CNC Cutting Solutions 2017 / 2018 CNC controller for cutting machines

Transcription

1 Laser Plasma Oxy-fuel CNC Cutting Solutions 2017 / 2018 CNC controller for cutting machines Water

2 CNC Cutting Solutions by Eckelmann More and more cutting machine manufacturers worldwide trust in CNC Cutting Solutions by Eckelmann. In addition to technical and economic factors, the cooperative partnership and economic stability in particular are decisive when choosing Eckelmann. Supporting all current processing methods and their combination: Thermal and water jet cutting, drilling, thread cutting, labelling and marking. The same control platform for all machine designs allows for streamlined procurement and warehousing as well as training and service. We offer interfaces to all technology providers and thus a free choice of cutting equipment. Control technology with long-term availability independent of short innovation cycles (in contrast to PC technology). Free choice of Eckelmann s scope of delivery: One-stop-shop from procurement of the pure control core to complete control and drive equipment. Optionally also inclusive nesting software with macro library. Developed and produced for the use in harsh environmental conditions. Compliance with all relevant national and international standards. Also with UL-certified switch cabinet construction as per UL File E Oxy-fuel / plasma cutting system: Sato Oxy-fuel / plasma cutting machine: ERL Automation GmbH

3 The Eckelmann Engineering Documentation Platform E EDP provides 24/7 current and quick online access to all technical information. No anonymous hotline, but personal customer service, including technical support, ensure quick problem solving. Comprehensive know-how protection for the machine manufacturer. Thus, your competitive edge is always secured. For customer care and support abroad, we have Eckelmann branches or representations in export markets such as China, India and Russia. Machine manufacturers can quickly and easily modify or extend the application programs of the controllers. Eckelmann s virtual 3D machine simulator offers machine manufacturers new possibilities in product development and training. Eckelmann is a medium-sized company group with more than 400 employees. Our head office is in Wiesbaden, near Frankfurt/Main (Germany). Our company was founded in 1977 and we have almost 40 years of experience in the development and production of CNC controllers. Continuity and extensive know-how in NC technology make Eckelmann a reliable partner for long-term cooperation. Dual oxygen cutting machine: Stako B.V. The Netherlands Retrofit of oxygen cutting machines: SAEHSEN Industrie-Service Germany and global

4 Features Interpolation types Staight line, circle Spline and polynomial interpolation Transformations 6-axes transformation (RTCP) Cylinder mantle transformation Transformation for rotation-axis Transformation for hexapod and tripod kinematics Transformation for robots kinematics 6-axes transformation for rotary table kinematics (RTCP) Cartesian polar transformation Tool path correction Tool radius compensation (WRK) Special modules for intermittent operation Axis correction 2D and 3D correction, sag compensation Directional height correction Spindle pitch error compensation Backlash compensation Programmable axis configuration Program interruption or termination Interrupt program call Storing of the abortion position Block scan and reverse for random access to the contour Switching function on the path depending on: Distance before M function Time before M function During acceleration or breaking Before and after a corner Technology functions Inclined axes (e.g. grinding) Height control (e.g. cutting) Pairing of axes path and rotation (e.g. grinding) Programming of tool spindles (e.g. grinding, milling) Non-cylindrical grinding Track in and move back strategies (e.g. measuring machine, eroding) Own CNC core Complete access to all functionalities Individual firmware extension, also exclusive Cutter + Plotter: Lasercomb GmbH Router: FlexiCAM GmbH Germany and United Arab Emirates

5 User Interface Cutting HMI The design of the user interface fully covers all cutting requirements and is based on Eckelmann Framework E Tools HMI. Design and functionality are entirely separated, allowing the machine manufacturer to adapt and expand the user interface individually. The user interface offers a fully integrated CAD/CAM basic system with a comprehensive macro library and geometry import in various file formats as well as automatic nesting for generating cutting programs at the machine. Furthermore, special cutting technology pages with interactive graphical user guidance and comprehensive help functions support the user when operating the machine. Eckelmann s image processing software allows for a camera image to be superimposed for sheet positioning detection, with automatic offset calculation and angle correction in the cutting program. Further options are: Offcut sampling, scanning of contour templates, or reading of product codes and plain text markings. Multifunctional cutting machine: Lind GmbH Pipe profile cutting machine: Müller Opladen GmbH

