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Bystronic – More Safety In The Laser Cutting Process

Tilted parts are a risk factor during the laser cutting process. They can cause a collision with the cutting head. This results in the disruption of cutting jobs, rejected parts and in the worst case, costly damage. However, they also impede automated unloading, as the automation system’s grippers have difficulty picking up tilted parts.

Until now, micro-tabs have been a time-intensive method of preventing cut-out parts from tilting. The software positions small connections between the contour of the part that is to be cut and the residual grid in the cutting plan. In this way, parts remain fixed to the surrounding sheet after cutting. One disadvantage of this solution is the cut parts require reworking in order to remove the traces of the micro-tabs. Another disadvantage is the automated removal of the finished parts is impeded because the micro-tabs make it difficult to remove the parts from the residual sheet.

Left: Perfect cutting result thanks to TiltPrevention.
Right: Tilted parts after laser cutting without TiltPrevention.

Another approach is to use software to guide the paths of the cutting head during the cutting process so that, as far as possible, it circumvents risky sections where parts could tilt. However, this solution does not eliminate the root of the problem: Parts protrude, still represent a risk and are difficult for automation systems to cope with.

Algorithm generates the ideal cutting sequence

With TiltPrevention Bystronic has now developed a new solution. In future, BySoft 7 will use this intelligent assistant function to compile cutting plans in such a manner that parts cannot tilt during the cutting process. This largely eliminates the need for micro-tabs.

How does it work? An algorithm calculates the mechanical behavior of the parts while they are being cut out of the sheet. To achieve this, TiltPrevention takes into account a wide range of parameters: What is the density of the material that is being cut? What is the geometry and weight of the parts that are to be cut? How high is the pressure of the gas that flows out of the cutting head during laser cutting and exerts pressure on the parts? How are the parts positioned on the cutting grate? Are there enough contact points?

Left: Simulation of the optimized cutting sequences using TiltPrevention.
Right: Laser cutting without TiltPrevention with piercings in critical areas (red) and risky paths of the laser.

Subsequently, TiltPrevention recommends lead-in and lead-out points of the laser so that tilting of the parts after cutting is prevented to the greatest possible extent. In addition, the function proposes the best possible route for the cutting head over the metal sheet. This creates an ideal cutting sequence for all parts on the cutting plan. Cutting in such a manner that the cutting head never travels over parts that have already been cut out.

Regardless of the users’ level of experience, TiltPrevention supports them with an ideal cutting strategy that can be automatically incorporated into the cutting plan. Users can carry out customized adaptations at any time using the simulation created by TiltPrevention: modify the nesting of parts, reposition the lead-in and lead-out points of the parts, and add micro-tabs where required.

For more information, please contact First Cut – Tel: 011 614-1112

TRUMPF Makes The World’s Most Flexible 3D Laser System Even Faster

At this year’s EuroBlech, TRUMPF launched the latest generation of its TruLaser Cell 7040, one of the most productive and versatile 3D laser systems in the world. As with previous versions, users can opt to equip their machine with either an energy-efficient disk laser or a CO2 beam source.

This allows the machine to process a broad range of materials, including steel and light metals, without the need for time-consuming re-tooling. Operators can choose between cutting and welding operations in 2D or 3D and TRUMPF has given this new model a major productivity boost by reducing non-productive time, integrating automation features and improving processing quality. Users also benefit from consistently high quality parts and excellent reproducibility as well as reduced energy and material costs. The new machine is particularly suitable for industries that need to produce many different product variants in a short space of time, for instance job shops, the automotive industry and aviation.

The TruLaser Cell 7040 is an inherently powerful and flexible machine, offering the largest range of beam sources and highest laser power on the market and capable of executing multiple machining processes. To make the machine even more efficient, TRUMPF has worked on cutting down nonproductive time. This encompasses any activity before or after processing that does not add value to the process – re-tooling or loading and unloading, for instance. “When companies are making batches of products that change on a frequent basis, the cost of this non-productive time really adds up,” says TRUMPF product manager Thomas Kirchhoff.

The TruLaser 7040 saves time thanks to its smart optic set-up station, a swivel-mounted apparatus mounted on the machine frame that automatically orientates the optics within the work area. This improves accuracy, resulting in consistently reproducible, high quality cutting results.

Two different beam sources allow the machine to process a broad range
of materials, including steel and light metals, without the need for time-consuming re-tooling.

It also enables the operator to start producing batches much faster than before, since hardly any time needs to be spent on set-up. As a further improvement, TRUMPF engineers have also included optimized cutting parameters for both beam sources in the machine control system. Thanks to these integrated laser technology tables, operators need only select the material and thickness and the machine will automatically choose the right cutting parameters for settings such as power and gas pressure. That eliminates the need to hunt for the best parameters manually and enables operators to start the process quicker. What’s more, it increases machining quality and decreases scrap rates by locking in the optimal parameters right from the very first part.

