technical datasheet kaast werkzeugmaschinen …ˆtter_drc_group/plasmasonic t… · plasmasonic tec...

Combined plasma/oxy fuel cutting machine

Plasmasonic TEC 4000

T e c h n i c a l D a t a s h e e tKAAST WERKZEUGMASCHINEN GMBH

Address

Gadelander Str. 172 D-24539 Neumünster / Germany

Telephone

+49 (0) 4321 25 200 3 - 0 ( -12)

E-mail

[email protected]

Quotation

OF 00002726

Date

8/02/2016

w w w . k a a s t . d e


TEKNOS 3 1.

DIMENSIONAL TRUTHFULNESS IN CUTTING PIECES 4 2.

HEIGHT CONTROL 5 3.

IMPACT CONTROL 6 4.

INTERNAL DRY CUTTING BED 7 5.

FUME SUCTION AND FILTRATION 8 6.

CONTROL SOFTWARE 9 7.

PLASMA GENERATOR 10 8.

TEKNOS MODEL CHARACTERISTIQUES 11 9.

AFTER SALES MAINTENANCE SERVICE 13 10.

WARRANTY 14 11.

INSTALLATION INVESTMENT 15 12.

PAYMENT TERMS 19 13.

DELIVERY TIME 19 14.

QUOTATION VALIDITY 19 15.

*The above specifications are subject to change without prior notice, no liability for printing mistakes. Machine may be shown with optional equipment.KAAST Werkzeugmaschinen GmbH · Gadelander Straße 172 · D-24539 Neumünster / Germany · Phone: +49 (0) 4321-25 20 03 -0 · Fax: +49 (0) 4321-25 20 03 -90 · E-Mail: [email protected]



TEKNOS 1.

Multi processes for large dimensions

Layout of a TEKNOS machine installation

TEKNOS

It is a multi processes machine due to its configuration flexibility for plasma cutting, oxyfuel, machining as well as tube cutting.

The range of TEKNOS machines has been designed for cutting with requirements for high definition, high capacity and large dimensions.

The TEKNOS range machines can be configured according to the client´s needs, with one or various cutting heads available in its configuration; master- slave cut, as well as mirror cut and machining.

TEKNOS, due to its robustness, can be equipped for the realization of plasma cutting and oxyfuel, straight and bevel cuts,plate marking, punching, drilling and tapping and tubes cuts.

Its mechanics are based on the use of mixed guiding systems, rollers and recirculating balls.

In order to guarantee the positioning accuracy of the entire machine, the motor´s measurement system is absolute, consequently the machine never needs to re-start from the beginning but will re-start at the previous finishing point in the event of a loss of the power supply.

New technologies 1.1.

The machine TEKNOS model comes standard the major technological developments such as:

1.1.1. IMZ (Intelligent Movement Z-axis)

The IMZ system (Intelligent movement Z-axis), is a TECOI process, which allows faster and more accurate head positioning movements in the Z- axis. It makes a movement without speed loss and increases cut numbers in different areas in shorter time.

This system reduces the cutting process time up to 30%, therefore it allows an increase in productivity of up to 70%between perforations, compared to conventional systems machines.

1.1.2. SAC (Anti-Collisions system)

SAC The three-dimensional anti-collision system of automatic reset /rearms and high speed, SAC, provides great safety to plasma, oxyfuel and laser torches (SAC-L), ensuring the positioning during the straight and beveling cutting tasks, coming back automatically to its position after any collision.

1.1.3. SPC (Controlled Piercing System)

SPC the Controlled Piercing System, SPC, allows an increase in piercing capacity with plasma, oxyfuel and laser up to 25% thickness and increases consumables span life up to 30%.




DIMENSIONAL TRUTHFULNESS IN CUTTING PIECES 2.

The servo- system works “in a c losed-loop”, interpolating the X and Y axis.

Working “in a closed loop”2.1.

The machine is constantly and in “real” time verifying the torch´s path, and comparing it with the path commanded by the control system.

