during cleanup, with the BySort sorting solution, which Bystronic integrates as an add-on solution on request. Thus, users have the option to clear away sorted, completed parts into an attached storage area or to store them in an additional unloading position next to the laser cutting system.

The latter supports the processing of large series, for example, for which individual cut parts need to be sorted separately according to job. A big advantage of BySort is the repeated, precise storage of all parts in one location: A task that is difficult to complete manually, particularly with large cut parts. The parts, exactly positioned on a palette, can be processed more easily during manual and automated subsequent processes, as their location is precisely defined.

 

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The Fully Automated Production Line

The Fully Automated Production Line

Pre-process, cut, transport, and sort sheet metal parts according to orders. All this is carried out by the fully automated Production Line. Bystronic is thus presenting a solution for sheet metal processing in the age of automation and digital networking.

The fully automated Production Line revolves around the ByStar Fiber laser cutting system and integrated automation solutions from Bystronic. The digital Shop Floor Control System integrates the Production Line into the existing sheet metal production environment. This guidance system enables users to set up a manufacturing landscape around the Production Line that permits all sheet metal processing steps to be seamlessly integrated.

The Production Line is capable of processing sheet metal parts both in large series and on a small scale. The integrated laser cutting and automation technologies adapt flexibly to changing order situations while also enabling customised expansion with modular options. The idea behind this manufacturing concept is to combine versatility and productivity. Both are important requirements for industrial sheet metal processing.

Bystronic recently showcased a solution that in the near future will enable the Production Line to be expanded to enable the pre-processing cut parts. ByFlex, an additionally integratable system, drills and deburrs holes, and cuts threads, if required even with countersinks, in sheet metal parts prior to the laser cutting process. The integration of this solution, even before the actual laser cutting process, allows users to make optimum use of secondary processing time within the Production Line.

ByTrans Cross And BySort In The 4020 Format

The objective of automation in the field of laser cutting is to make it possible to process not only large series but also small batch sizes, while maintaining the flexibility that users require to always respond to changing order situations. Bystronic offers the ByTrans Cross automation solution and the BySort module in the 4020 format. This provides users with an extremely versatile extension for the ByStar Fiber 4020 laser cutting system. The ByTrans Cross handles the entire loading and unloading process on the shuttle table of the fibre laser cutting system. This enables metal sheets of up to 4m by 2m to be handled.

As an upgrade module for ByTrans Cross, BySort expands the sorting process for finished cut sheet metal parts with a weight of up to 100 kg. What makes this solution so special: BySort enhances the range of functions in the automated unloading process without requiring the user to expand the footprint of the ByTrans Cross.

Due to the extremely fast throughput times of the ByStar Fiber laser cutting system, with an output of up to 10 kW, automated material loading and unloading is virtually a must, explained Product Manager Alain Meyer. Users can only fully exploit the potential of the fibre laser technology if the material flow is perfectly matched to the laser cutting system’s throughput times.

An additional aspect is the reduction of the machine operators’ workload and the associated increase in process reliability. The loading of raw sheets and the removal of residual grids in the 4020 format is difficult to carry out manually. Here, automation ensures safety and simple workflows. Mr Meyer also emphasised another benefit, “Automation enables users to utilise their laser cutting capacities efficiently around the clock with little manpower, even when faced with high order volumes and short delivery times. The increased autonomy thus also makes it possible to work lightly-manned night shifts.”

Flexibility For Varying Order Situations

The modular design of the ByTrans Cross means that the BySort upgrade can be retrofitted as a sorting solution at any time. For this, Bystronic expands the existing ByTrans Cross system with a bridge on which two sorting heads can operate. Both heads automatically equip themselves with a selection of gripper modules. Depending on the sizes and geometries of the sheet metal parts that are to be processed, the user puts together the matching magazine of grippers.

BySort removes finished parts, sorts them by order, and deposits them on various unloading positions next to the laser cutting system. Mr Meyer explained, “Depending on the production environment, BySort can stack finished cut parts on trolleys, pallets, conveyor belts, or even autonomous transport vehicles.”

This diversity in the unloading process supports sheet metal processing companies that are faced with the challenge of adapting to changing batch sizes. It also helps users to automate the production of small batches so that a variety of downstream processes, such as bending, welding, or painting, can be integrated as easily as possible with laser cutting.

For example, when parts are positioned on a pallet with high precision, they can be processed more easily in the bending step, because the robotics used here or the operator no longer have to check them and adjust them to the correct position. “The precision with which BySort stacks the parts translates into accurate gripping and error-free bending in the next processing step,” said Mr Meyer.

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Bystronic “TiltPrevention” Solution Optimises Laser Cutting Processes

Bystronic “TiltPrevention” Solution Optimises Laser Cutting Processes

With the “TiltPrevention” assistant function, Bystronic is increasing process reliability in the field of laser cutting. The intelligent function enables users to create cutting sequences that minimise the risk of creating protruding parts in the sheet. This reduces the disruption of cutting processes and downtime caused by cutting head collisions.

Tilted parts are a risk factor during the laser cutting process. They can cause a collision with the cutting head. This results in the disruption of cutting jobs, rejected parts, and in the worst case, costly damage. However, they also impede automated unloading, as the automation system’s grippers have difficulty picking up tilted parts.

Until now, micro-tabs have been a time-intensive method of preventing cut-out parts from tilting. The software positions small connections between the contour of the part that is to be cut and the residual grid in the cutting plan. In this way, parts remain fixed to the surrounding sheet after cutting. One disadvantage of this solution is: The cut parts require reworking in order to remove the traces of the micro-tabs. Another disadvantage: The automated removal of the finished parts is impeded because the micro-tabs make it difficult to remove the parts from the residual sheet.

Another approach is to use software to guide the paths of the cutting head during the cutting process so that, as far as possible, it circumvents risky sections where parts could tilt. However, this solution does not eliminate the root of the problem—parts protrude, still represent a risk, and are difficult for automation systems to cope with.

Algorithm Generates The Ideal Cutting Sequence

With “TiltPrevention”, Bystronic has now developed a new solution. In future, BySoft 7 will use this intelligent assistant function to compile cutting plans in such a manner that parts cannot tilt during the cutting process. This largely eliminates the need for micro-tabs.

How does it work? An algorithm calculates the mechanical behavior of the parts while they are being cut out of the sheet. To achieve this, “TiltPrevention” takes into account a wide range of parameters:  What is the density of the material that is being cut? What is the geometry and weight of the parts that are to be cut? How high is the pressure of the gas that flows out of the cutting head during laser cutting and exerts pressure on the parts? How are the parts positioned on the cutting grate? Are there enough contact points?

Subsequently, “TiltPrevention” recommends lead-in and lead-out points of the laser so that tilting of the parts after cutting is prevented to the greatest possible extent. In addition, the function proposes the best possible route for the cutting head over the metal sheet. This creates an ideal cutting sequence for all parts on the cutting plan. Cutting in such a manner that the cutting head never travels over parts that have already been cut out.

Regardless of the users’ level of experience, “TiltPrevention” supports them with an ideal cutting strategy that can be automatically incorporated into the cutting plan. Users can carry out customised adaptations at any time using the simulation created by “TiltPrevention” —modify the nesting of parts, reposition the lead-in and lead-out points of the parts, and add micro-tabs where required.

 

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