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Integrated solutionsfor application-oriented, efficient processes

Handling andAutomation

2Integrated material and data flow, efficienthandling

Bystronic’s highly-developed handling and

automation systems increase workflow and

assure smooth processes. The high-perform-

ance components offer need-oriented inter-

faces for data communication, they are opti-

mally attuned to one another, and easy to

operate. Thus is it possible to exploit the entire

potential of innovative production technology

in an economical total solution.

The infrastructure requirements as well as the

production machines differ according to the

industry, location, and job structure. Given four

need profiles, Bystronic derives different solu-

tions with functional units that can be com-

bined in different ways. These can be inserted

flexibly into the individual production environ-

ment and are available in a variety of levels to

meet specific manufacturing needs.

Added value for the user

Fully-automatic operation

High degree of utilization

Improved machine utilization

Reduced handling and secondary process

times

Optimized material and data flow

Transparent job processing and storage

Increased work and process safety

Based on its decades of experience with the automation

solu

tion

son

dem

and

Need profile IFlexible and quick job processing comes first.

The deadline rules.

The planning horizon for jobs is less than two

days.

The production structure is marked by non-

repeating small jobs.

Primarily complex parts are produced.

Frequent change requests are typical.

Need profile IIThe production structure is marked by medi-

um-sized and large jobs.

Jobs are, as a rule, produced repeatedly.

The planning horizon for jobs is longer than

two days.

Raw material storage is small; only a few

different material types and sizes are stored.

Need profile IVThe production structure is marked by small,

medium-sized, and large jobs.

In addition to repeated jobs, individual jobs

are accepted.

The planning horizon for jobs is longer than

one day.

Material storage is large; more than 40 differ-

ent material types and sizes are stored.

Need profile IIIThe production structure is marked by fre-

quently repeated jobs.

Primarily material thicknesses from 1 to 6 mm

are worked.

3

of laser cutting systems, Bystronic has developed a product line that is oriented towards four need profiles.

The goal is an optimization of prototype and short-

run construction.

A compact and economical solution is desired.

The right solution:

Byloader – the automatic table loader

4

Longer production runs or several jobs using the

same materials are grouped, resulting in few material

changes

Machine utilization is important.

The goal is to operate several machines with one

operator.

Focus is on reducing cost of labor.The right solution:

Bytrans – the automatic table loader and unloader

5

The production process often requires material

changes and the return of unused material back

into storage.

Demand for high production.

Machine utilization is important.

The goal is the central control and operation of

several machines by one operator.

To reduce cost, flexible night and weekend produc-

tion with minimal manpower is desired.

The right solution:

Bycell – the fully-automatic compact cell

with integrated storage system

9

The sizes of the parts produced lie between

100 x 100 and 600 x 1 200 mm.

The other requirements correspond to those of

Need profile II.

The right solution:

Bysort – the automatic table loader and unloader

with individual part removal

8

4Automatic table loading, flexible job processing

Byloader is an automatic sheet metal loader. In

addition to increasing economy, it also increas-

es work safety. One employee can perform

material handling and operate the system.

The degree of utilization* of a machine

equipped with Byloader is, as a rule,

maximally 60 %.

*Relationship of machine operation time/cutting time

The sequence of steps

The sheet metal sheets are brought from

storage with a crane or forklift and placed in

the correct position on the sheet loader

table.

The integrated sheet loader, Byloader, con-

veys the sheet metal sheets without addition-

al handling onto the laser machine’s shuttle

table.

The finished components and skeleton scrap

can be removed manually from the shuttle

table during the ongoing cutting process.

Shuttle table of the Bystroniclaser machine

Individual adjustable andsuppressible valves for theproduction of special formats

Suction units with automaticstandard format recognition

Sheet metal table

Fanning magnets

Sheet metal separation withmagnet.

Byl

oade

r

Length

Wid

th

In the standard configuration, the sheet metal table isstationary behind the standardized shuttle table. It is alsooptionally available in manual and motor-driven models.

Combination with Length Breadth Height

Bysprint 3015 mm 11100 5 300 3 000

Bystar 3015 mm 10 300 5 800 3 000

Bystar 4020 mm 13100 6 900 3 000

Bystar 4025 mm 13100 7400 3 000

Byspeed 3015 mm 12 500 5 600 3 000

Bystar

5Robust portal solution, vibration-free production

Bytrans assures the automatic loading and

unloading of laser cutting systems and enables

the comfortable operation of several machines.

The system is specially designed for companies

that primarily produce medium-sized to large

orders with a small selection of raw materials.

Bytrans is available in various stages of expan-

sion and in the BytransLine and BytransCross

models. The choice depends on the individual

requirements and the space relations in the

production environment.