If for any reason, the tool holding head is describing a different path than the one it should be following, the control system will correct its position taking it back to the correct path or it will stop the machine if the deviation from the theoretical path is outside the programmed tolerance threshold.

This way, the possible existence of a mechanical error or a collision is identified.

In case the machine collides against an obstacle or a person, it will automatically come to a stop. This feature gives an extra safety warranty.

Interpolating the moving axis 2.2.

Consists in co-ordinately moving them with the purpose of outlining the “true” paths.

Each axis moves using the velocity and position parameters corresponding to the mathematical formula of the curve it should be describing.

The control system is a real guarantee that the machine is cutting the truly desired figure, while preventing the accumulation of errors throughout the cutting process in a large set of pieces (multiple pieces in one plate).

Another key advantage control system is that since it is describing “true” curves, it can generate them in any dimension.

Bevel ARC plasma cutting head on TEKNOS machine Oxyfuel cutting heads on a TEKNOS machine




HEIGHT CONTROL 3.

The cutting head automatically detects the surface of the piece to be cut, and continually makes an automatic follow up during the cutting operations.

Ignition 3.1.

The machine operator can choose between four different options for the initial detection of the ignition height (beginning of cutting):

1. Piece detection by capacitive sensor

Piercing plates and/or grid in oxyfuel and plasma

2. Piece detecting by contact

High positioning accuracy in plasma

3. Fixed ignition height

Thick thicknesses and profiles cutting. High positioning speed in Z-axis

4. Piece detecting by arc

The torch is positioned at the desired height depending on the voltage supplied by the plasma

Surface following during the cutting 3.2.

The machine operator can choose among four different options to regulate the height during cutting:

1. Regulation by voltage

Total regulation of the head height

2. Capacitive regulation

It measures the capacitance value between the plate and the plasma/oxyfuel ring sensor

3. Fixed cutting height

Constant height during the cut

4. Regulation by height

Automatically it corrects the voltage fluctuations which could influence in the height control. TECOI’s exclusive system.

Detail of a BEVEL ARC plasma cutting head on a TEKNOS machine




IMPACT CONTROL 4.

SAC the three-dimensional anti-collision system

All of the moving parts of the machine are electronically controlled to constantly measuring the stress suffered. There are maximum stress thresholds programmed for each moving part, so that when these levels are reached or exceeded, motors are immediately stopped.

Furthermore, in the case of the tool holding head or heads, where the risk of impact is higher, a series of specific measures have been arranged, such as:

1. The cutting head is �xed to a “�oating” anchor that allows its dislocatio n in case of an impact from any direction of movement, including vertical movements.

2. When it is dislocated after an impact, it automatically stops the machine taking the program that is being executed to a “paused” state.

3. Once the mechanics and the program execution are halted, the head is raised free-up the cutting head from the element that caused the collision.

4. The anti-collision system springs re-arm the mechanics allowing the machine to continue its work without the need for the operator to manually re-arm.

5. Once re-armed, the system waits for the operator intervention to resume the program. (Safety requirement imposed by CE standards).

6. To resume the program, the operator must press the buttons in the control panel, without accessing the cutting grid.



Plasmasonic TEC 4000 INTERNAL DRY CUTTING BED 5.

Detail of a cutting bed module that the machines equip

The machine set can be installed in any position, as well as form the exits of fume extraction by both ends of the machine.

The dry cutting is formed by an interior table, totally independent from the base plate of guided.

Under the grid there place two longitudinal collectors of aspiration, located in both sides of the interior base plate. Each collector of aspiration has floodgates of pneumatic operation each 820 mm. With what the aspiration is located under the torch, to the step of the bridge.

The operation of the hatches is effected mechanically by means of pneumatic valves to the step of the cutting bridge, piloted by the control of the machine and with electrical operation (without mechanical levies).

Mechanically, the cut grid is composed by a raisable autoportante frame, to facilitate the cleanliness of the machine. The rims are arranged in each suction module in two halves on the autoportante frame, with the mechanical peculiarity of their inferior beam.

This suction base plate, it completely has been designed by Tecoi, applying all our experience in cut with the main plasma generators.




