Advanced Cutting Technology

Prima Power North America, Inc. (Arlington Heights, IL) launched the new 5 kW Platino® Fiber laser that delivers piercing time reductions of up to 90 percent, near-zero lens setup times and cutting speeds of up to 5 m/min on stainless steel, which is on average 20 percent faster than the 4 kW machine. These advances result in ground breaking levels of productivity and cost reduction. Nitrogen piercing, which uses a flush of nitrogen to suppress the plasma, reduces piercing times in mid-to-high thickness material by up to 90 percent. For 12 mm mild steel, the 5 kW Platino Fiber pierces in less than one second. During trials, on a sample 12 mm thick mild steel part with 120 holes, cycle time reductions were around 25 percent. Additional benefits for users of nitrogen piercing include significantly less heating of the part during piercing, which means a better quality part due to a smaller heat affected zone and the cooling effect of the nitrogen.

As well as nitrogen piercing, this new Platino Fiber has an option for a Laser Piercing Monitor. LPM gives real time feedback and a check when piercing is completed. This system adds to the reliability of the cutting process, and is especially useful for automated operation as it reduces the possibility of unplanned machine stoppages. In addition, it makes the laser less sensitive to material quality issues and it is effective with material up to 20 mm thick. The redesigned fiber head uses a single universal lens for all materials, eliminating the need to change lenses resulting in near-zero setup time. Furthermore, the optical chain is completely sealed to eliminate the possibility of any contamination.

Other features of the new fiber head include a 35 mm stroke on the focal axis, a dedicated lens drawer with OPC (Optical Precision Control) quick alignment technology, and exchangeable protective glass that allows easy inspection to keep the optics safe and reliable. OPC uses a machine cut reference figure to compare the actual position of the beam with its theoretical position. The operator simply follows on screen instructions to quickly adjust the beam position for precise alignment, ensuring repeatability and accurate production of parts.

Other features of the new fiber head include a 35 mm stroke on the focal axis, a dedicated lens drawer with OPC (Optical Precision Control) quick alignment technology, and exchangeable protective glass that allows easy inspection to keep the optics safe and reliable. OPC uses a machine cut reference figure to compare the actual position of the beam with its theoretical position. The operator simply follows on screen instructions to quickly adjust the beam position for precise alignment, ensuring repeatability and accurate production of parts.

This new machine includes Fiber Plasma Monitoring to detect problems with the cutting and the formation of plasma when cutting is lost. An automated cycle then resolves the problem by moving back a preset distance along the cut path and starting the cut again from a safe stand-off position. Cutting speeds are reduced, parameters on the machine are automatically adjusted, and a warning is sent to the CNC control on the machine before cutting is automatically restarted, further reducing the possibility of unplanned stoppages, essential for reliable automation. The machine is available with a wide range of nozzles for any application, with an option for automatic nozzle exchange, and comes with SIPS (Safe Impact Protection System), which protects the head in the event of a collision to further add to efficiency, safety and low cost operation.

For even higher efficiency on material up to 5 mm thick, the new machine integrates a new piercing strategy which results in drastic cycle time reductions, especially on complex nests of parts. Another function that dramatically increases productivity is the SmartMoves technology for intelligent management of cutting parameters that allows shorter cycle times and increased reliability through smoother operation. The new 5 kW Platino Fiber is more compact thanks to a redesigned fiber path that enables the overall machine to be 230 mm shorter. Not only does this save weight and material, but it also reduces inertia in moving parts leading to higher reliability and faster cycle times. The new machine also comes with an option for a basic cabin which comes fully assembled. The advantages are reduced cost for the cabin, a fixed roof, fast, on-site, plug and play installation and easier transportation.

To provide high levels of thermal stability and vibration damping, the frame of the Platino Fiber is built from synthetic granite. Its wide access doors make it easy to access the workings of the machine, facilitating ergonomic operation. The laser itself comes in a compact and rugged cabinet which is easy to install. The high quality 5 kW Ytterbium Fiber laser offers over 30 percent wall plug efficiency and has been designed to deliver an excellent Beam Parameter Product (BPP) that is constant across the entire power range, making it possible to achieve a very small focused spot over a large working distance.

For 24-hour lights out operation, the machine can be automated with a range of automation systems. The Compact Tower handles blank material and finished parts and can have 3, 10 or 15 pallets and, with the addition of a second tower, can go up to 36 pallets. The system automatically loads a new sheet on the 5 kW Platino Fiber table ready for cutting, and unloads a finished sheet of parts when the tables are exchanged at the end of the cutting cycle. Logic in the control enables a list of different sheets of parts to be selected and cut in a sequence that meets the production schedule for fully automated production. The LST system goes a stage further, with robot picking of parts as they are cut, sorting and stacking them as they are finished. For the ultimate solution, the Night Train FMS® system links different machines and handling systems together to make a comprehensive and flexible system that produces finished parts without any operator intervention.

Overall, the 5 kW Platino Fiber is designed to ensure reliability and speed in 24/7 production. Fast nitrogen piercing, 5 m/min cutting speeds and SmartMoves technology combine to minimize cycle times. Advanced technology in the Laser Piercing Monitor and automated parameter setting and tip replacement, together with automatic restart functions, as well as fault notification by SMS, should operator intervention be required, add together to minimize the chance of an unplanned delay in production. The new 5 kW Platino Fiber offers low power consumption, less gas usage, the ability to cut reflective materials and minimized maintenance, as well as significantly faster production cycles, technology aimed at improving both process and mechanical reliability, and automation options that can transform productivity levels.

Prima Power North America, Inc., 555 West Algonquin Road, Arlington Heights, IL 60005-4411, 847-952-6500, Fax: 847-952-6590, [email protected], www.primapower.com.