The degree of utilization* of a machine

equipped with Bytrans is, as a rule,

higher than 70 %.

*Relationship of machine operation time/cutting time

The sequence of steps

The sheet metal sheets are brought from

storage with a crane or forklift and placed

in the correct position on the loader table.

The integrated table loader transfers the

sheet metal sheets without additional hand-

ling automatically onto the laser machine’s

shuttle table.

Cut sheets up to 12 mm thick are automati-

cally removed from the shuttle table during

ongoing cutting operation and stacked on

the unloading table. Sheets over 12 mm are

removed manually.

Automatic operation can continue until the

sheet metal stack is used up, a new job

requires a material change, or the stack of cut

parts has reached the maximum height.

Cut sheets are manually sorted outside of the

system.

Byt

rans

Line

/-C

ross

The sheet metal sheet islifted from the stack with thesuction unit.

The rake system unloads thecut sheet.

The cut sheets are laid on thestack.

In its standard model, Bytransoffers a sheet separator withmagnets, a cross-blowingunit, and thickness measur-ing.

Bytrans is designed as a portal solution, pro-

viding vibration-free handling of the cut sheets.

The vacuum suction chamber for loading the

sheets and the rake system for unloading cut

sheets is the same in all models.

6

Shuttle table of theBystronic laser

machine

Table for stacking up thecut parts with skeletons

Combination with Length Width Height

Bysprint 3015 mm 19 000 6 500 3 900

Bystar 3015 mm 19 000 6 500 3 900

Bystar 4020 mm 23 500 7500 3 900

Bystar 4025 mm 23 500 8 300 3 900

Byspeed 3015 mm 21000 5700 3 900

Combination with Length Width Height

Bysprint 3015 mm 15 500 7500 3 900

Bystar 3015 mm 15 500 7500 3 900

Bystar 4020 mm 20 000 8 500 3 900

Byspeed 3015 mm 17500 17500 3 900

Slim length construction, space-saving system

BytransLine is constructed by extending the

shuttle table. In the standard model, two manu-

ally-mobile carriages are arranged in a row. In

the short version depicted here, the sheet metal

table is stationary. The table placed above it for

the parts with skeletons is motor-driven.

The parts carriages can be moved to the back

for access to the sheet metal table.

Length Length

Wid

th

Byt

rans

Line

ByspeedByspeed

Loading and unloading unitmoves on the portal

Tables for sheet metalpackagesTable for stacking up

the cut parts with skeletons

7

Table for rawmaterials

Loading and unloadingunit moves on the

portal

Shuttle table of the Bystroniclaser machine

Table for stacking upthe cut parts with skeletons

Modular construction, expandable concept

BytransCross is a modular design and built

across the shuttle tables. Thus up to eight

stacking or loader tables can be placed in front

of and/or behind the shuttle table. The basic

model includes one table for raw material,

and one table for stacking finished parts.

Both tables are movable manually, or optional

motorized tables are also available. The basic

BytransCross module is also used for the inte-

gration of storage systems.

Length

Combination with Length Width Lengthening Height

Bysprint 3015 mm 11000 11000 2 850 3700

Bystar 3015 mm 11000 11000 2 850 3700

Bystar 4020 mm 13 500 13 200 3 600 3700

Bystar 4025 mm 13 500 16 000 4 400 3700

Byspeed 3015 mm 13 000 11000 2 850 3700

On demand, BytransCross is also available for larger formats.

Byt

rans

Cro

ss

Wid

thLe

ngth

enin

g

Byspeed

8Integrated individual part removal, high efficiency

To complete Bytrans, Bysort offers an integrat-

ed individual part removal system. Material

flow is optimized and the efficiency of the

machine is increased. The system is centrally

controlled and especially well suited to large or

frequently repeated production runs. Bysort can

be used for material thickness from 1 to 6 mm,

with part size ranging from 100@100 mm to

600@1 200 mm.

The degree of utilization* of a machine

equipped with Bysort is, as a rule,

higher than 80 %.

*Relationship of machine operation time/cutting time

The sequence of steps

Raw material is brought from storage with a

crane or forklift and placed in the correct

position on the loader table.

The integrated loader automatically places the

sheets without additional handling onto the

laser machine’s shuttle table.

At the same time, a manipulator with a suc-

tion system assures that the cut parts will be

removed from the shuttle table automatically

during ongoing cutting operation and sorted

and stacked on pallets.

The skeletons are stacked on the waste sheet

metal carriage by the rake system.

Bys

ort

The size of the parts deter-mines how many suction unitswill be switched on.Their arrangement is definedwith the help of the usersoftware Bysoft and takenover into the box plan.

