LVD YSD LaserONE is a new cost-effective laser cutting machine designed to put the advantages of fiber laser technology within easy reach of sheet metal fabricators by eliminating the extras that increase machine cost and complexity. LaserONE is offered with a 2- or 4-kW laser power source in a 3000 x 1500mm table size and with optional Load-Assist automation.
Developed to address the market need for a low-cost, ultra-practical fiber laser cutting machine, LaserONE is designed, manufactured, sold and serviced by LVD. It cuts a variety of materials and thicknesses with the flexibility of fiber laser, has low operating and maintenance costs, and provides a quick return on investment.
The machine features a Precitec cutting head with NC-focus, automatic focal adjustment and crash protection, Raycus laser source, Siemens control, servo motors and drives.
The YSD LaserONE is equipped with an automatic pallet changer for fast interchanging of the shuttle tables in a cycle time of approximately 30 seconds. An optional Load-Assist automation system offers easy loading/unloading.
LVD Company nv introduces the Strippit PL Punch-Laser combination, a machine that combines the punching and forming advantages of the Strippit PX or V Series punch press with the speed and versatility of fiber laser cutting to complete multiple processes on a single machine, answering the need for flexible manufacturing. Three punch-laser models are available: the single-head style Strippit PX 1530-L and Strippit V 1530-L in thick- and thin-turret configurations.
Small batches, short lead times, increasingly complex parts drive the need for flexible manufacturing. Strippit PL offers two technologies in one machine for more versatility than single-process equipment. Strippit PL can laser cut intricate shapes and process materials up to 10 mm, efficiently punch holes up to 6.35 mm, produce forms and bends up to 90 mm in length and up to 75 mm high on the Strippit PX 1530-L.
Combination technology offers complete part processing. The punch press handles high-speed punching and forming operations. The fiber laser delivers high-quality cutting of outer contours, intricate inner contours and can be used for material etching.
The combination of technologies eliminates processes, can improve part quality, reduces production time and material handling, and lowers the cost per part in both small lot sizes and high production runs.
In 1978, Strippit brought punch-laser technology to sheet metal fabrication. Today, a combination machine is more practical than ever because of advances in laser cutting and punching technology.
The solid-state fiber laser has minimal components, offers high cutting speed, and low-maintenance costs making cutting operations faster, more accurate and cost-effective. Strippit PL is offered with a 3 kW or 4 kW fiber laser source.
The Strippit PX single-head 20-ton punch press can punch, form, bend and tap, forming flanges up to 75 mm high, countersinking and scribing with top productivity. Twenty indexable tool stations hold any size tool, up to a maximum tool diameter of 90 mm.
The Strippit V thick-turret model features a versatile 48-station turret. The Strippit V thin-turret configuration has a 40-station turret. Both 30-ton machines are equipped with four programmable 88.9 mm indexable stations and are designed to handle high tonnage applications.
TRUMPF has announced a close business cooperation between TRUMPF Laser- und Systemtechnik GmbH and SPI Lasers UK Ltd., which are both wholly owned subsidiaries of the TRUMPF Group. TRUMPF Laser- und Systemtechnik GmbH will combine the business operations of SPI Lasers UK Ltd. to bring advantages in industrial applications via both disk and fiber technology and enhance customer service offerings. As of the 1st July SPI Lasers products will begin to be available via the TRUMPF sales channels.
SPI Lasers UK Ltd. has been a wholly owned subsidiary of the TRUMPF Group since 2008, quickly establishing themselves within the group as experts in the field of fiber laser design and manufacture. With fiber lasers becoming important laser sources for material processing, both companies agree that “joining forces and integrating SPI Lasers into TRUMPF is a sensible move for both companies and, more importantly one that will be extremely beneficial for our customers”.
This value-enhancing step ensures that SPI customers will benefit not just from high quality fiber laser products but also first-class standards of customer service. In addition, both companies are expecting synergy effects and an improved cost structure, e.g. in R&D.
The relevant steps are expected to be completed in the third quarter of 2020.
The strategic partnership with IPG Photonics is strengthening Bystronic’s innovative capacity: Together, these two technology pioneers are developing the next generation of fiber lasers. In addition, Bystronic benefits from attractive procurement terms and can set itself apart by offering exclusive customer services.