FUME SUCTION AND FILTRATION 6.

ECOTEC filter installations indoor and outdoor

All machines incorporate suction systems ECOTEC with cartridges of the latest technology Flame Retarded from 6 to 32 cartridges and powers from 7,5 kW to 32 kW.

It is available with sparks- killer system and ATEX regulation. It can also be equipped with SILENTEC.

Other auxiliary filter equipment is the DUSTEC a dust collector with high capacity and reliability that solves the problems of dust extraction filter suctioning automatically and periodically up to a central of large capacity.

The ECOTEC filters incorporate the latest advances in filtering technology. Due to this, an optimal purification of the cutting gases is achieved.

The filters are responsible for collecting the gases produced during the cutting process and return them to the outside environment in a non-harmful state.

These filters are monitored from the machine-tool panel control or from its electrical board located in the premises’ wall.

Each filter has an automatic cleaning system that avoids maintenance in the short run.

The filter ECOTEC 16 is ideal for the composition of the TEKNOS machine and is characterized by:

• Tube and profile welded structure

• 16 flame retarded high performance oval section cartridges

• 2 spark killing traps with a heavy slag collection box

• 2 - 45 liter dust collection boxes

• 16 Power Pulse rapid discharge cleaning valves

• 1 automatic cleaning control system with visualization

• 1- 18 kW motor-fan with a backward-curved blades fan wheel

• Frequency inverter to control motor load, soft start-up and adjustment

• Motor - fan integrated within the filter

• Maximum volume of displaced air 14.500 m³/h (a 250mca)

• Minimum volume of displaced air 9.500 m³/h (a 370mca)

• Optional features (automatic dust extraction, mufflers, etc.)

• Inside and outside installation ready

• Remote start up and stop interface control from NC

• Dirty filter exit signal

• Low noise level




CONTROL SOFTWARE 7.

The machine is controlled from this panel via a FANUC-TECOI Control that has a 15” �at TFT screen , Pcmcia disk drive, mouse and control buttons, all within a WINDOWS environment.

The machine management system developed by is visual and identifies at all times, next to the machine, the work- in-progress taking place seen on the PC, enabling the operator to quickly and easily vary the cutting parameters.

Two developed CISCAD (CAD/CAM) software license are included for the management of the machine and to control the cutting machines (one license for the machine and one for the technical office).

CISCAD is a unique program made up of four interrelated modules:

Sheet/Plate Module 7.1.

Define the sheet/plate or remnant sheet/plate in which the cuts are to be made or its origin. In this module, the cutting base bed size (blue outline) and the size of the sheet/plate to be cut (red outline) are defined. Irregular remnants can also be defined by recognizing them by points using the cutting torch as a tracer (manual movement of the bridge).

Drawing Module 7.2.

Define the outline or form of the piece or pieces to be cut. It is a simple drawing program with functional tools based on an AutoCAD type program. Importing and exporting options are available for drawings in the AutoCAD format (.DXF y .DWG).

Matrix Module 7.3.

The program fills up the sheet/plate or remnant with as many pieces as possible or, it incorporates the indicated quantity. It allows turning, erasing, etc., of piece safter nesting.

Machine Module 7.4.

Program the cutting paths and parameters (material, thickness, cutting speed, penetration time, cutting height, height control system, etc). It has a display screen showing the operations that are being carried out by the machine at all times. The parameters for the selection of the material to be cut and its thickness are automatically programmed by the machine.

Screen captures of the CisCAD program




PLASMA GENERATOR 8.

Kjellberg HiFocus440i plasma generator

Incorporates into their machines plasma brands leaders in the World, including technologies of High Definition with high quality in pieces marking.

Kjellberg Hi Focus series represents extremely high quality of cut. The pieces only can be cut with perpendicular flat and smooth surfaces, they do not require to be touched after the cut.

Hi Focus 440 i8.1.

Unmatched flexibility with new high precision plasma system Hi Focus 440i for CNC guided cutting of all electrical conductive materials:

• Presently worldwide strongest high precision plasma cutting machine

• Extended Hi Focus cutting range.

