BALLIU nv Machine Tool Corporation

Transcription

1 1894 BALLIU nv Machine Tool Corporation Sheet and Tube CO 2 - cutting solutions

2 Balliu history balliu uses CATIA to design your machine Since Balliu was founded in 1894, it has been developing machines for the industry. In 1985 we first began integrating a cutting laser into an existing CNC milling machine. Two years later we developed, built and programmed our first own Numerical Controlled 3-axis laser cutting machine, the Minotaur. Since then, Balliu vastly expanded its product range as explained on the next page. Today, laser-equipped machines are the core-business of Balliu. Balliu covers 90% of the production process of its machines: CAD-design, machine frame welding, paint-job, milling of parts, electric wiring, programming and testing are all done in-house. The competence acquired in all these areas makes Balliu the ideal partner for building the best machine for your application, whether it is a standard application or a custom-made application. An important step in Balliu s history was the integration in 2003 of the company by OGEPAR, a Luxembourg based financial holding that groups amongst other several technological companies in the metal industry. Important technological milestones in Balliu s history are the development of the first gantry-machine with linear motors in 1994 and the first SLF-tubecutter in Ninety percent of the machines are for export. We have machines on every continent. Balliu competences Quality components Balliu only integrates components from renowned manufacturers with worldwide presence. Siemens delivers the Numerical Control, the PLC and the servo motors. Rofin is our standard supplier for Slab and fiber lasers. Laserline is our standard supplier for diode lasers Siemens, Rofin and Laserline provide worldwide service support for their products. Precitec supplies the cutting heads. Bosch Rexroth supplies the hydraulic groups that power the pallet changers and loading systems. Festo supplies the pneumatic equipment. 2 - balliu.be Balliu designs and manufactures Laser integrated production machines. Its product range is split into two groups: Standard machines and customized machines. Standard laser cutting of sheets and tubes with the RP, LD, LM and SLF-series machines covered in this brochure. Customization of the fore mentioned standard machines. Some clients process special sheet sizes or coils and prefer a machine that can process these. A customized loading system for these sheet sizes is also possible. Some examples are covered in this brochure. Customized 3D machines. Three-dimensional objects that have to be cut/welded/cladded require a minimum of 5 axis to do the job. Customized laser welding machines using CO2 and fiber lasers. A combination of welding techniques is possible. Mig/MAG together with laser welding is just one example. Another important customization are the fixtures that clamp the pieces together during the welding. Laser cladding machines using diode lasers. With a growing installed base, Balliu has a vast expertise in this niche market. Customized Laser ablation machines for the industries that produce tailored blanks. Our client list include the following companies: Arcelor Mittal (USA), Bosch (Germany), Heras (The Netherlands), Indian Railways (India), Blücher (Denmark) balliu.be - 3

3 RP standard: Entry-level Sheet cutting L1 L2 L3 Z Y W1 X The RP is a budget friendly Laser cutting machine for companies that switch from time-consuming outsourcing to in-house production of lasered parts. For them, cutting accuracy and flexibility is more important than high volume production. Standard the machine has a fixed pallet of 1500 x 3000 mm. The loading and unloading is done with the cantilever arm aside the cutting area. Several pallet options are available: a fixed table or a manual pallet for easy loading and unloading outside the machine enclosure. Page 7 gives an overview of popular options and the available lasers for this machine. : RP1500n Footprint dimensions Length L mm Length L mm Length L mm Width W mm Axis Range X-axis 1525 mm Y-axis 3050 mm Z-axis 100 mm Axis speeds Speed X&Y-axis 60 m/min Combined (X&Y) >80 m/min Speed Z-axis 50 m/min Accuracy X, Y & Z-axis +/ mm Repeatability +/ mm Maximum Load 750 kg RP1500n with two sliding doors. With the manual pallet option, the operator can load & unload the pallet outside the machine enclosure. This option is required when a rotating axis is installed on the machine. 4 - balliu.be balliu.be - 5