Innovative features, excellent service
Bystronic is one of IPG’s most important customers in the field of materials processing. What started as a simple supplier-customer relationship has evolved into a strategic partnership: In 2018, the two companies initiated joint development projects within the framework of a collaboration agreement. “This offers us the opportunity to adapt the laser sources to our specific needs and to develop innovative features for our customers,” says Christoph Rüttimann.
One such collaboration includes for example, Bystronic technicians being qualified to replace defective transport fibers at the laser source or to exchange laser modules. “We can thus set ourselves apart by offering comprehensive services from a single source. Our customers appreciate having a single point of contact for all their concerns,” Christoph Rüttimann emphasises.
Leader in the race for higher output
The output of fiber laser cutting machines has increased rapidly over the past few years. Two years ago Bystronic launched a 12-kilowatt system on the market, and this October with 15 kilowatts, the next power level will be launched. Christoph Rüttimann is convinced that the race for power will continue. And Bystronic is at the forefront – also thanks to its partnership with IPG.
Pioneering work for the smart factory
For Bystronic’s customers, the performance increases achieved over the past few years have translated into higher productivity and above all greater flexibility. This tangible customer benefit can be enhanced even further thanks to innovative features. The exchange of ideas and know-how with IPG is fertile ground that generates valuable ideas to drive forward the development of the systems.
Strong partnership for a dynamic and evolving market
The joint innovations show that with IPG, Bystronic has found an ideal partner to drive development of next generation fiber laser solutions. Christoph Rüttimann observes: “Within a rapidly evolving market, our partnership provides technology leadership, delivering leading-edge productivity and superior cost of ownership to our customers, and strengthening the future prospects of Bystronic.”
Laser technology provides a high level of flexibility and quality when processing hairpins for the electric motors. Article by TRUMPF.
(Above, left) Hairpin with PAI coating after blast off process. High edge quality and low pulse overlap as well as line overlap. (Above, right) A row of single pulses. (Bottom) Surface after ablation with blast off process. Single spots are visible. This can be reduced by using repetitions with a higher frequency and higher line overlap after decoating.
Nowadays, manufacturers of electric motors are also looking for more productive processes for volume quantities, with the same high-quality requirements when it comes to the welding result. An important impetus here is achieving a higher degree of automation to be able to produce higher quantities.
One method in the construction of stators has therefore largely prevailed: Instead of winding copper wire around the individual stator grooves, as was often the case before, manufacturers have started embedding rectangular copper rods—called “hairpins” due to their shape—into the entire groove using compressed air. The typical edge lengths of the rectangular cross section of the hairpins is between 2 and 4 mm. The process achieves higher process speeds and can easily be automated. As the hairpins are stiffer than round wires, their alignment in the motor can be better controlled. The larger fill factor also results in a higher thermal load capacity, and higher motor power.
The copper rods are coated with an insulating layer, which requires ablation at both ends locally—called hairpin stripping—to enable contacting. Pulsed laser processing is suitable here to strip the hairpins. Compared to mechanical processes, such as planing and milling, laser processing is up to 80 percent more productive. Once the hairpins have been embedded in the grooves, protruding ends on the top and bottom of the stator are twisted together using a fixture (necking) or fixed in place, and then welded for contacting. The ends are not always ideally aligned to each other, however. If you use automated remote welding, a camera-based sensor system integrated in the laser optics helps achieve a reliable and reproducible result, and therefore the highest possible current flow.
Stripping of Hairpins
Common insulating layers for copper hairpins are polyamide-imides (PAI), polyether ether ketone (PEEK), and polyamide-imides with polyimide foil (PAI+FEP).
In the past, PAI coatings were almost exclusively prevalent in the industry, but we are now seeing a tendency towards a steady increase in PEEK and PAI+FEP. However, PAI coatings still have, and are likely to have in the future, the largest share by far.
