CO2 2-Dimensional Laser Processing Systems ex Series Eco Changes is the Mitsubishi Electric Group s environmental statement, and expresses the Group s stance on environmental management. Through a wide range of businesses, we are helping contribute to the realization of a sustainable society. K-K-02-2-C9029-A NA-1207 Printed in Japan (MDOC) 2012 New publication effective Jul. 2012. Specifications are subject to change without notice.
Advanced Solution for Productivity and Environmental Requirements The faster processing speed and optimized control system of the ex Series reduces thin-plate processing time by approximately 20%*. The cutting-edge piercing technology allows for about a 30% reduction* in processing time of mid-thick and thick mild steel plates. *In-house comparison When not processing, the system switches to ECO mode and the resonator stops idling. Minimizes energy consumption, reducing running costs by up to 99%* during standby. Quickly resumes normal operation. Mitsubishi Electric s original resonator reduces CO2 emissions by approximately 30% compared to standard high-speed, axial-flow resonators. *In-house comparison The ex delivers maximum productivity and incorporates 2 Action Cutting which provides extremely simple operation. It also features an ECO mode that reduces power consumption during standby by up to 99%*. *In-house comparison 2 Action Cutting allows for the entire process, from job setup to parts cutting, to be completed in two simple actions. Delivers easy operation and stable performance. CAD/CAM computer, connected via network, is a great aid for operators on the shop floor. 3 4
1986 L Series 1994 LB Series 1995 LX Series 1983 MX Series 1998 LZ Series 1982 MH Series 2001 LV Series It Just Keeps Getting Better Exceeding Customer Expectations with the New Series 2008 LVPlus Series Two-dimensional Laser Processing Systems Series 1 2
Faster Moving Axes Increased machine tool rigidity, Helical Rack and Pinion on the X and Y axes and optimized path-control technology result in approximately 1.2 times faster movement and 2 times faster acceleration speeds compared to previous model. The result is amazingly short processing times. Thin-plate High-speed Cutting Productivity has been dramatically enhanced owing to improved acceleration and the latest control technologies exclusive to Mitsubishi Electric. An example is Dross Reduction (DR) Control, which contributes to high-speed corner processing while maintaining high quality. Mild-steel Cutting Less time is required for piercing and changing conditions, resulting in substantially reduced operating cost and enhanced productivity when cutting medium and thick mild steel plates. Mid-thick mild steel Thick mild steel 138mm 100mm 188mm 200mm Material: SECC t1mm 150mm Material: SS400 t6mm Material: SS400 t16mm Comparison when cutting 159 parts of the above sample Processing time (SECC t1mm) Comparison when cutting 247 parts of the above sample Processing time (SS400 t6mm) Comparison when cutting 105 parts of the above sample Processing time (SS400 t16mm) 147 minutes 371 minutes 837 minutes 45 minutes 248 minutes 461 minutes 32 minutes 29% shorter 162 minutes 35% shorter 185 minutes 60% shorter Operating cost (SECC t1 mm) 5,949 yen Operating cost (SS400 t6 mm) 4,172 yen Operating cost (SS400 t16mm) 17,832 yen 2,374 yen 2,876 yen 17% reduced 2,044 yen 2,803 yen 27% reduced Calculation conditions Electricity cost 20 yen/kwh Outstanding Productivity for Thin & Thick Plates Alike 4,457 yen 11,431 yen Laser-gas cost 8.94 yen/l 61% reduced Assist-gas (N2) cost Assist-gas (O2) cost 0.15 yen/l 0.13 yen/l Technologies Supporting Thin-plate High-speed Cutting High-speed Cutting Technology for Mid-thick Mild Steel Plates High-speed Cutting Technology for Thick Mild Steel Plates Head retraction method Blow piercing Beat piercing The optimum retraction method may be set according to the material and plate thickness. Minimize processing time and achieve better stability by selecting the best retraction method. Normal retraction (LZ/LV/eX) Diagonal retraction (LV/eX) Arc retraction (ex) Produces smaller piercing holes faster in mild steel up to t16mm in thickness by controlling the oxidation reaction and optimizing beam quality. Air