6 Laser cutting For laser cutting, a focused laser beam is absorbed at the cutting front and thus applies the required cutting force to the material. Gases push the ablated material from the cutting kerf. Gas and exhaust control, nozzle cleaning etc. Interfaces for conveyor lines and sheet bearing connection Technology table for storing all relevant cutting parameters: Material thickness, type and quality of material, cutting speed, laser power, cutting gas type Track speed dependent analogue output and PWM signal for the laser power control: Kjellberg Finsterwalde Plasma und Maschinen GmbH The pulse-width modulated output has a maximum frequency of 10 MHz and a resolution of 16 bit. Thus, the laser power can be controlled extremely precisely depending on the material to be processed and the track speed of the guiding axles. Important components of any laser-cutting machine are the laser beam source (resonator), the laser beam guide and the cutting head (focusing optics) including the cutting nozzle. period duty The most important laser-specific functions of the Eckelmann CNC: Control of the cutting components and the cutting peripherals: Laser beam sources from IPG, Coherent-ROFIN, SPI Lasers, TRUMPF Laser cutting heads from Precitec, HIGHYAG und Laser Mech Shuttle table of varying designs The fly-cut option reduces cutting time significantly. During the scanning of all horizontal and vertical cuts with a consistently high speed, the laser beam is switched on and off on the fly by activating and deactivating the signal directly in the fine interpolation cycle of the control. Here switching times are in the microsecond range. Laser cutting machine: Motofil Equipamentos de Corte, Lda Portugal Laser cutting system Proteck Machinery Pvt. Ltd. India

7 Frog-jump function for the parabolic traversing of the laser cutting head between the beginning and end of the new contour section in z-direction This prevents any collision between the laser head and the cut parts and reduces the traversing time compared to a separate z-axis movement. Frog-Jump Quick height adjustment for a constant distance between the workpiece surface and the cutting nozzle by recording the analogue distance signal using characteristic linearization. CNC-controlled compensation mechanism for an optimal laser focus position with directional correction. Compensation of deformations in the focus geometry by corresponding corrections. Integration of manufacturer specific laser diagnostic tools directly into the CNC user interface. Height adjustment Further universal functions for cutting applications: Sheet position detection and offsetting, kerf compensation, reverse travel and returning to the contour Consumables monitoring, operating data acquisition and order management, error log etc. Laser Plasma Cutting speed Oxy-fuel Sheet thickness Laser marker: Baublys 7000 Laser cutting system Lasercomb CLS 2115

8 Plasma and oxy-fuel cutting For plasma cutting, the sheets are cut using a conductive gas (plasma), which is generated by an electric light arc. Kjellberg Finsterwalde Plasma und Maschinen GmbH For oxy-fuel or flame cutting, the metal sheet containing carbon is first heated to ignition temperature and then burned in the oxygen jet. Often plasma and oxy-fuel cutting are used in one machine. The control system must manage both cutting processes and must be able to support additional units: Drilling and thread cutting heads with or without automatic tool change Marking devices with pin marker, inkjet printer or plasma marker Additional rotary axis on flatbed machines for tube cutting Standard functions for all cutting applications: Sheet position detection and offsetting Kerf compensation with automatic overcut Reverse travel and returning to the contour Throttle control at the extraction table Consumables monitoring Operating data acquisition and order management Error log Operation with multi torch carriages: Individually motor-driven, with automatic band clamping or both on one machine bridge 2 or more bridges on one track are possible thanks to multichannel CNC and collision monitoring Oxy-fuel bevel cutting machine: Lind GmbH Oxy-fuel / plasma cutting machines: Hollysen China

