A drastic reduction in production costs and times is being achieved with a laser profiling and cutting machine equipped with a highly dynamic, lightweight head.
Effectively two machines in one; the Syncrono incorporates a highly dynamic and ultra-lightweight head integrated with a machine with a large operating envelope, both of which are perfectly coordinated to optimise processing times. With the highest dynamics applied to the smallest masses, this concept achieves extreme performance, excellent cutting quality and reduced running costs, while active compensation of masses and control algorithms ensure smooth and vibration-free motion. The result is a machine that guarantees hitherto unimaginable processing times; 6G acceleration enables more than 1000 holes to be cut in a minute, twice that of other laser machines currently on the market.
The flexibility and quality of laser cutting has allowed a continuous and steady growth of the laser machines sector during the past decade.
Plasma-arc cutting and punching are no longer the undisputed leaders, as the laser has become the leading technology in the sheet metal cutting field.
Today's market requirements are forcing manufacturers towards solutions that not only provide excellent quality and great flexibility but also high cutting speed and therefore, greater and greater productivity.
Syncrono is Prima's answer to this market need.
Machine, laser, CNC and electromechanical parts are all integrated in a compact, modular structure that is easy to transport and which does not require machine foundations.
The bed is manufactured from synthetic granite, while aluminium carriages ensure high mechanical stability and rigidity.
The machineandsup1;s key features include the following.
* Flying optics: providing speed and precision, irrespective of the gauge of metal being processed.
* Compact design and easy installation: machine foundations are not required.
* Modular construction: choice of a large number of configurations plus flexibility to meet future production needs.
* Application versatility: the rapid adjustment from 5 to 7.5in optics enables a wide variety of different materials and thicknesses to be processed.
Syncrono also features independent and programmable control of the focal position and an active workpiece collision avoidance system.
The innovation of Syncrono is its fusion of two synchronised machines; an ultra-lightweight and super-fast head providing 'micro' level movements, effectively mounted on a 'macro' machine with a large working area.
Both mechanisms are coordinated by algorithms that automatically control the local axes of the head and the main axes of the machine.
The local axes perform 'micro' movements (to cut holes, corners, small shapes, or paths with frequent changes of direction), while the main axes carry out 'macro' movements (for contours, large shapes, etc).
The 'micro' and 'macro' movements are undertaken simultaneously, like those of a human hand and arm when writing or playing a keyboard.
The numerical control, like the human brain, synchronises them in order to ensure continuous, rapid and coordinated movement.
The focusing head utilises parallel kinematics with direct drives to achieve more than 6G acceleration during cutting cycles.
Syncrono performs even the most complex paths with unrivalled cutting quality and speed.
Typically, high dynamic laser machines use direct drives in all axes.
However, their combination of large mass and rapid movement make them prone to vibration.
By contrast, Syncrono uses direct drives only for the micro carriage, dramatically reducing vibration.
Reliability and accuracy are through an active anti-vibration system, which minimises impulsive stress on the machine's structure.
The machine's design ensures a constant length optical path throughout its cutting cycle - for high precision and repeatability across the machine's entire working range.
Syncrono is offered with Prima's fast axial flow CP 4000 or new CV 5000 laser.
The company's latest generation of CV lasers utilise magnetic bearing turbines, solid state high voltage power units and servo-controlled gas mixing to enable high powers to be achieved with maximum efficiency.
Syncrono is designed throughout for maximum operational efficiency.
* The worktable is divided into segments for optimising fumes extraction and its pallet for holding 2D workpieces.
* Wheeled scrap collection drawers provide fast and easy movement.
* Polycarbonate glazed cabin with large windows, for total safety and optimum visibility of the work area.
* Internal cabinet for storing frequently used tools and materials (lenses, tips, kits for cleaning and centring optics, handbooks, etc) reduces machine maintenance and down time.
Even the most basic Syncrono model has all the technological solutions developed through Prima Industrie's long experience of laser machine technology; enabling extremely short cycle times and excellent cutting quality to be achieved as a matter of routine.
They include the following.
* Laser piercing monitor.
* Advanced restart functions.
* High-speed cutting with plasma formation.
* Automatic management of technological parameters for small and complex profiles.