All of these insulation coatings can be burnt away from the copper quickly and in a targeted manner using laser pulse processing. The laser light couples into the insulating layer, heats it up, and burns it off. PEEK behaves as a volume absorber for laser light, anyway; for PAI and PAI+FEP, it is recommended that the first run over is used to carbonize the material in order to increase the absorption. The copper discolours due to the heat influence during laser ablation. This is not relevant for the further processing, however, as the structure of the copper is not changed. Burrs also form at the boundaries to the coated copper, which, in unfavourable circumstances, could lead to the burr becoming stuck on a surrounding component or fixture. The formation of burrs and edges can be optimized, however, through reworking using another femtosecond-pulsed laser.
Hairpin stripping can be done with different types of TRUMPF ns laser. Most common is the TruMicro 7000 series with a laser power of up to 2 kW (pulse energy 100 mJ) at a pulse repetition rate of 5 to 250 kHz and a pulse duration of 30 ns.
There are two stripping processes for the hairpins depending on the coating type:
For coatings which are transparent to the laser a “blast off” process can be used.
For non-transparent coatings an evaporation process is needed.
Many processes in the sheet metal industry are developing rapidly. Laser cutting, for example. In this interview, Johan Elster, Bystronic’s Head of Business Unit Markets, explains where the journey is headed.
Nowadays, sheet metal is cut using both fibre lasers and CO2 lasers. how will these two technologies develop?
Johan Elster (JE): Over the past few years, the fibre laser has experienced massive technological advances. We launched our first cutting system with fibre laser technology in 2010. Since then, the output power has grown six-fold. Our current top-of-the-line model, the ByStar Fiber, has an output of twelve kilowatts. This progress has also resulted in a massive expansion in the range of applications. Initially, fibre laser technology was suitable only for thin sheet metal; but today, fibre lasers can be used to cut sheet metal thicknesses of 40 mm and beyond.
For a long time, thick sheet metal was considered the domain of CO2 lasers. is this no longer true?
JE: The CO2 laser still possesses good characteristics for the cutting of thick sheet steel. It also allows good results to be achieved in terms of the price per part. Nevertheless, its market share has decreased significantly in recent years; today our sales of CO2 systems are almost negligible.
So, fiber lasers are now the preferred solution for many sheet metal processing companies. what is the key to the success of fiber laser technology?
JE: Fibre lasers achieve up to five times higher cutting speeds than CO2 lasers and exhibit three times the energy efficiency. The operating and maintenance costs are also considerably lower. The fibre laser offers highest cutting speeds, an attractive cost-performance ratio, high cutting quality, and increased flexibility.
JE: Absolutely. Around 70 to 80 percent of our customers are job shops that do not produce any products of their own. They must be prepared to deal with a broad spectrum of orders. Manufacturing a wide variety of parts at the lowest possible cost and in the desired quality is what their business is all about. Fibre lasers make this possible. The ByStar Fiber cuts stainless steel, aluminium, non-ferrous metals, mild steel—and all of these from the thin to thick range of material.
High-performance fiber lasers are all-rounders; what are the most important criteria when selecting their power output?
JE: The criteria vary from customer to customer. Companies that primarily cut thin sheet metal can usually get by with three, four, or six kilowatts. Users that frequently cut in the medium range, for example mild steel between 6 and 15 mm, and want to use nitrogen as the cutting gas, are optimally served with ten or twelve kilowatts. For large companies, the output of the laser is obviously the most important factor for the efficient processing of large batches. Here, the higher output has a significant effect on both speed and profitability.
What does the higher cutting speed mean for the overall production chain?
JE: In fact, the challenge with the latest generation of fiber lasers is to keep up with the loading and unloading. Hence, as a general rule, it makes sense to combine fiber lasers with an automation system. Our ‘ByTrans Extended’ and ‘ByTrans Cross’ loading and unloading systems take automation to the next level. Many small and medium-sized companies are currently in the process of progressively automating their production processes. We are experiencing an increased demand, in particular for sorting solutions. Nowadays, our customers no longer want to sort manually. For this, we offer our highly flexible BySort solution.
What can customers who want to increase their level of automation expect from Bystronic?