4 RP rtx custom Popular Options Option: LPM LPM or Laser Piercing Monitoring LPM is a hardware option that is active during the drill-cycle. During the drill-cycle the laser beam is piercing a hole through the material. Once the material is pierced the cutting of the part can start. Without LPM, the drill cycle is fixed and often is longer than necessary. Once the LPM detects that the material is pierced, the machine immediately starts cutting. The LPM-option has a multitude of advantages. The thicker the material, the more time and energy is saved. As a result, the area under the sheet is less damaged. With LPM the operators don t have to bother looking for piercing parameters, a time-consuming task for apprentice operators. A rotating axis always requires the customization of a standard RP. The customization depends highly on the type of parts the client will cut. The picture above shows an example. The rotating axis has a 3000 mm long frame which is placed adjacent to the pallet. The height of the frame determines the diameter range the RP rtx can cut. Tubes up to 3000 mm can be front-loaded, longer tubes are loaded through an opening in the machine enclosure. To the left is the pneumatic chuck that holds the tube, to the right is the steady rest with the exhaust system flexible attached to it. Two tube supports inbetween support the part once it is cut. This client primarily cuts 5 mm thick square beams of 100 x 100 mm and the parts are between1000 and 2500 mm long. The 6 meter long beams are fed through an opening in the enclosure. The part is cut from left to right. Then the right end is cut en finally the left end is cut. The part is then removed by hand. Laser choice Option: AFC AFC or Auto Focus Control The vertical position of the focal point relative to the surface of the material is critical for quality laser-cutting. Without AFC, the operator has to change the vertical position of the lens in the cutting head each time the material/thickness changes. With AFC, the focal position is automatically changed as soon as the new material/thickness is selected in the material-library. With AFC the operator can alter the focal position during piercing and between piercing and cutting leading to a faster, a safer and a better result. Balliu uses the Rofin DC-lasers as standard laser for CO 2 -laser equipped machines. These are some of the benefits: Low service requirements thanks to the robust, low-maintenance design Minimal gas consumption due to diffusion cooling Energy-saving standby operation with minimal energy consumption A 3D design of one of the parts that is cut on the RP rtx TECHNICAL DATA Beam excitation: RF Output Power: 1000 W, 1500 W, 2000 W, 2500 W, 3000 W, 3500 W, 4000 W, 4500 W, 5000 W Wavelength: 10,6 µm Beam Characteristic Number: K = 0,95 The most suitable laser output power is chosen depending on the machine type and the required applications, quality and productivity. 6 - balliu.be balliu.be - 7

5 LD standard: High speed, High production Sheet cutting Z Y W2 X W1 L2 L1 Powerful linear motors on the horizontal axis make this machine very fast. Together with the standard pallet changer the LD ensures the highest possible production volume. If you only process thin sheet material and highly reflective materials like copper and aluminium, you should consider the fiber-version of the LD in our fiber-solutions brochure. Page 7 gives an overview of popular options and the available lasers for this machine. : LD1250PS LD1500PS LD2000PS Footprint dimensions Length L mm mm mm Length L mm 8850 mm mm Width W mm 3375 mm 3975 mm Width W mm 5650 mm 6250 mm Axis Range X-axis 1275 mm 1525 mm 2025 mm Y-axis 1275/2550 mm 3050/4050 mm 3050/4050/6050 mm Z-axis 80 mm 80 mm 80 mm Axis speeds Speed X&Y-axis 150 m/min 150 m/min 150 m/min Combined (X&Y) >200 m/min >200 m/min >200 m/min Speed Z-axis 50 m/min 50 m/min 50 m/min Accuracy X, Y & Z-axis +/ mm +/ mm +/ mm Repeatability +/ mm +/ mm +/ mm Maximum Load 500 kg 750 kg 1250 kg 8 - balliu.be balliu.be - 9

6 LD custom Balliu often customizes the LD s length and width because clients all over the world use different sizes of sheet material. Up until now the biggest LD ever made can process sheets of 2000 x 8000 mm. Of course the pallet changer is adapted to the surface and weight of these large size sheets. The LD 2000 RTX has another feature. An numerical controlled rotating axis was added at the front side of the machine because the customer occasionally has to cut cylindrical pieces of maximum 2000 mm long. The diameter range of the rotating chuck is between 20 and 200 mm. The front door slides open to access the tube cutting area. Tubes up to 2000 mm can be loaded via the front door. Longer tube sizes can be slid into the rotating chuck via an opening in the machine enclosure. A linear loading/unloading system is often customized to the client s wishes. The production autonomy depends on the complexity of the parts and the thickness of the sheet material: The more complex the part and the thicker the sheet material, the longer it will take to cut one part. The purpose is to continuously operate in absence of the operator (night/weekend). Once the operator returns, a fresh stack of sheets has to be loaded and the pallet with the cut parts and skeletons has to be exchanged with an empty pallet balliu.be balliu.be - 11

7 LM & LM rtx standard: Ideal jobshop solution for cutting sheets and tubes W1 W2 Like the LD-series, the LM-series is equipped with powerful linear motors on the horizontal axis. The gantry covers the length of the cutting area. Therefore two sliding doors allow the operator to easily access the complete cutting area. The linear motors together, with the standard pallet changer ensure the highest possible production volume. The difference between the LM- and the LM rtx-version is the rotating axis. The rotating axis allows cutting tubes from 20 to 250 mm in diameter. These tubes must be front loaded and have a maximum length of 3000 mm. Tubes from 20 to 100 mm can be loaded through a hole in the enclosure and can be longer than 3000 mm. If you only process thin sheet material and highly reflective materials like copper and aluminium, you should consider the fiber-version of the LD. Page 7 gives an overview of popular options and the available lasers for this machine. Z Y X L1 The tube cutting area can also be used for flat cutting 3D objects (ex. enclosures, steel beams, etc.). Footprint dimensions : LM1500PS LM1500RTX Length L mm 9650 mm Width W mm 4125 mm Width W mm balliu.be balliu.be - 13 Axis Range X-axis 1525 mm 1525 mm Y-axis 3050/4050 mm 3050/4050 mm Z-axis 80 mm 80 mm Axis speeds Speed X&Y-axis 150 m/min 150 m/min Combined (X&Y) >200 m/min >200 m/min Speed Z-axis 50 m/min 50 m/min Accuracy X, Y & Z-axis +/ mm +/ mm Repeatability +/ mm +/ mm Maximum Load 750 kg 750 kg