9 Plasma cutting Oxy-fuel cutting Basic quality features and control requirements for plasma cutting are: Burr-free cut Reduced roughness of cutting edge Rectangular cutting edges Plasma power sources and automatic gas consoles of the manufacturers Kjellberg Hypertherm Thermal Dynamics are supported. For an automatic communication with the plasma power source, the associated databases of the manufacturers are integrated into the CNC control. The distance between the plasma torch and the metal sheet surface can be adjusted using external height control systems, for example from IHT Automation, Kjellberg or by using arc voltage inside the CNC; with corner signal and other special functions. Technology tables for oxy-fuel cutting Configurable speed reduction at cutting start and end Variable control of the gas technology depending on valve arrangement and valve type: Switching valves Proportional valves with pressure rampus Height control of the oxy-fuel torch using external height control systems or CNC-integrated height control through recording and linearization of a capacitive measuring signal. Bevel cutting with 3 torches arrangement: Automatic motorised torch angle and lateral adjustment Several oxy-fuel bevel cutting units are possible on one machine Cross section of the thermal cutting processes Almost any TCP and non-tcp kinematics for 3Dprocessing (bevel cutting) Several bevel units on one machine are possible, also together with rotary axles for round tube and section tube cutting Plasma Laser Oxy-fuel Oxy-fuel / plasma cutting machine: Rate China Oxy-fuel / plasma cutting machine: Swayambhu Engineering India

10 Waterjet cutting For waterjet cutting, water is pushed through a nozzle with a pressure of 4000 to 6000 bar and accelerated to twice the speed of sound. Important control requirements for water jet cutting: Avoiding bevel cuts and maximising cutting speed are important challenges. Here, the control requirements are material parameter management using a technology table and bevel cut adjustment through supporting relevant axle kinematics. A precise cut requires accurate and quick distance control between the cutting nozzle and the workpiece surface. For this, the height of the workpiece is scanned using displacement sensors, configurable in the control, and various measuring strategies. Special speed ramp functions for minimising the whip effect, in particular for corners and small radii Luca Fabbian/Shutterstock.com One differentiates between the pure water cutting for cutting soft materials and the abrasive cutting with added abrasives for cutting hard materials such a glass, stone and metal. Water jet only and abrasive water jet cutting support with parameterisable abrasive dosing Connection of high pressure pumps using varying interfaces and protocols Freely programmable sequential control for water preparation can be integrated Several cutting heads on one machine bridge and several machine bridges on one track are possible 3D workpiece processing thanks to supporting various cutting heads kinematics Pure water cutting Abrasive cutting Waterjet cutting system: STM GmbH, Austria Waterjet cutting system: Sato

11 Additional cutting / separation processes There are several other material-specific separation processes, in addition to water jet and thermal cutting. For this, varying tools, requiring specific control properties, are used. Electric discharge machining - EDM Wire-cut EDM Revolving band knives for foam cutting of upholstery, mattress, packaging and insulation materials Tangential tool tracking Turning points on the contour Brass wire for wire-cut EDM or graphite electrodes for electric discharge machining for tool and mould making Discharge gap control Reverse retraction Jigsaws and knives for cutting clothing products and technical textiles Tangential tool tracking Compensation of knife regrinding Special strategies for corners Rotation-symmetric tools for milling and engraving machines for the processing of wood, metal and plastics Tool radius compensation Length compensation Cutting wheels for scratching glass in preparation of the subsequent breaking of the glass Tangential tool tracking Heating wire for cutting EPS materials (polystyrene) Special thermal functions Control of cutting pressure Special strategies for corners Textile cutting machine: Kuris Glass cutting machine: Hegla

12 Range of products and service Custom operating panel with E Tools HMI Connection of peripheral and auxiliary units, for example, plasma power source, marking system etc. CNC controller E EXC 66 and I/O modules E LBM Box PC E PC B0101 Drive controller E Darc Safety logic controller E SLC 204 Safety I/O module E SLC SIO084 and CAN bus coupler E SLC CAN Camera E CAMBOX Motors E SL3 compact Example of complete equipment for a 4 axis-cutting machine (CNC supports up to 16 axes) Oxy-fuel / plasma cutting machine: Proarc India Water jet cutting system: Atech