• Stainless steel from 1.0 up to 100 mm thickness with – virtually dross free up to 70 mm

• Mild steel from 0.5 up to 80 mm material thickness

• Superior quality through all ranges of thickness and materials.




TEKNOS MODEL CHARACTERISTIQUES 9.

TECOI TEKNOS -MACHINECutting capacities

Useful cutting area TEKNOS 4000 6200 x 3100 mm

12200 x 3100 mm 24200 x 3100 mm


12000 x 4100 mm 24000 x 4100 mm


12000 x 5100 mm 24000 x 5100 mm


12000 x 6100 mm 24000 x 6100 mm


12000 x 7100 mm 24000 x 7100 mm

Main machine features Minimum plate thickness 1 mm Maximum plate thickness 300 mm Maximum drilling thickness 200 mm Positioning speed 40 m/min Maximum Acceleration 1000 mm/s2 Gantry Gantry – Multi Head X-axis guidance Mechanized double track Z-axis free height 300 mm Useful Distance Z- axis with Bevel Arc 170 mm Cutting table Independent cutting table with drawers for dross Cutting precision ±0,1 mm Positioning precision ±0,1 mm Beveling tolerance ±1º Root tolerance ±2 mm Countersinking capatity M4 < M24 Drills diameter 5mm < 40mm Drill maximum thickness 200mm Spindle Power 15 kW Cone ISO 50 Gantry Weight 1,5 t Maximum plate weight 1,2 t/m2 Maximum electrical consumption 9 kW 230V. 3ph/50Hz

TEKNOS MODEL CHARACTERISTIQUES 9.

TECOI TEKNOS -MACHINECutting capacities


12200 x 3100 mm 24200 x 3100 mm


12000 x 4100 mm 24000 x 4100 mm


12000 x 5100 mm 24000 x 5100 mm


12000 x 6100 mm 24000 x 6100 mm


12000 x 7100 mm 24000 x 7100 mm

Main machine features Minimum plate thickness 1 mm Maximum plate thickness 300 mm Maximum drilling thickness 200 mm Positioning speed 40 m/min Maximum Acceleration 1000 mm/s2 Gantry Gantry – Multi Head X-axis guidance Mechanized double track Z-axis free height 300 mm Useful Distance Z- axis with Bevel Arc 170 mm Cutting table Independent cutting table with drawers for dross Cutting precision ±0,1 mm Positioning precision ±0,1 mm Beveling tolerance ±1º Root tolerance ±2 mm Countersinking capatity M4 < M24 Drills diameter 5mm < 40mm Drill maximum thickness 200mm Spindle Power 15 kW Cone ISO 50 Gantry Weight 1,5 t Maximum plate weight 1,2 t/m2 Maximum electrical consumption 9 kW 230V. 3ph/50Hz




TECOI TEKNOS - MACHINE Heads

Plasma head Optional Plasma head´s maximum number 8 Oxyfuel head Optional Oxyfuel heads maximum number 16 STO (Triple oxyfuel blowing torch) Optional Laser head N/A BEVEL ARC (Bevel cutting head) Optional BevelArc head´s maximum number 8 SBC (Bevel calibration system) Optional DRILLTEC (Drilling head) Optional DRILLTEC head´s maximum number 2 PUNCHTEC (Unique punching head) Optional Laser marker Optional Plasma marker. Arc writer /Fine Marker Optional Ink marker Optional

Equipment SUCTION SYSTEM ECOTEC - Filters Optional SILENTEC – Filter´s acoustic reduction Optional DUSTEC – Filter´s dust extractor Optional DROSS, CHIPS AND SMALL PIECES COLLECTION/EXTRACTION Removable drawers Optional Liftable drawers Optional VIBRATEC – Dross extraction Optional Dross and small pieces conveyor belts Optional Chips conveyor belts N/A Tool automatic changer 4 < 10 positions

Equipment SOFTWARE / COM MUNICATION FANUK - CNC Standard LANTEK - Software Optional CisCAD - Software Standard Communication Ethernet USB Optic Fiber OTHERS Inactinic curtain Optional IP Camara Optional Motors FANUC Automatic lubrication Standard

Technologies IMZ (Intelligent Movement Z-axis) Standard SPC (Controlled Piercing system) Standard SAC (Anti-Collision system) Standard CBM (Cold Bevel Milling technology) N/A Absolute encoder Standard Height control Standard




AFTER SALES MAINTENANCE SERVICE 10.