In a bid to further boost productivity, TRUMPF experts have also drawn on the latest generation of TRUMPF lasers. The range of compatible products includes highly efficient TruDisk lasers up to 5kW as well as tried-and-tested CO2 TruFlow lasers offering as much as 6kW of laser power. During laser cutting, X-Blast technology ensures increased process reliability by enabling the nozzle to machine the sheet metal at twice the distance. That results in fewer collisions, guaranteeing higher quality, burr-free cutting results even in the case of highly complex components.

The TRUMPF experts have also set out to significantly boost part quality by integrating BrightLine Weld, a technology developed by TRUMPF for low-spatter laser welding. “With this technology, not only do we get a better quality of weld seam, we can also triple welding speed and achieve a major boost in overall productivity,” says Kirchhoff. The developers have also incorporated doors made of glass fiber composites into the new design. These are almost half the weight of their steel equivalent, shaving the time needed to open and close the doors by three seconds. That can help achieve time savings of up to 35 percent per processing cycle.

Last but not least, TRUMPF has taken operators’ needs very much into account in this new version of the TruLaser Cell 7040. Programming and teach-in are easier because operators can now see inside the machine without having to make unnatural movements. This improvement stems from a moveable, swivel- mounted control panel that operators can quickly adjust to their height and stature. The white paint finish and balanced lighting give operators a clear view of the work area at all times.

For more information, please contact Retecon – Tel: 011 976-8600

Trulaser Series 1000 – Re-Engineered From The Ground Up

TRUMPF has re-engineered the TruLaser Series 1000 from the ground up. These machines can now be automated across the board. The TruLaser Series 1000 also handles many cutting-related processes autonomously to drive down part costs.

Equipped with a robust laser and proven functions such as collision protection, these machines cut sheet metal in a process-reliable way. And the intuitive operating concept reduces training time. Beyond that, TRUMPF added new features such as protective glass monitoring and BrightLine fiber. Previously available only in higher 2D laser classes, they serve to optimize processes and boost machine efficiency.

The cutting head deflects if it collides with a tilted part.

The new series consists of two types of machine, the TruLaser 1030 fiber and the TruLaser 1040 fiber with work areas three and four meters long, respectively. The TruDisk solid-state laser operates at constant power and is insensitive to reflections off copper, brass and other materials that reflect when cut. TRUMPF ships these machines out with data for cutting many commonplace materials and thicknesses of sheet metal. It enhances their process reliability – they can even cut copper with nitrogen. Machines with a fourkilowatt laser are equipped with BrightLine fiber. With this function, they can cut thick mild steel in a process-reliable way. In the event of a collision with tilted parts, a special protective mechanism deflects the cutting head to prevent damage. The TruLaser Series 1000 deposits slag and small parts in five pull-out drawers below the machine’s frame.

This re-engineered line of TRUMPF machines is far more dynamic than its predecessor. Positioning speed is up from 85 to 140 meters per minute. This speed is down to the design of the machine’s body, which combines a rigid machine frame with a lightweight motion unit and powerful drives. The machine cuts all materials and sheet thicknesses with the same cutting head. It changes nozzles automatically thanks to the optional nozzle changer. Sensors monitor the optics’ protective glass and let the operator know when it is time for a replacement. Visual inspections are a thing of the past. All this reduces the machine’s set-up time. The TruLaser Series 1000 also saves time during the cutting process. The PierceLine feature reduces piercing time by up to 80 percent and protects the machine and material. These machines operate very energy-efficiently with an average power consumption of 13 kilowatts for the 3-kilowatt laser and 14 kilowatts for the 4-kilowatt laser. They also come with more energy- conserving features, as do their periphery modules.

The TruLaser Series 1000 automatically changes nozzles to the correct type.

The TruLaser Series 1000 features a new 18.5-inch multi-touch control panel. It displays the most frequently used menu items at the top level. If the operator interrupts an operation, the control unit enables processing to resume at the same point. The monitoring capability is not limited to the protective glass: Other sensors track the condition of components that impact the machine’s cutting performance. A traffic-light readout on the control panel called the Condition Guide indicates the status. It also offers guidance when the operator needs to take action. Flow charts make it easier to forecast actionable events and provides a more efficient way of scheduling maintenance work.

A semi-automatic pallet changer is a standard feature. The operator can prepare new sheets, while the machines are operating and sort or unload cut sheets parallel to the cutting process. Users may also opt to equip the TruLaser Series 1000 with automated LiftMaster components. They load raw sheets and remove the cut sheets. TruLaser Series 1000 machines may be connected to the compact TruStore storage system or to a large Stopa storage system.

The MobileControl app serves to operate the TruLaser Series 1000 using a touchpad situated near the machine. TruTops Monitor software tracks the machine’s status continuously and notifies the operator in the event of a malfunction. The TruLaser Series 1000 affords users the opportunity to access the machine’s digital enhancement. It contains five apps that assess machine data and deliver the results to users. AXOOM, a TRUMPF subsidiary, provides the cloud platform for processing these data. The apps provide an insight into tool and material usage and display the current machine status to users on the go.

For more information, please contact Retecon – Tel: (011) 976-8600

Interactive Control To Guide Industrial Robots

Scientists at the Fraunhofer Institute for Machine Tools and Forming Technology IWU have developed an innovative technology enabling people and large industrial robots to work together in an intuitive way that feels a lot like human teamwork.