JE: As a general rule, our customers have a great deal of expertise in their core processes. We can help identify customer-specific bottlenecks: For example, we can find out where time is being wasted or where there is potential for improvement. This requires all the processes to be analyzed. We build on this and show what options are available to customers to optimize their production processes. Frequently, our customers are interested in compact cells that combine efficiency and flexibility. Accordingly, our solutions are configurable – not only in terms of hardware, but also with regard to software.
JE: This must be implemented step by step. Nowadays many suppliers offer a range of processes: cutting, bending, welding, etc. Regardless of how many processes are involved, it is possible to digitalize. We can help network our customers’ production environments in a gradual and process-specific manner using suitable software solutions.
What is the role of laser cutting in the context of Industry 4.0?
JE: Laser cutting is just one building block in a smart factory. Intelligent and networked production encompasses all the processes of a sheet metal processing company, in particular also those upstream and downstream of the production process: calculations, the preparation of offers, production planning, etc. A manufacturing execution system (MES) controls the production line. This enables production processes to be optimized fully automatically by comprehensively evaluating the data generated during the individual processes and optimizing the processes for the following orders.
There are hurdles that must be overcome on the path towards networked production—which of these is the most challenging?
JE: Since with regard to interfaces, our industry does not have the kind of standards as those found in the IT world, the integration of a variety of different machines into a networked system is very challenging. As a result, the process flow of each individual customer must be taken into consideration.
Bystronic is the only supplier that also integrates third-party machines. what are the reasons for this decision?
JE: We are convinced: The customer wants to be able to pick and choose the best solutions. In our view, suppliers that only integrate their proprietary products are following an outdated approach. For example, no supplier’s portfolio currently includes paint finishing systems. But it is precisely this process step that many customers also want to integrate. What is more, our customers generally already have machines that they wish to integrate into an overall system. This is why it is clear to us: Optimizing a production environment and achieving a higher level of overall efficiency requires not only expertise, but above all openness.
Langen CNC Metalltechnik GmbH & Co. KG has been successfully processing metal for 30 years. Here’s how the company was able to further increase its cutting capacity by 35 percent by phasing out two equipment, while simultaneously reducing energy consumption. Article by Vanessa Salbert.
Franz Langen (right) in conversation with the operator of the ByStar Fiber 8025. The quality of the cutting edges is essential for the further processing of the parts. A high-quality laser cut eliminates the need for costly reworking.
In northern Germany, Langen CNC Metalltechnik GmbH & Co. KG has been successfully processing metal for 30 years. The family-owned company has continuously invested in state-of-the-art laser cutting technology and infrastructure. Recently, their production hall has become home to a ByStar Fiber 8025 with a customized automation solution from Bystronic.
A green light behind a tinted window, the laser cutting head whizzes around in all directions. With precise and agile movements, it cuts contours out of a metal sheet. The ByStar Fiber 8025 has been in operation at Langen CNC Metalltechnik in the German municipality of Hilkenbrook since February.
“We wanted a machine that cuts efficiently and that is capable of processing large formats. We bend metal parts with lengths of up to eight meters and we, thus, also wanted to be able to cut parts of this size,” explained Franz Langen, Managing Director of Langen CNC Metalltechnik.
Since such a large laser cutting system in combination with an automation solution did not yet exist on the market, a lively exchange was initiated with Bystronic in Switzerland. The result is a powerful 10kW cutting system that cuts 8×2.5-metre metal sheets up to a thickness of 30mm like butter.
An operator from Langen CNC Metalltechnik monitors the cutting process on the ByStar Fiber’s two touch screens. Depending on the configuration, the screens show when which parts will be cut and display all the relevant details of the cutting jobs that are in progress.
Technology and on-site service
Another requirement Langen CNC Metalltechnik had for their ByStar Fiber solution was an automatic loading and unloading system that could handle the large-dimension parts cut by the laser cutting system. And that at any time, the huge cutting table should be able to accommodate either one large metal sheet (8×2.5m) or two standard metal sheets (for example, in the 4x2m format).
“With the Bytrans Cross 8025, we have a system that fulfils precisely these requirements,” said Langen. “The sheets are loaded onto the shuttle table in a fast and reliable process. This increases efficiency and ergonomics throughout the cutting process.”
