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www.bystronic.com
BYSTRONIC LASER AG, NIEDERÖNZ, SWITZERLAND
FAST, EFFICIENT AND
LASER-SHARPBystronic Laser AG develops and sells sheet metal working systems around the globe. The company's headquarters in Niederönz, Canton of Bern, Switzerland, produces state-of-the-art laser and waterjet cutting machines. The latest innovation, the ByAutonom laser cutting system, is equipped with the Laser Gas Regulator (LGR) newly developed by HOERBIGER. In part thanks to the outstanding performance of this novel gas and pressure change system for laser cutting machines, the ByAutonom is signifi cantly faster and more effi cient than the machines offered by the competition.TEXT: LUDWIG SCHÖNEFELD · PHOTOS: BYSTRONIC
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Home to approximately 1,600 residents,
Niederönz in the Canton of Bern is
truly not a town you would know. The
fact that one of the leading manufac-
turers of laser and waterjet cutting
systems in the world has its headquarters here is
related to Bystronic’s history: the company was
founded in 1964 in the village of Bützberg, locat-
ed just a few miles away. The company name re-
sulted from the combination of the names of the
three founders Byland, Schneider and Trösch.
After initially focusing on glass processing ma-
chines, Bystronic started to develop laser cutting
machines in the early 80s. The success of the
new market segment resulted in the inception of
a separate entity, Bystronic Laser AG, in 1986.
Two years later, the company unveiled the first
waterjet cutting machine, the ByJet.
Expansion in Germany and ChinaSince 1994, Bystronic has been part of Conzze-
ta AG, a Switzerland-based industrial holding
company primarily engaged in machinery and
systems engineering. This enabled Bystronic’s
management to acquire the press brake depart-
ment from Swiss Hämmerle AG in 1997. Another
production location for press brakes was added in
2002 as a result of the acquisition of Beyeler Group
in Gotha, Germany. Hämmerle machines have also
been produced in Gotha since 2004.
The Bystronic headquarters in Niederönz is
home to development, production and assembly,
an apprenticeship center, as well as a demon-
stration and training center for customers.
Approximately 500 of the some 1,500 employ-
ees worldwide of the Bystronic Group work here.
In addition to the site in Gotha, Germany, anoth-
er development and production location for laser
cutting machines and press brakes in Tianjin,
China, has been part of the Group since 2002.
Bystronic is presently active with its own sales
and service companies in around 30 countries
on three continents. In addition, the company is
represented with agencies and agents in numer-
ous other countries.
High level of in-house developmentBystronic develops all the components that play
a decisive role in the performance of the systems
either on its own or jointly with select partners. This
includes, for example, CNC controllers for all ma-
chine systems, laser sources for the laser cutting
machines, and high-pressure pumps for waterjet
cutting. Every tenth Bystronic employee is involved
with the development of products and services.
One of Bystronic’s select partners is HOERBIGER
Automatisierungstechnik in Altenstadt, Germany.
HOERBIGER has developed drive systems for
press brakes for the Bystronic location in Gotha
for years, but the collaboration in the field of
laser cutting systems is still relatively young.
Laser cutting on the cutting edgeFor the development of a new generation of laser
cutting machines, which were planned to be
autonomously operating machines using different
automation modules, HOERBIGER Automati-
sierungstechnik GmbH in Altenstadt offered
Bystronic Laser AG to develop a new, fast Laser
Gas Regulator based on the tried and tested
HOERBIGER piezopneumatic modules.
Given the good partnership for drives used in
press brakes, Bystronic Laser AG accepted the
offer, even though previously the performance-
defining key components had been primarily
developed in-house, especially for laser cutting
machines.
In the end, the Laser Gas Regulator designed
by HOERBIGER eliminated any doubts that
Bystronic had. Its technological unique selling
propositions were compelling for the Bystronic
developers in every respect. The HOERBIGER
Laser Gas Regulator regulates the process gas
used during laser cutting up to five times more
quickly and considerably more reliably than con-
ventional gas and pressure change systems
used in laser cutting machines.