Finished components orfalling sheet remnants are,depending on the programcontrol, either placed onpallets or caught in theholders provided.

The manipulator is mountedon the lengthened portal ofBytransCross.

9Compact laser processing cell, excellent machine utilization

Bycell is a fully-automated, compact laser pro-

cessing cell that integrates loading/unloading

with a storage/retrieval tower system for both

raw sheet and cut parts warehousing. Thus the

often costly need to transport material between

storage and the laser machine is eliminated. In

addition, one machine operator can operate

several systems at the same time.

Bycell is available in the BycellCross and

BycellLine models. The choice depends on the

storage capacity required and on the number of

laser cutting systems that are integrated in the

process. Thanks to user-friendly software, the

system is easy and comfortable to operate and

control.

The degree of utilization* of a machine

equipped with Bycell is, as a rule,

higher than 80 %.

*Relationship of machine operation time/cutting time

The sequence of steps

On the basis of the cutting plan data for the

laser machine, the selected material is

retrieved from the storage system and trans-

ported onto the shuttle table.

During ongoing cutting operation, the cut

parts are automatically placed in a storage

cassette. The storage cassette can be filled

with a stack of finished parts, a specific job,

or an individual sheet up to 12 mm thick.

Parallel to this, the corresponding job num-

ber is transmitted from the laser control

stand to the storage administration.

The capacity for storing the finished parts

enables operation over several unmanned

shifts.

Parts processed during unmanned operation

can be retrieved and sorted without inter-

rupting the system’s automatic operation.Byc

ellL

ine/

-Cro

ss

During the storage process, thesheet metal packages areunpacked independently ofautomatic operation andplaced in the proper position inthe cassettes.

Storage administrationadministers the stock of rawmaterials and the cut sheetmetal sheets. The stock of rawsheet metal is checked andcorrected for deviations witheach storage movement bythe integrated weighingmechanism.

The cassettes with the cutsheets are stored via theintake and discharge points ofthe storage system. Employeeshave very good access to theparts from all sides. The intakeand discharge carriage is openabove so that a pull-lift can beused for heavy parts orskeletons.

A sheet metal sheet isremoved with the suction unitfrom a prepared sheet metalcassette. Then the cassettemoves back into the waitingposition and the sheet metalsheet is placed on the lasermachine’s shuttle table.

10

Byc

ellC

ross

Intake and discharge pointsfor the storage of sheet metalpackages and the storage of

cut sheets

S/R machine with spindle hubmovement for loading and

unloading the cassettes and integrated

weighing equipment

The sheet metal and partscassettes are moved on the

lower intake level and upperdischarge level from the

storage tower beneath theloader and unloader

Loading and unloading unit

Storage towers withsheet metal

and part cassettes

Synchronized processes, integrated double-tower storage system

BycellCross is a fully-automated laser processing

cell with an integrated double-tower storage

system. The storage system is mounted across

the machine and it is suited for the automation

of a maximum of two laser cutting systems. The

laser cutting systems are placed at the rear of

the storage system.

The storage system isoperated and controlled

independently of the lasermachine via the operator

terminal

Shuttle table ofthe Bystronic

laser machine

11

Capacity and measurements Format 3015 Format 4020

Storage capacity per storage space for sheet metal packages 3 000 kg 5 000 kg

Storage capacity per storage space for cut sheets 1500 kg 1 500 kg

Length with retracted carriage Bystar/Bysprint 12 000 mm 14 000 mm

Length with retracted carriage Byspeed 14 000 mm not available

Additional length with pulled-out carriage 4 000 mm 5 000 mm

Width with one machine 10 500 mm 13 000 mm

Width with two machines 15 500 mm 19 000 mm

Minimum system height 4 400 mm 4 400 mm

Maximum system height 8 200 mm 8 200 mm

Minimum number of storage spaces with cassettes/standard for 1 machine 25 pcs. 25 pcs.

Maximum number of storage spaces with cassettes/standard for 1 machine 63 pcs. 63 pcs.

Minimum number of storage spaces with cassettes/standard for 2 machines 23 pcs. 23 pcs.

Maximum number of storage spaces with cassettes/standard for 2 machines 61 pcs. 61 pcs.

Height increase/2 cassettes 200 mm 200 mm

Safe distance from ceiling 200 mm 200 mm

Safe distance from crane traverse 500 mm 500 mm

WidthWidth

Leng

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eigh

t

Byst

ar

Byst

ar

Byst

ar

12Comfortable multiple machine operation,lengthwise shelf system

BycellLine is conceived as a one or two-row

storage system suitable for automating several

laser machines. In contrast to BycellCross, the

system is equipped with a lengthwise shelf

system.