However, not only the laser cutting machine is important, but also the production environment into which it is integrated. “We needed an alternative solution for the unloading of the trucks that deliver the sheet metal. Before we had the ByStar Fiber 8025, we used forklift trucks,” Langen added.
In order to save time and effort in the future, the company invested in a special magnetic handling technology that can lift sheet metal bundles of up to 5.0 metric tons. “We can now unload 25 tons of sheet metal in just 30 to 40 minutes,” he said.
The integration of the new laser cutting solution took several months. “We formed a working group for this phase,” Langen said. This was important to ensure everyone involved was on board to help achieve the optimal result for both the staff and the company.
The effort and motivation have paid off. The company currently cuts some 200 metric tons of material per week, which corresponds to 40,000 to 50,000 individual parts.
“Thanks to the new fibre laser system from Bystronic, we have been able to increase our capacity by 35 percent, in spite of phasing out two CO2 laser machines, while simultaneously achieving tremendous energy savings,” Langen said.
Langen CNC Metalltechnik has been manufacturing for more than 30 years. For the past 20 years, the company has relied on cutting technology from Bystronic. The company currently has some 220 employees at its 40,000 square meter site and trains apprentices in six different professions. Most of the parts they produce are used in the special machinery, vehicle, and shipbuilding industries.
“We work for approximately 20 large customers, but we are also pleased to accept small jobs,” Langen said. “We never decline an order.”
In general, the company maintains sustainable, long-term business relationships. “We have been supplying to our oldest customer for almost 30 years,” Langen concluded.
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.
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.
Bystronic presented its innovations for the sheet metal processing industry at Competence Day, 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.
With new solutions for sheet metal processing, Bystronic, a leading global provider of high-quality solutions for the sheet metal processing business, takes customers to the top of the competition at the EuroBLECH 2018 in Hanover, Germany.
At the most important sheet metal processing industry event, Bystronic presented comprehensive innovations for all aspects relating to cutting, bending, and automation. In the future, networked manufacturing processes, integrated automation, and digital service solutions will help customers to profoundly optimise the manufacturing of sheet metal products.
Bystronic is systematically refining the vision of “World Class Manufacturing”. This is based on a comprehensive range of new technologies and services with which Bystronic is gearing its users’ process landscape towards networked production. In this way, Bystronic accompanies customers step by step on their path towards the smart factory.
World Class Manufacturing goes far beyond the conventional idea of a machine tool. The focus lies on digitally networked production, which combines the individual processes related to laser cutting and bending to form a network of intelligent components. Users thus achieve a higher degree of flexibility and transparency in their production environment. Both are important prerequisites in order to manufacture products faster, more cost-effectively, and more intelligently than ever before.
Production Line: Fully Automated Laser Cutting
With the Production Line, Bystronic presented its highlight in terms of laser cutting automation. Within this fully automated manufacturing solution, sheet metal parts are pre-processed, cut, transported, and sorted according to orders. The heart of the Production Line is the ByStar Fiber laser cutting system. Powered by a 10kW aggregate, this is where the speed of the entire production process originates.
The ByTrans Cross and BySort loading and unloading automation is connected directly to the fibre laser. It handles the entire material flow between the laser and the integrated storage system. The storage system supplies all the raw metal sheets required for the cutting jobs: steel, stainless steel, aluminum, and non-ferrous metal sheets in thicknesses ranging from 0.8 to 25mm with a maximum overall capacity of 24 tonnes. It also returns finished cut parts and residual sheets to storage.
Bystronic presented a showcase at EuroBLECH to demonstrate a solution that will enable the Production Line to be expanded in the near future. ByFlex, an additional integrated system, drills holes and cuts threads into sheet metal parts prior to the laser cutting process. In addition, a labelling function marks the parts that are to be cut with a code. This allows all the information about the sheet metal parts that are being produced to be scanned in at the downstream processing stations.
Bending Cell: The Fully Automated Bending Centre
The Bending Cell automatically bends the cut sheet metal parts. For this, Bystronic expands the high-end Xpert Pro press brake with an agile robotics system. A 7-axis robot picks up the sheet metal parts that are to be bent, places them with high precision on the Xpert Pro for bending, and subsequently sorts them according to jobs. The Bending Cell can handle sheet metal parts up to 270kg.