ByAutonom—debut at the EuroBLECHBystronic presented the innovative ByAutonom
laser cutting machine equipped with the
HOERBIGER Laser Gas Regulator (LGR) for the
first time to a broad trade audience at the
international EuroBLECH 2012 trade show.
The name selected for the new machine—
ByAutonom—says it all: using the Bystronic
automation modules ByTrans, ByTower and
Bycell, the machine can be operated largely au-
tonomously with little manpower requirements—
just as set out in the specification sheet. This
also applies if the type and thickness of the raw
material change. The machine simply picks a
cutting head with the suitable focal length and
corresponding nozzle, centers the nozzle
automatically, and then carries on cutting. When
a part becomes tilted, ByAutonom detects the
problem, immediately stops processing, checks
the nozzle, then moves to the centering station,
and automatically realigns the nozzle. The
ByAutonom controller memorizes the problem,
skips a faulty part if necessary, and reliably
carries out the subsequent steps.
Considerable cost advantages“The ByAutonom cuts more parts than any of its
predecessors thanks to its unmatched laser cut-
ting technology. And it operates extremely
reliably,” explains Dr. Jürgen Hohnhaus, Head of
R&D and a member of the Bystronic Manage-
ment Committee. “More parts mean that the
cost per part is reduced. This is a significant
competitive advantage for our customers.”
Latest-generation linear motors accelerate the
ByAutonom with breathtaking speed, giving the
machine dynamism that is unequaled by any
other Bystronic system. The extremely rigid
machine bed and the lightweight bridge are
additional factors that support the machine’s
high operating speed. A special 9-inch cutting
head is included in the standard configuration.
This cutting head can cut high material
thicknesses more quickly and better than
conventional systems. These are generally only
equipped with a 7.5-inch cutting head.
Simple user interfaceBystronic has enhanced its own ByVision
controller with several new features to assure the
system’s process reliability. For example, the
Condition Messenger graphically displays the
current status of the individual components to
the operator, notifying the operator
ByAutonom design
Compared to older designs, the ByAutonom laser
cutting system made by Bystronic looks incredibly
attractive: numerous housing parts were produced from
plastic to be able to implement new, ergonomic shapes.
And Bystronic selected a new color scheme. Why these
changes? “Because nowhere is it written that
profitability, ergonomics and beauty are mutually
exclusive,” says Dr. Jürgen Hohnhaus.
The new Bystronic design is
characterized by ergonomics
and user-friendliness: thanks
to practical drawers, the operator
of the ByAutonom 3015 laser
cutting machine has cutting
heads, nozzles and tools all
conveniently at hand. The safety
gate runs lengthwise and can be
opened quickly and easily.
It allows the operator optimal
access to the cutting area.
DR. JÜRGEN HOHNHAUSHEAD OF DEVELOPMENT AND
MEMBER OF THE BYSTRONIC
MANAGEMENT COMMITTEE
”The intelligent controller leaves it up to the operator whether and when to react to the messages of the Condition Messenger. It may well be that an important job is being processed, which the operator wants to complete before carrying out or organizing the maintenance work. The customer can rely even more on the availability of their machine than before.“
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This article includes texts by Justus Krüger and Martin Engel from Bystronic’s customer magazine “BystronicWorld,” 3/2012 issue.
We appreciate being given the appropriate rights.
PARTThe productivity of a gas laser hinges on the
precision and speed of the control system in
the cutting head regulating the supply of
assist gas, oxygen and compressed air.
Bystronic is using the Laser Gas Regulator
(LGR) newly developed by HOERBIGER for
the first time on the innovative ByAutonom
laser cutting system. The LGR regulates the
process gas used during laser cutting up to
five times more quickly and considerably more
reliably than conventional gas and pressure
change systems in laser cutting machines.