outlet High-peak power control realizes the same level of quality as the previous slope piercing while reducing the piercing time of mild steel up to t25mm by a maximum of 50% compared to the previous model. Applicable thickness of blow piercing Processing nozzle Piercing time Applicable thickness (mm) 0 2 4 6 8 10 12 14 16 18 20 Previous model In addition to the latest control technologies, travel in the Z-axis is 3 times faster and has twice the acceleration speed (compared to previous model), enabling shorter processing times. Faster Z-axis DR Control reduces dross adhesion at corners, realizing high-speed processing while maintaining high quality. Dross Reduction (DR) Control DR Control off DR Control on Previous model ex Increased 78% ex 50% shorter 0% 20% 40% 60% 80% 100% * Material / Thickness: Mild steel / t25mm Piercing time on ex as compared to previous model which is taken as 100% * Data in this catalog is for reference only, and may vary from actual values. 5 6
Simple Two-action Processing Automatic setup realizes simple operation in two effortless actions. This not only prevents operation and setup errors, but also contributes to enhanced productivity. Press the start button Read barcode Automatic tilt measurement Automatically measures the tilt of the workpiece on the work table Barcode reader (handle box shown on left) Automatically loads onto NC Easy to Use, Even for Beginners Automatic nozzle change and height calibration Starts cutting * To create instruction sheets with barcodes, a CAD/CAM software capable of producing barcodes is required. * The nozzle changer is optional Extremely Versatile - From Simple 2 Action Cutting to Advanced Applications Features Designed for Experienced Operators Simple Nesting New Reset Restart Function E-Processing mode Pro-Processing mode Double-cut function Offcut Cutting Allows for rectangular nesting at the laser s NC control to meet urgent needs for additional parts. If the system resets in the middle of processing, it will easily restart cutting once the cause of stoppage is eliminated. Allows the operator to check and adjust the restart position quickly and easily on the control. A novice-friendly operating environment can be created by hiding the advanced settings screen. The advanced settings screen can be displayed for advanced laser applications. Allows high quality cutting of poor quality material and protected sheet metal, which often causes cutting defects, in two runs. Easily cut offcuts into several pieces by using the Offcut Cutting screen. Offcut Cutting screen Reset position 1 st cut: Surface removal 2 nd cut: Main processing Restart position Red: Processing complete Green: Processed incomplete Sample using the double-cut feature 7 8
ECO mode available for increased energy savings Costs during standby have been dramatically reduced by incorporating Mitsubishi s original just-on-time discharge method. ECO mode allows the processing machine to quickly resume operating. Energy-saving/Low Operating Cost Reduced assist gas usage (ECO conditions) A technology that optimally controls assist-gas conditions has realized a large reduction in the consumption of nitrogen gas. Comparison when cutting 45 parts of the sample on left Calculation conditions Processing time (SUS304 t12mm) 38 minutes 138 minutes 48 minutes 21% reduced Material Thickness Electricity cost Laser-gas cost Assist-gas cost SUS304 t12mm 20 yen/kwh 8.94 yen/l 0.15 yen/l Operating cost (SUS304 t12mm) 34,231yen 22,048yen 46,773yen 36% reduced Work Environment Partitioned dust-collection function An automatic flap opens and closes according to the movement of the processing head, offering on-the-spot dust collection during processing Eco mode After processing, equipments automatically shut down one by one. Step 1: Resonator shuts down Step 2: Beam path purge gas stops Step 3: Cooling unit shuts down This process reduces costs during standby by up to 99%. Processing machine will resume processing in 1 to 3 minutes* after pressing the LASER key. * Time required for equipments to resume operation varies depending on the equipment and the conditions of use. Flap opens Cost Stop processing Ease of Maintenance Step 1: Resonator shuts down Resume processing Step 2: Beam path purge gas (N2) stops Step 3: Cooling unit shuts down Restart Self-check Monitors the main components on a regular basis and displays results on the screen. Supports continuous operation. Help screen Step-by-step instructions are given with pictures and illustrations to help operators perform important tasks for each component. E.g.: Vacuum pump oil change Time Laser-gas change Gas change time is improved by 50% over previous model. Gas change time Previous model Lower Operating and Maintenance Costs Total Cost Savings 9 10 ex 50% shorter 0% 20% 40% 60% 80% 100%
