PRODUCT REVIEWS
Smart fibre laser technology
From the BySmart Fiber to the ByCut Smart , Bystronic presents its new generation of laser cutting machines from the “ Smart ” series . The new flexible ByCut Smart 3015 cuts steel ; aluminium ; stainless steel ; brass and copper using high laser power ( three to 15 kilowatts ), an optimised cutting process and smart features . It boasts a sharp and modern design to significantly increase user friendliness . Different access door configurations provide flexibility , including front and / or side access as well as multiple windows with direct views of the cutting process . Overall , the new design offers better access to the interior space .
“ Laser power levels from three to 15kW ensure excellent cutting performance and high parts output for thin to medium sheet-metal thicknesses . Depending upon the production range and customer request , the ByCut Smart 3015 is available in a selection of different laser powers of 3- , 4- , 6- , 8- , 10- , 12- and 15 kilowatts . Non-ferrous metals can also be processed ,” explained Swiss sheet-metal specialist , Bystronic .
Smart features such as the Nozzle Control Tool ( NCT ) and KerfScan , the Parameter Wizard and cutting with MixGas , in addition to more laser power , are designed for higher cutting quality as well as increased productivity .
“ The NCT provides automatic nozzle centring at the beginning of a cutting plan and after collisions . As a result , manual interaction from the operator is no longer required , reducing time expenditure by up to 95 %. Centring is completed within seconds , rather than minutes ,” outlined Bystronic .
“ KerfScan also serves as a monitoring function , increasing process reliability . Through greater autonomy , customers benefit by producing less scrap due to incorrect settings , poor material quality or hot sheet metal , which reduces waste costs and makes production with flame cutting more cost-effective and reliable ,” it added .
The Parameter Wizard determines the best parameters with N₂ and MixGas for steel with thicknesses of 4-15mm . It optimises the entire cutting process and ensures its smooth functioning , which improves production time without downtime .
“ MixGas combines the benefits of O₂ and N₂ and is an alternative to cutting with pure nitrogen or oxygen . Cutting with MixGas ( a mix of nitrogen and oxygen ) massively improves cutting quality in thicker steel at increased cutting speeds . MixGas also contributes to achieving better cutting results with varying qualities of steel . The higher the laser power ,
The new ByCut Smart 3015 .
the greater the advantage ,” Bystronic told ISMR .
With the new shuttle table concept , users can load their ByCut Smart up to 40mm over the entire surface on both tables or 60mm over the entire surface on one table .
“ Bystronic software and automation solutions integrate the ByCut Smart into sheet-metal production . Loading and unloading solutions can be selected in a variety of designs and degrees of automation . Our systems organise the material flow fully and semi-automatically according to the order situation , and provide enough flexibility to process smaller orders manually ,” added Bystronic .
“ A fast cutting process and extremely low maintenance requirements guarantee high machine uptime and longevity , and therefore more profit per part ,” it concluded . n
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. bystronic . com
Virtual commissioning of Bihler machines
Otto Bihler Maschinenfabrik creates digital twins of complex manufacturing solutions and commissions the entire system virtually in advance .
“ This allows the machine to be configured optimally , increases the quality of the software and ensures fast , smooth initial commissioning and optimisation of the production system ,” it told ISMR .
Bihler creates a digital twin of all its hightech manufacturing solutions , such as the BIMERIC servo production and assembly system , creating a virtual image of the entire manufacturing process . This enables the virtual commissioning of the machine long before the start of productive assembly .
Virtual commissioning provides valuable insights throughout the entire life cycle . It allows a wide variety of production processes to be run through and tested in their entirety . Malfunctions and sources of error are quickly revealed and can be eliminated as early as the design phase .
“ Virtual commissioning therefore makes real commissioning during final assembly far easier and ensures problem-free assembly .
It also enhances the quality of the Bihler system and the associated software , for example in the form of a tailored user interface for customer-specific solutions . As a result , the customer receives a particularly reliable , high-performance Bihler solution with maximum process reliability ,” Bihler explained .
At Bihler , the digital twins of the systems are created during the development process on the basis of the design data . After the process sequence has been configured , the program created on the VC 1 controller is transferred to the real machine . The system can then be started up in real-time with all the requisite tools and components .
To date , Bihler has already commissioned more than 20 highly complex manufacturing solutions virtually . The feasibility of components with a high degree of variability has also been successfully confirmed , including testing for crashes and the sequencing of the positioning axes .
“ In all projects , it became apparent that the simulations enabled all subsequent setup and commissioning times to be reduced by up to 15 per cent . The time savings come from the fact that work can be done on the system in parallel . Our software specialists program virtually , while at the same time engineers set up the real system . We use this time saving to reduce lead times and increase quality ,” concluded Bihler .
The digital twin of the Bihler system can subsequently be used for training purposes , such as virtual Bihler VC 1 training . This technology is also used for feasibility and project studies where production processes are simulated even before a quotation is prepared . n
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. bihler . de
58 | ismr . net | ISMR July / August 2023