* Microjoints.
* High-pressure cutting for high cutting speed and oxidation-free edges.
* Automatic detection of the metal sheet position for consequent adjustment of the program.
Programming Syncrono is extremely simple.
The primary and secondary axes are controlled fully automatically and 'transparently' for the user.
The Primach-20L CNC has an operator/machine interface with Web technology, Windows 2000 operating system, LCD flat screen, touch-screen and trackball; the 'Easy Cut' option enables fast programming directly on the machine.
Syncrono can be programmed off-line with PICAM, CAD-CAM 2D software for fast and simple generation of the complete machining program, based on mathematical models of the workpieces.
Parameter tables allow a choice of the best cutting parameters for every process.
Offering easy customisation to specific user requirements, these tables are always available in official versions of Prima's CNC and PICAM system.
Similarly, production times and costs can be further optimised by using the company's nesting and common line cutting modules.
What makes Syncrono unique?
* It is the fastest machine on the market (more than 6G acceleration during cutting), for consistently shorter cycle times, and corresponding production cost savings.
* Extreme speed and maximum cutting quality without compromise, i e, without the need to sacrifice one parameter to achieve the other.
* Uniform precision and cutting quality throughout the entire work area.
* Minimised operating costs through innovative machine design - with high dynamic minimum masses.
* Vibration-free for in-service precision and reliability over extended production runs.
Complementing Syncrono's capabilities is the following range of Prima productivity enhancing solutions.
* Automatic pallet changer; for minimum loading/unloading times - a virtually necessity for such a fast machine.
* PrimaServer range of automated material handling and storage systems.
The modular design of these systems allows installations to be upgraded at a later date, as production requirements increase, up to fully automated production units.
* PrimaServer Manager for controlling unmanned production.
* Remote sensing and safety cut out - with automatic reporting on the status of the machine via CNC.
Using the above options, it is possible to tailor installations precisely to customer production needs, right up to fully automatic, 'lights-out' operations.
With PrimaServer, a number of unmanned production options are available.
TowerServer (customisable with additional towers and rack feeder).
Automatic stacker/de-stacker for handling blank and processed sheets.
Tower unit with up to 15 storeys.
Elevator for loading and unloading work pallets on and off the tower.
Single sheet separation, measuring systems and sheet reference.
Unmanned production.
* Or CompactServer (extremely compact overall dimensions).
Automatic stacker/de-stacker for handling blank and processed sheets.
Twin-storey units (one for the blank sheets and one for the processed sheets).
Single sheet separation, measuring systems and sheet reference.
Controlled directly by the Syncrono CNC.
* The company's LaserServer with PrimaSorting systems enable stand-alone automatic manufacturing cells to be created.
LaserServer for automatic loading/unloading of sheets.
Three stations for loading sheets, unloading the 'skeletons' and unloading finished parts.
Sorting gripper for picking up and stacking finished parts.
Automatic programming of sorting cycles.
Other solutions, integrated to specific customer requirements, are available as multi-tower and multi-machines.
Multi-tower systems enable plant production capacity to be increased in stages.
They operate in conjunction with the automatic pallet changer - the interface point of with the machine - and provide virtually limitless configuration possibilities.
Multi-machine solutions link several machines simultaneously.
At their heart is The PrimaServer Manager system, which controls unmanned production and ensures both simplicity and efficiency - even in complex installations with several machines operating in extended workshop areas.
Syncrono's unparalleled capabilities can be demonstrated by simple analysis of the cycle times it achieves.
The following examples provide direct comparisons with machines that were regarded as benchmark laser cutters prior to the Syncrono's launch.
The first shows Syncrono's ability to cut a matrix of holes in light gauge sheet metal (1mm carbon steel).
The machine produces 1034 holes/min, against a 'benchmark' of 600 holes/min.
The second example represents the complete production cycle of a test workpiece including contouring, plus the production of a series of holes and slots with various shapes.
Using linear motors machines, the benchmark cycle time was 22s for the production of this component in 1mm thick carbon steel.
By comparison, the Syncrono completed the component in just 13.4s.
These cycle times demonstrate how Prima's new machine represents an effective answer to the market's ongoing demands for enhanced productivity.