8 LM custom The owner of the LM2000RTXi had the following demands: A fast laser cutting machine Able to cut 2000 x 6000 mm sheets A pallet changer for high production volume Able to cut tubes A customized LM2000rtx was our answer. We kept the 2000 x 3000 mm cutting area. Instead we chose to cut the 2000 x 6000 mm sheet in two steps. Once the first half of the sheet is cut, the pallet moves through the machine to the indexed position, about 3000 mm further. Balliu already made machines that cut 2000 x 8000 mm sheets. These were cut in 3 steps. The specs for cutting tubes are the same as the standard LM rtx. Mirrored Machines Several clients have chosen for two mirrored machines. The extra cost for purchasing a mirrored machine is quickly recuperated by the savings that are made by operating both machines with only ONE operator. The machines are mirrored in such a way that the operator has a quick overview of the operator consoles and the ongoing process. All the machines in this brochure can be mirrored. Two mirrored LM-machines 14 - balliu.be Two mirrored SLF-machines balliu.be - 15

9 SLF standard: Tube cutting The standard SLF 110 is a very versatile tube cutter. A 3.5 ton, up to 7 meter long bundle of round, square, rectangular or oblong tubes ensures a substantial production autonomy. The maximum tube diameter is limited to 110 mm in diameter for round tubes. X-axis speeds go up to 165 m/min. The machine setup is done automatically when changing tube type. The unloading station has a front and a back position for sorting different types of parts. An important option is the weld seam detection. By automatically detecting the weld seam on the tube, the designers can have the part cut in such a way that the weld seam is hidden in the final product. This is important in the furniture industry. Page 7 gives an overview of popular options and the available lasers for this machine. The SLF can be customized for tubes up to 13 meter long and larger tube diameters. : SLF110 Footprint dimensions mm Width W mm Width W mm A displaceable steady rest is a standard feature of the SLF. During normal operation the tube is held by the chuck and the steady rest and no cutting is done in the zone inbetween. When the last part is cut, the cutting head goes all the way up, the steady rest moves about 400 mm forward to allow the cutting head to cut close to the chuck that clamps the tube. A recent redesign further reduces the length of the remaining scrap part to a mere 80 mm balliu.be W2 W1 Length L1 L1 balliu.be - 17

10 SLF custom: Strip Steel & Tube cutting SLF custom: Popular Options This machine is made to cut only round stainless steel tubes with a diameter of 50 to 600 mm. A special steady rest supports the tube while a roll on a pneumatic cylinder pushes the tube downwards. In the back we see the weldseam detection unit going down. Under the cutting zone a pneumatically operated scrap valve is opened when scrap falls. The valve instantly closes just before the final cut that makes the part fall down on the conveyor. A conveyor under the scrap valve transports the scrap to a container. Strip steel laser cutting has some major advantages compared to sheet metal cutting. Less and smaller scrap allows separate and automatic unloading of scrap and parts. This allows the machine to continue to produce after working hours without supervision. The cutting of the parts is faster because the rounded sides of the strip steel often don t have to be cut. Furthermore this machine is also a full automatic tube cutting machine for round and square tubes up to 110 mm diameter and a length of 7 meter. The machine has 2 unloading positions for parts up to 6 meter long. Stainless steel strip steel part The unloading table supports the strip steel part while it is cut. The catcher tube is slid into the tube under the cutting head. The laser beam is absorbed into the catcher to prevent it from damaging the inside of the part. For the same reason the sparks and smoke are sucked out through the catcher. Up to 4 V-shaped NC-driven tube supports can support the part when it s too heavy. Once the part is cut, the tube supports are slowly lowered to reduce the height from which the part falls on the conveyor balliu.be balliu.be - 19

11 Quality Quality is assured by the following strategy: We use high quality components from renowned suplliers with worldwide presence. See page 3 for more information. Intense training with emphasis on customer applications and maintenance. Service Worldwide Service is assured via: Remote diagnostic via internet. Application advice and support during start-up. A multilingual international team of service engineers. Sheet and tube CO2 v1/en/ Document realized with the help of Flanders Investment and Trade Headquarters: BALLIU MTC nv an OGEPAR Wolfsakker 8 B-9160 Lokeren BELGIUM Tel: Fax: info@balliu.be company Agent / Distributor coordinates