Greater Flexibility Increases Cutting Capabilities Material / Thickness: SECC /t1mm Model: φ1mm Material / Thickness: SUS304 / t25mm Model: ex-60xf Material / Thickness: SS400 / t6mm Model: Material / Thickness: SUS304 / t16mm Model: ex-60xf Brilliantcut 90 Material / Thickness: SS400 / t25mm Model: φ2mm 30 Material / Thickness: A5052 / t15mm Model: ex-60xf Material / Thickness: SS400 / t9mm Model: Material / Thickness: SUS304 / t9mm Model: * The above are processing capabilities based on special conditions. The acceptance criteria are as stated in the specifications. * The actual performance/quality may vary depending on the surface condition and deviation in the material composition even if materials are of the same specifications. * Variations in processing performance/quality may occur depending on the part geometry. * Regarding mild steel (SS400), capacities listed in this catalog are based on LS material (steel plate for laser cutting) of Chubu Steel Plate Co., Ltd. 11 * Optional features may have been used in the above cut samples. 12
Machine High-speed, High-stability Processing Machine Resonator SD Excitation 3-Axis Cross Flow Resonator Key Technologies Ensuring High Stability and High Productivity Mitsubishi Electric s cutting-edge technologies provide ultimate stability to ensure non-stop operation, realizing higher productivity and ease of maintenance. Unique Technologies Supporting Highly Reliable Processing Mitsubishi Electric s resonator series realizes further enhancements in performance and stability, and incorporates original technologies that ensure high reliability. Auto Focus Preset Head Magnetic Damage Reduction Mechanism Total reflection (TR) mirror Automatically controls the focus according to the given NC command. Lens movement is five times faster*, realizing reduced piercing and processing times. Incorporates a magnetic part to hold the processing head in position which allows recovery in less than 1 minute after collision. Discharge electrodes * Compared to previous model. Partial reflection (PR) mirror Laser beam Gas flow Heat exchanger Axial blower to circulate gas High-speed power sensor Mitsubishi s high-speed power sensor, which comes standard on the ex, monitors the laser output in real time. Maintains an output true to the desired setting with a power variation less than ±1%. Allows processing of highly reflective materials such as aluminum and copper. Laser beam Stable control of output Resonator Reflected beam Highly reflective material Electrode Output is constantly monitored Patent No. 1836228 Kokoku (examined patent publication) No. 4-56479 Gas-sealed resonator High-speed axial-flow laser resonator of other companies Electricity cost Laser-gas cost The seal-off operation reduces gas consumption to only about four gas cylinders per year (operating 250 days per year). Allows 24 beam on hours at rated power between gas changes. Significantly reduces operating cost and eliminates the need to change gas cylinders on a frequent basis. Mitsubishi Electric CO2 laser resonator (ML45CF-R) 77% of axial-flow resonator 0 200 400 600 800 1000 1200 Cost (yen/hr) Constant Beam Length System Maintains consistent beam quality by fixing the system s beam path length regardless of the position of the processing head. Provides stable and superior cut quality. Far point Resonator Near point Constant beam length system Processing table Constant beam length system Processing table Processing Lens Monitor Monitors the condition of the processing lens at all times, contributing to stable performance. Constantly monitors the condition of the lens Sensor Processing lens Just-On-Time discharge method The Just-on-time discharge method significantly reduces power consumption when the beam is turned off. * Comparison when processing a t6mm mild steel at a 50% operating ratio (resonator only, does not include processing machine) Electricity Energy saving High-speed axial flow resonator of other companies Mitsubishi Electric 3-axis cross flow resonator Resonator Beam off Beam on Beam off Time 13 14