13 Embedded controller E EXC 66 Includes drive interfaces CANopen, EtherCAT, Sercos III or analog; ports for Ethernet, RS232, USB as well as SD card slot and watchdog. Its powerful CNC operating system offers new cutting specific additional functions. Machine manufacturers can independently extend its SPS application software for all cutting methods. Local bus modules E LBM Provides activation of the machine signals (digital, analogue, serial, PWM) as well as an interface for a separate machine operating panel and fieldbus modules for a distributed I/O structure. Operating panel Offers a large 21.5 multi touch panel in 16:9 format with Full-HD resolution. Operating elements can be fitted as needed by the machine equipment. The panel can be placed up to 100 m away from the switch cabinet IPC at an ergonomic place on the machine. Box-IPC For panel mounting in various performance and equipment variants; in connection with operating panel (see above). Additionally, we offer integrated panel IPCs as alternative to the above remote solution. Safety Logic Controller E SLC204 For safe connections and prefabricated components that are graphically programmed in the function chart. Interface connection to E EXC 66 via CANopen. Servo controller and motor family For a wide power range from 200 W to 16 kw. With different motor features, several encoder systems and types (also linear motors), designed for maximum energy efficiency with high dynamics. EPS cutting system: Pantel + Brömser Foam contour cutting machine: Bäumer

14 Industry 4.0 The path to an intelligent and flexible production Image processing as automation tool In industry 4.0, production and modern information and communication technologies are intertwined. This is due to digital networked systems, so that users, machines, plants, logistics and products can communicate and interact directly with each other.. Machine vision is an important catalyst for increasing the level of automation in production processes. It has become indispensable in quality control and for the identification of products as well as in process control and monitoring. istock.com/mstay Eckelmann advises and accompanies you on the way to Industry 4.0 and to a Smart Factory. During the cutting process, the CNC control systematically collects and analyses continuously generated data in the Big Data analysis. Thus, the complete production process can be monitored and controlled from an office. All relevant information, such as current cutting jobs, cutting times, cost calculations and machine state and machine utilisation, is available online. When using Eckelmann industrial cameras and image evaluation software, in addition to the pure process visualisation, the position of the sheets on the machine table and the offset and angle correction are also automatically calculated in the cutting program. Furthermore, residue plates can be detected and thus reused. Additionally, it is possible to scan in cutting contours (sheet or drawing) and to read and verify product codes and markings in plain writing. Cylindrical and non-cylindrical grinding machine: CNC-Technik Weiß Wire bending and forming machine: Post

15 Additional services Switch cabinet construction at Eckelmann Meyer Werft GmbH & Co. KG Furthermore, Eckelmann offers machine manufacturers electrical design and switch cabinet construction. Our electrical design engineers use EPLAN, promis, ELCAD, RUPLAN As we are a UL-certified switch cabinet manufacturer, you do not require any expensive, on site UL-inspections. The following services are offered for machine integration into the end customer s production environment: CNC connection to higher level IT systems, a requirement for Industry 4.0 Manufacturing Execution Systems (MES) Control solutions for conveying and storage technology Alternative compact controller E EXC 880 Plug-and-play ready all-in-one controller especially for series application. Price-optimised solution with precisely defined scope of service and reduced commissioning efforts at the machine. Also available as export variant (no BAFA export licence required). Please contact us for detailed information about the E EXC 880! Depaneling machine: Systemtechnik Hölzer PCB processing: Asys

16 Networked intelligence the Eckelmann Group Thanks to continuous internal growth and investments, the engineering firm, founded by Dr.-Ing. Gerd Eckelmann, has grown into a leading medium-sized company group for automation technology. Eckelmann AG Berliner Straße Wiesbaden Your representative: Nils Scholbrock Telephone N.Scholbrock@eckelmann.de Ferrocontrol Steuerungssysteme GmbH & Co. KG Bodelschwinghstraße Herford Rex Automatisierungstechnik GmbH Fichtenweg Erfurt Eckelmann Industrial Automation Technologies (Beijing) Co., Ltd. Fl. 3 of West Plant Kangzhen Yuan, No. 69 of Yangzhuang Street Shijingshan District Beijing P.R. China Your local representative: Eckelmann Group Source of inspiration Your representative: Peter Schicker Telephone PSchicker@ferrocontrol.de Your representative: Matthias Rex Telephone M.Rex@rex-at.de Your representative: Roland Simon Telephone R.Simon@eckelmann.de Eckelmann AG 09/2017 All registered trademark are the property of the respective manufacturers. Technical modification and errors excepted.