The core of the Laser Gas Regulator is
an electrically piloted proportional valve. In
addition, three gas selection valves are inte-
grated in the HOERBIGER LGR. They allow
different process gases to be selected as a
function of the material that is being cut.
Instead of the customary heavy solenoid
control valves, which are not particularly
dynamic, the HOERBIGER LGR employs
piezopneumatic modules developed and
produced in-house, which have been tried
and tested millions of times. In conjunction
with precision engineering, electronics and
sensors, the modules assure extremely fast
and reliable gas changes in the HOERBIGER
LGR. The innovative assist gas control system is very lightweight,
enabling fast movement of the cutting head.
“Weighing just a few grams, the piezopneumatic module switches
extremely quickly. Within fractions of a second, it controls the gas that
is fed with high precision,” explains Dr. Jochen Schaible, Head of the
Technical Competence Center of HOERBIGER Automatisierungstech-
nik GmbH. In addition, piezopneumatic modules are considered to be
extremely reliable: “For years now, this technology has been proven in
sophisticated medical respirators,” says Dr. Schaible.
Thanks to its unique selling proposition of changing the gas
within a few hundred milliseconds, the HOERBIGER Laser Gas Regula-
tor operates up to five times faster than conventional systems. The
piezopneumatic system provides a consistently stable gas pressure
(pressure stability: ±0.03 bar) and assures precise cutting edges in
consistent quality when cutting thin metal sheets.
www.hoerbiger.com
PART OFLaser cutting, also called laser beam cutting, is a thermal severing
process. It is generally used for sheet metal, but also for wooden panels
and organic materials, wherever complex contours, precise and fast
processing, the production of three-dimensional apertures and/or con-
tactless, virtually force-free processing are
required. Compared to alternative methods
such as stamping, for example, laser cutting
is already economical at very small lot sizes.
Key elements of a laser cutting machine
are the laser beam source, the laser beam
guidance and the processing head with the
fo cusing optics and the nozzle. The focusing
optics focuses the laser beam and generates
the necessary intensity for cutting. The
process gas required for laser cutting is fed
via the cutting nozzle.
Laser cutting is composed of two
concurrent subprocesses. For one, the
focused laser beam is absorbed at the cut-
ting kerf, thereby introducing the energy
required for cutting. Secondly, the cutting
nozzle located concentric relative to the laser
provides the process gas, which protects the
focusing optics from vapors and spatter and
drives the material ablated by the laser out of
the kerf. A distinction is made between three
laser cutting variants depending on whether
the material removed from the kerf is a liquid,
oxidation product or vapor: laser beam fusion
cutting, laser beam flame cutting and laser
beam sublimation cutting.
At present, the maximum steel panel
thickness that can be processed is approximately 40 mm. For alumi-
num, laser cutting is possible up to approximately 20 mm.
http://de.wikipedia.org/wiki/Laserschneiden
PARTNERSHIPBystronic generates revenue of approximately 440 million euros world-
wide (2012). A total of 58 percent of this sales volume is generated in
Europe, with 22 percent coming from Asia and 20 percent from the
Americas.
The cooperation with Korean equipment manufacturer Hana
during the advanced development stage of the ByAutonom shows the
mutual trust that exists between Bystronic and Hana and demonstrates
the significance of the Asian market for the Swiss company.
HOERBIGER has supported Bystronic in the development of
press brake drive units for many years. Relatively new, but very
prom ising, is their collaboration for the development of gas and pressure
change systems used in laser cutting machines.
Bystronic’s production plants in Niederönz and Gotha are
supplied by HOERBIGER Automatisierungstechnik GmbH in Altenstadt.
The Bystronic production plant in Tianjin is working closely with
HOERBIGER (Wuxi) Automation Technology Co. Ltd.
www.bystronic.com
when a component needs to be inspected.