Features A Variety of Optional Choices Layout f254mm (f10 ) lens Improves the processing capability when cutting stainless steel with nitrogen. Automatic Nozzle changer This combined package includes the magnetic damage reduction and a nozzle changer, realizing shorter setup times and higher productivity. ML3015eX-35CF-R ML3015 ML3015eX-60XF Magnetic Damage Reduction Mechanism Protects the head and eliminates the need for nozzle centering in the event of a crash. Allows quick recovery. Unit: mm 5600 1595 2955 1050 2000 1500 Cooling unit Maintenance space Drawer maitenance space Hydraulic pump unit Safety fence 227 2247 2890 2710 195 Area sensor 407 2710 6735 3475 1730 14650 Nozzle Changer These features reduce setup time and allow automated high-mix, low volume production, while maximizing productivity. 15 16
Specification Cutting Capability Resonator Material Assist gas Mild steel (SS400) Oxygen ML35CF-R Stainless steel (SUS304) Air Aluminum alloy (A5052) Mild steel (SS400) Oxygen Thickness (mm) 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 ML45CF-R Stainless steel (SUS304) When using f254mm (f10 ) lens Aluminum alloy (A5052) Air When using f254mm (f10 ) lens Mild steel (SS400) Oxygen ML60XF Stainless steel (SUS304) When using f254mm (f10 ) lens Aluminum alloy (A5052) Air When using f254mm (f10 ) lens * The above are processing capabilities based on special conditions. The acceptance criteria are as stated in the specifications. * The actual performance/quality may vary depending on the surface condition and deviation in the material composition even if materials are of the same specifications. * Variations in processing performance/quality may occur depending on the part geometry. * Regarding mild steel (SS400) with a thickness over t19mm, capacities listed in this catalog are based on LS material (steel plate for laser cutting) of Chubu Steel Plate Co., Ltd. Optional Processing Machine Specifications Model name Drive system Control system Dimensions and Performance Target workpiece dimensions (mm) Max. workpiece weight (kg) Table pass height (mm) Stroke Speed Rapid travel speed X axis (mm) Y axis (mm) Z axis (mm) X, Y axis (m/min) Z axis (m/min) Maximum processing feedrate (m/min) Positioning Accuracy accuracy Repeatability (mm) Processing head Power requirement (processing machine) (kva) Weight (kg) Machine weight (excluding resonator) Pallet changer weight Cooling System Specifications X, Y axis (mm) Z axis (mm) ML3015eX-35CF-R ML3015 Flying optic (3-axis beam movement) ML3015eX-60XF 68 X-Y-Z simultaneous 3-axes (Z-axis height control is also possible) 3,050 1,525 950 880 3,100 1,565 150 Maximum 100 Maximum 65 50 0.05/500 0.1/100 ±0.01 Auto focus preset head 77 Approx. 8,500 Approx. 2,100 98 Control System Specifications Model name SVK 720/1 SVK 1080/1 Applicable resonator Cooling method Safety Fuse (A) Cooling Capacity (kw) External dimensions (mm) Weight (kg) 35CF-R, 45CF-R 80 76 Approx. 1,040 Air 2,000 1,500 2,055 60XF 125 90 Approx. 1,240 Model name Display screen Hard disk (GB) Program input method Operation method LC30BX 15 TFT (touch panel) 20 Screen creation, USB (ver. 2.0), Ethernet Memory operation, HD direct operation Resonator Specifications Model name ML35CF-R ML45CF-R ML60XF Excitation method 3-axis SD excitation cross flow resonator Rated output (W) Beam mode 3,500 4,500 Lower order (TEM01 *main component) 6,000 Laser output characteristics Power stability (%) Output power adjustable range (%) ±1 or less during power control (relative to rated output) 0 100 Laser gas composition Laser gas consumption (L/hr) Power requirement (resonator) (kva) External dimensions (mm) Weight (kg) Standard features 60 CO2:CO:N2:He=8:4:60:28 Approx. 3 2,500 800 1,810 Approx. 2,200 69 90 2,600 800 1,960 Approx. 2,250 Beam shutter, Visible laser, High-speed power sensor 17 18