Line with shelf operation device. BycellLine is available with one or severalintake and discharge points for sheet metalpackages as well as cut parts.

The operator terminal can be completed withadditional control and operation units withstorage administration software.

Loading and unloading units

Storage towers with sheetmetal and parts cassettes

Byc

ellL

ine

13

Mobile shelf operation device fortransporting the storage cassettes

For calculating a binding bid, detailed information about the nature and scope of facility utilization as well as the individual production environment arerequired. Layouts and technical data are available on request.

This brochure may show parts that do not belong to the standard equipment but that can be purchased as optional equipment. To provide a better view of machine details inthese pictures, some safety covers have been opened up or removed. Size, construction, and equipment are subject to change.

14Experienced total provider, innovative automation solutions

As a specialist in highly-developed laser cutting

systems, Bystronic combines many years’ expe-

rience with the extensive know how of a total

provider. Automation solutions that assure high

machine utilization. The systems are exceed-

ingly compact and modular construction allows

a wide variety of layout options to address

individual requirements. They are easy to oper-

ate and increase process reliability due to the

automated material flow.

sust

aina

ble

perf

orm

ance

Waterjet cutting systems forcutting metals, glass, synthet-ics, ceramic, and many othermaterials

lase

r cu

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Laser cutting systems for theinnovative processing of awide variety of materials andgeometries

Extensive know how forprogressive technologies

At Bystronic, the customer’s success is the

central concern of our company’s thinking and

actions. We are constantly expanding and

further developing our product line to suit

many applications.

wat

erje

t cu

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15

cust

omiz

ed r

elat

ions

hip Customer-oriented systems,

secure partnership

Bystronic is a worldwide supplier of high-quality solutions for

the economical working of sheet metal, other flat materials,

and tubes. Customers profit from application-oriented sys-

tems and services for laser and waterjet cutting processes as

well as bending. Bystronic stands for reliability, high-perform-

ance innovations, an excellent price-performance ratio, and

user-friendly operation. Our focus is on the automation of the

entire material and data flow along the cutting and bending

process chains. As a partner, this pioneering company offers

innovation, reliability, and support.

Service & Support

Bystronic’s systems and modules save maintenance costs.

Extensive after-sales service assures a long lifespan and

guarantees support on location if necessary. Contact people

for hardware and software support as well as professional

training programs are available worldwide.

Bystronic is DIN ISO 9001 certified.

shea

ring

Hydraulic shearing, precisionshearing with variable cuttingangle, and heavy duty swingbeam shears for first-classcutting results

soft

war

e

auto

mat

ion

User-friendly software withneed-oriented user programsand interfaces to CAD andERP systems

High-performance handlingand automation solutionsfrom simple loading systemsto fully-automated laser pro-duction cell with integratedstorage system

bend

ing

3-point and air bendingmachines for high-precisionforming of sheet metals

Aut

omat

ion

/ 03

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Sw

itzer

land

cont

actInnovative handling and automation

systems – application-oriented and universally-applicable

Bystronic’s handling and automation systems

assure a smooth production flow and optimize

the processes. Users profit from the compe-

tence of a total solution provider who produces

highly-developed functional units with a view

to the whole. Thus arise high-performance,

reliable systems that can be inserted optimally

into any production environment. Just as the

market requires: economical, flexible, high-

performance.

Bystronic Laser AGIndustriestrasse 21CH-3362 NiederönzSwitzerland

Phone +41 62 956 33 33Fax +41 62 956 33 80info.laser@bystronic.comwww.bystronic.com

Bystronic Inc.185 Commerce DriveHauppauge, NY 11788USA

Phone +1 631 231 12 12Fax +1 631 231 10 40sales@bystronicusa.comwww.bystronic.com

Bystronic Pte Ltd.2 Leng Kee Road #03-05Thye Hong Centre159086 Singapore

Phone +65 6472 2478 Fax +65 6472 2418BystronicAsia@bystronic.com.sg www.bystronic.com.sgwww.bystronic.com

AFM (Tianjin) Machinery Ltd.Economic Development ZoneNinghe CountyTianjin 301500People’s Republic of China

Phone +86 22 6958 9988Fax +86 22 6958 8168afmtianjin@yahoo.comwww.bystronic.com

Beyeler GmbHMühlhäuser Strasse 3D-99867 GothaGermany

Phone +49 3621 3 83-0Fax +49 3621 38 33 83info@beyeler.dewww.beyeler.dewww.bystronic.com

Offices in Austria, Brazil, China, France, Germany, Italy, Mexico,Spain and Sweden.