Contract SILVER 10.1.

Annual maintenance intervention Quick change neck replacing Torch replacing Connection neck replacing Main contactor replacing Liquid coolant replacing Coolant liquid filters replacement Full machine check-upAligned check-upSuction check-upElectrical Components and cabinets cleaning Software update (if necessary) Telephone / Online support 90 minutes per month free 10% discount on labor assistance Free labor in replacing damaged materials within maintenance Single annual fee

Contract GOLD 10.2.

Biannual maintenance intervention Quick change neck replacing Torch replacing Connection neck replacing Main contactor replacing Liquid coolant replacing Coolant liquid filters replacement Full machine check-upAligned check-upSuction check-upElectrical Components and cabinets cleaning Software update (if necessary) Telephone / Online support 180 minutes per month free 5% discount on consumables 15% discount on labor assistance Free labor in replacing damaged materials within maintenance Single annual fee

* Upon request is given a personalized service quotation for your machine.




WARRANTY 11.

The maximum warranty period is for 1 year (12 months) starting from the machine start-up date or for a maximum of 2.000

working hours (pro rata).

This warranty period is absolutely inextensible even if carries out repairs or substitutions during this period of time.

Within the warranty duration period, takes care of the costs associated with substitutions or repairs, of any goods that

are found to be or considered as faulty.

All costs relative to the restoration or repair of the faulty goods will be paid.

The substituted faulty parts or goods under warranty will be handed over and become its property.

It is not considered responsible for the damages or losses caused by installation shut downs or for any other tax or

additional costs.

The warranty of the elements constituting the machine will be considered invalid if the use or maintenance practiced does not

correspond to that shown in our instruction manuals. The same will apply to the auxiliary equipment and their manuals.

This warranty substitutes any stated or unwritten one, and any other obligation on behalf.

The warranty will be effective from the machine start-up signature and in no case after 60 days of the installation of the

machine in the dependences of the costumer.

The scope of the warranty is total: travel, workforce, supplies, etc., excluding conductions, heads, torches, utility supplies and

consumables.

Thanks to the remote internet assistance system, which comes as a standard on all machines, technical advice

processes and the determination of possible breakdowns are speeded up, facilitating precise and rapid technical

interventions, reducing stoppage and travelling time related costs.

Nevertheless, technical and operative questions can be directly addressed to the factory in Spain, where they will directly

solved.




INSTALLATION INVESTMENT 12.

Plasma cutting machine model: TEKNOS 4000

1 independent motorized head for plasma cutting. Two useful cutting areas of 10.000 mm x 2.500 mm each one. Bridge with double brushless motorization and absolute encoder. Helical line rack 65rockwell hardness. FANUC control with Z axis integrated in technological tables. 80 GB hard disk memory storage. Different and automatic cutting technologies for holes and exteriors. Direct communication with the factory to get real time help. Closed and fireproof cable drags chains. S.P.C. controlled piercing system for thick plates in plasma Automatic changeover from cutting to marking in 2 sec. within the program (when equipped with

automatic gas console) Double anti-collision system with automatic reloading. CISCAD software license (Sheet, drawing, nesting and CNC). Transmission of information via ethernet from/to technical office. Integral automatic lubrication.

Double track

24.000 mm of double longitudinal rail Includes 4.000 mm extra of longitudinal rail for bridge parking. Includes leveling plates and screws. (The customer must provide the UPN beam or the HEB

beam with legs, depending on the type of cleaning drawers installed in the cutting table. Quotation available upon request to Tecoi. Tecoi does not include the installations of the beams.)