With high precision, the robot also automatically sets up the press brake with the appropriate tools. To achieve this, Bystronic has integrated a tool magazine into the Bending Cell that keeps a range of required bending tools on standby. Thanks to a maximum press capacity of 320 tonnes, the bending automation solution can process a wide range of sheet metal products. The Bending Cell is ideally suited both for the efficient processing of high-volume repetitive jobs and for changing lists of jobs with small batch sizes.
Bystronic MES: Transparency From The Incoming Order To The Finished Part
The Bystronic MES is the navigation system for sheet metal processing. An intelligent software solution that helps users manufacture and ship sheet metal products with precisely defined costs and deadlines. The Bystronic MES determines the ideal path on which sheet metal products are guided through the processing stations for cutting and bending. This optimises throughput times and costs in the sheet metal production chain. And it helps users to perfectly attune all the process steps, machine systems, and workstations within their production environment.
Shop Floor Control System: The Digital Guidance System For Production Lines
In the future, how will users control and monitor production lines in which automated production cells and individual machine systems are networked? With the Shop Floor Control System, Bystronic showcased a newly developed software solution at EuroBLECH. Networked with sheet metal processing stations, the Shop Floor Control System assumes the centralised control function and helps users to always maintain an optimal production flow. The system also provides information about potential bottlenecks or downtimes within the production line. This enables scheduled production times and delivery deadlines to be adhered with a high degree of reliability.
ByStar Fiber: Laser Cutting With 12 Kilowatts
Bystronic projects promising prospects for fibre laser cutting: With 12kW, the high-end ByStar Fiber laser cutting system will soon feature a new performance level. This will boost the profitability and speed of the cutting process right up to sheet thicknesses as high as 30mm. This will provide customers with an almost unbeatable competitive edge in the competition for jobs. In order to optimally integrate the higher laser power into the cutting process, Bystronic has rigorously enhanced the design of the ByStar Fiber’s cutting head. Thus, users always achieve outstanding cutting results in a wide range of materials.
BySmart Fiber: The Fiber Laser For A Flying Start
The new generation of BySmart Fiber is already available now. Bystronic has fundamentally redesigned the entry-level solution for fibre laser cutting and expanded it with numerous features. The result is a versatile cutting system with up to 6kW of laser power and matching automation solutions. Thus, Bystronic is opening up the full potential of fibre laser technology to users in growth industries: high parts output, a broad spectrum of applications, and automation for optimised material handling.
Xpert Pro: Bending Technology For The Highest Demands
With the new Xpert Pro press brake, Bystronic is taking the successful Xpert product line a step further. The Xpert Pro supports demanding users with maximum flexibility and performance for the bending process. A variety of configurations are available for a wide spectrum of bending applications.
Features such as dynamic crowning and the patented pressure reference technology ensure consistently high bending quality on the Xpert Pro. On top of this, the Xpert Pro boasts intelligent assistance functions, such as the material curve generator and the LAMS angle measuring system. These enable users to achieve maximum precision from the very first bent part.
APMEN’s exclusive interview with Norbert Seo, Bystronic’s Senior VP Market Division Asia & Australia. By Ahmad Alshidiq.
What’s new from Bystronic in EuroBLECH 2018…
We have many new features on Industry 4.0. We have the full set of automation solutions with integrated software which allows you to combine automation with intelligent systems to monitor production schedules, machine status as well as to analyse the storage.
Bystronic’s main market in SEA…
Vietnam is our main market in Southeast Asia. We established our new demo centre in Ho Chi Minh last year. We call it the “Experience Center”, where we placed a laser machine and one bending machine. Malaysia market is looking interesting as well and we are looking at investing more in the country, in Thailand as well as Indonesia.
Industry outlook for 2019…
Business perspective is quite uncertain, however, we are looking at the demand of our customers and monitoring closely on where is necessary to expand our products and technologies.
What to expect from Bystronic in 2019…
We are launching a new series of BySmart Fibre from 2kW to 6kW which gives a lot of opportunities to the high-sensitive market. We are also attending seven exhibitions and are having five in-house shows in 2019.