These components include the laser source, the
nozzle changer and the beam path.
In its enhancement of the controller, Bystronic
attached importance to maximum simplification
of the user interface: “Let’s take the highly
unlikely, yet nonetheless possible, scenario of a
hole in the bellows, so that the beam path is
no longer sealed. The corresponding display
switches from green to yellow, or even red—
depending on how serious the problem is,”
explains Dr. Jürgen Hohnhaus.
To ensure that the operator is not taken by
surprise, the machine also issues early warnings.
This allows any maintenance work that may be
required to be planned and prevents sudden
production shutdowns. “The intelligent controller
leaves it up to the operator whether and when to
react to the messages of the Condition Messenger.
It may well be that an important job is being
processed, which the operator wants to complete
before carrying out or organizing the mainte-
nance work,” adds Dr. Hohnhaus.
Another new element of the controller is the
Maintenance Messenger: it alerts the operator
when the machine and laser source are due for
maintenance. Dr. Jürgen Hohnhaus: “The cus-
tomer can rely even more on the availability of
their machine than before.”
Stress test in South KoreaThe South Korean company Hana located in
Pyeongtaek, a city located outside of Korea’s
capital of Seoul, supplies global corporations
such as Samsung and LG with laser-made preci-
Hana subjected the ByAutonom to a six-month
stress test on the factory floor. From day one, the
machine was operated in three shifts.
“So far, the system has fully conformed to our
high expectations. For us, the most important
question was how the machine would cope un-
der real-life conditions month after month,” adds
Im Chang-Bien. “Impressive specifications are
great of course,” says the experienced engineer.
“But the real question is if a new system can
stand the test of the daily factory grind. After put-
ting it to the test, I can say that the machine
operates extremely reliably.”
1 Hana CEO Im
Chang-Bien:
“The Swiss machines
are simply excellent.
This is why we used
Bystronic equipment
from day one.”
2 Bystronic laser
technology for high
precision: Hana cuts
parts for microchip
production lines.
There is zero tolerance
for inaccuracies when
dealing with these
parts.
sion components. With diligence and persis-
tence, company founder Im Chang-Bien built his
company into one of the leading suppliers to
manufacturers of microchips and LCD displays,
for example. In addition to five other production
plants in South Korea, Hana operates a factory
for automobile components in Tianjin, China.
The company’s primary customer there is
Korean automobile manufacturer Hyundai.
Above the desk of Im Chang-Bien, who founded
the enterprise in 1996, hangs a sign bearing the
company’s motto: “Kindness—Harmony—Inno-
vation.”
Im Chang-Bien explains that the last item not on-
ly referred to the employees, but also to the ma-
chines. Hana already has several of Bystronic’s
machines in operation, in particular the Bystar
and BySprint laser cutting machines. Because
these have been successfully applied, but also
thanks to Hana’s enthusiasm for innovations,
Bystronic was able to extensively test the new
ByAutonom in Korea. A prototype of the newly
developed ByAutonom was installed at Hana in
the spring of 2012.
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1
”Impressive specifications are great of course. But the real question is if a new system can stand the test of the daily factory grind. After putting it to the test, I can say that the machine operates extremely reliably.“IM CHANG-BIEN, HANA CEO
Through thick and thin
A wide variety of sheet metals made of various
materials can be cut quickly, effi ciently and precisely
with the HOERBIGER Laser Gas Regulator, LGR. The
performance-defi ning component for laser cutting
machines was unveiled for the fi rst time to the expert
audience at the EuroBLECH 2012 in Hanover.
piezopneumatic module in the HOERBIGER Laser
Gas Regulator (LGR) switches extremely quickly and
regulates the gas supply with high precision.”
The piezo-
pneumatic module
Dr. Jochen Schaible, Head of
the Technical Competence
Center of HOERBIGER Auto-
matisierungstechnik GmbH
in Altenstadt, says: “Weigh-
ing just a few grams, the