Two sucction tables + drawers

Two cutting bases plate with measures 10.000mm x 2.500mm each one. Fume suction system with double integrated longitudinal conductions integrated inside the base

table. Localization of the suction under the grid in 3000 x 800 x 600 mm. sections with double pneumatic operation.

Opening and closing of the gates under the cutting torch, using solenoid pneumatic valves governed by the software.

Interior base table modules made of 150 x 6 mm lamels, separated 120 mm. Eyebolt reinforce metallic drawers for easy handling with wheels in the bottom to facilitate the

cleaning operations of the machine and the withdrawal of pieces fallen from the cutting grid.

INKJET marking unit

1 REAJET 7 INK-JET marking unit with nozzle ink-jet marking unit capable of printing charactersbetween 5 and 27 mm high or equivalent to 1 line of text.

Marking head + Ink tank and Control unit with integrated keyboard.




Fume extraction system

2 filters ECOTEC 16 composed by a welded structure 16 flame retarded high performance oval section cartridges 2 spark killing traps with a heavy slag collection box 2 - 45 liter dust collection boxes 16 Power Pulse rapid discharge cleaning valves 1 automatic cleaning control system with visualization 1- 18 kW motor-fan with a backward-curved blades fan wheel Frequency inverter to control motor load, soft start-up and adjustment Motor - fan integrated within the filter Maximum volume of displaced air 14.500 m³/h (a 250mca) Minimum volume of displaced air 9.500 m³/h (a 370mca) Optional features (automatic dust extraction, mufflers, etc.) Inside and outside installation ready Remote start up and stop interface control from NC Dirty filter exit signal Low noise level

Plasma generator with manual gas console

1 Kjellberg plasma generator HiFocus 440 i 440A focal double, high definition and marking. Maximum Piercing in mild steel, aluminum and stainless steel 50 mm. Maximum thickness of cut in production in mild steel, aluminum and stainless steel 80 mm. Consumables long life

Automatic gas console in substitution of manual gas console

Automatic gas console for plasma generator Kjellberg Hi Focus 440 i Thanks to The control FANUC and the software CISCAD exclusive of Tecoi, the works can be

done cutting and marking consecutively, guaranteeing maximum agility and precision. With the automatic console, TECOI regulates the gases and power of a different way according

to the geometry of the contour to cutting.; Thus, inside the same work, the cuts are realized by " different qualities " improving obviously the perpendicular in critical holes, the definition of small contours, the maximum speed and minim fin in wide paths, etc.

Automatic bevel head – Bevel ARC

Automatic bevelling of any contour with plasma Maximum possible angle: -50º until +50º Positioning speed 120º/s Limit of draft infinite Speed of reaction of collision100 mile seconds Resumption alter collision Automatic Height control




Triple oxyfuel head (STO)

Triple torch oxyfuel system for bevel cutting with infinite rotation. Manual adjustment of angle between torches.

Automatic gas plant oxyfuel

Automatic proportional gas console CGP 612 Omni Flow up to 150 m3/h, thickness Up to 3 torchs (máx.): 300 mm

Software

1 LANTEK software license with automatic nesting




Included12.1.

CisCAD software license (Sheet, drawing, nesting and CNC). Training and learning for machine operators, software and cutting methodology, at the customer’s premises. Installation and start-up the machine

Not included12.2.

Exterior and interior base bed levelling elements if the pavementunevenness is higher than ± 10 mm. Means for discharging the equipment and suitable lifting means for mounting all components. Civil Works. Electrical and pneumatic lines to machine connections. Transportation EXWORKS –Incoterms 2010-




PAYMENT TERMS 13.

The following payments are required, under the terms of this contract:

30% advance payment at the acceptance of the quotation by the customer, to begin with the construction of the machine.

70% at the delivery time of the machine at the factory (Ex-Works).

DELIVERY TIME 14.

16 weeks (provision of the machine components) from receipt of the advance payment.

* Delivery times vary depending on the model and the final configuration of the machine.

QUOTATION VALIDITY 15.

12 weeks


technical datasheet kaast werkzeugmaschinen …ˆtter_drc_group/plasmasonic t… · plasmasonic tec...

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