Using the benefit of this technology, robots can recognize gestures, faces and postures to make this collaboration that much safer and more efficient. Fraunhofer IWU presented this innovation at the Hannover Messe Preview in January, 2019 as well as presenting it at Hannover Messe in April 2019.

A cursory glance at shop floors is all it takes to see human-robot collaboration has gone mainstream in manufacturing. However, a second glance reveals that this is more to each his own than we’re in this together. Heavy-duty robots operate alongside their human coworkers without safety fencing, but direct interaction is a no-go. Safety precautions dictate that the robot freezes as soon as a human sets foot in a sizable surrounding safety zone.

Safe, effective and direct – a better way of working together

The Fraunhofer Institute for Machine Tools and Forming Technology IWU has come up with an unprecedented technology to make human-machine teamwork more efficient, benefiting the entire manufacturing workflow.

Various safety zones around the robot determine whether and how robot and human can work together in each zone. © Fraunhofer IWU

“We have added effective, secure and flexible interaction to legacy technology. This is the first time humans can communicate and collaborate directly with heavy-duty robots based on hand gesture in the industry,” says Dr. Ing. Mohamad Bdiwi, head of department for robotics at Fraunhofer IWU. This collaboration goes something like this on the shop floor: The machine recognizes human gestures, faces and postures when a person enters the robot’s work zone. This data serves to make the teamwork safe and to control the robot. The human simply gestures, using hands and arms to instruct the mechanized coworker to perform a task. The robot is able to interpret even complex movements. “Our technology brings gesture control to industrial applications. To date, it has been used mainly in gaming applications, for example, consoles,” adds Bdiwi. The robot does not only track hands, it also scans faces. For example, if the human glances sideways or rearward to talk to another coworker, the machine knows to ignore gestures meant for others. Human and robot can work together directly and even pass parts and tools back and forth. The robot sees when a hand is too close to the worker’s face and waits for it to be extended out of the danger zone before handing the object over. This human-robot interaction comes courtesy of smart algorithms and 3D cameras that lend the robot the power of sight.

The algorithms are ready for action. Visitors to Hannover Messe can see a gesture-controlled, interactive demo application at Hannover Messe in April, 2019.

Spectrum Machine Tools Africa Appoints New MD

Spectrum Machine Tools Africa recently appointed Vaughn Hanwith-Horden as its new managing director.

Vaughn, previously the managing director at F&H Machine Tools, brings vast experience to the new company which evolved from the restructuring of Durma SA.

Spectrum Machine Tools Africa’s line-up of agencies include Durmazlar, Hyundai, Eurostamp, Hypertherm, Precitec, Centri Cut, Matrix, Tamsan, LissMac, Coiltech and Herrblitz.

Denel Strategy Gathering Momentum

Denel remains positive about its future as the issues raised by Fitch Ratings will be resolved through the successful implementation of the company’s recently approved strategy. Fitch Ratings recently down-graded the company’s national long-term rating from ‘AA-(zaf)’ to ‘B(zaf)’.

“We know that Government is cognisant of the fact that Denel is in need of additional liquidity to rebuild its business,” says recently appointed Denel Group Chief Executive Officer, Danie du Toit.

During the Minister of Finance budget speech in February, Minister Mboweni announced a contingency reserve of R13 billion for 2019/20 which Denel is preparing to submit a funding application.

Denel has undertaken a strategic review of its business to establish the extent and timing of the required government support, taking into account the benefits to be realized as implementation of the company’s strategic plan gains traction.

A lot of headway has been made by the current Board in support of the turnaround and growth of the business.

“The Board has taken far-reaching steps to restore good corporate governance. We have a new experienced management team, with a number of executive positions currently being filled as we speak. We have a new strategy and a management structure that has recently been approved to stabilise Denel and achieve long-term growth”, says Du Toit.

As part of the company’s new strategy, Denel will dispose of non-core assets, including under-utilized properties and enter into strategic equity partnerships in some of its businesses to strengthen market access and enable the development of new technology, whilst ensuring the protection and growth of strategic defence capabilities.

Part of the turnaround has seen the company put systems and processes in place to strengthen governance, improve programme management, drive efficiencies and grow revenues.

“We are confident that the outlook for Denel will be further improved once the implementation of the new strategy and operational plan are in place and all corporate governance issues have been successfully dealt with,” says Du Toit.

Denel has established a team to investigate all cases of possible irregular expenditure and recommend corrective action. “There will be consequences for those executives implicated in irregularities including disciplinary and legal action taken against the individuals” says Du Toit. The company is also cooperating with the judicial commission into state capture – Zondo Commission of Inquiry – and investigations by the Special Investigating Unit (SIU) and other applicable state agencies.

Key issues identified by the Auditor General in the last assessment of Denel’s financial statements are being addressed. An independent audit firm was appointed to bridge the IFRS technical skills gap within the organizations and Denel’s supply chain management policies are currently being reviewed.

Du Toit says the Board together with management are committed to not only strengthening corporate governance within Denel, but are further working on rebuilding the loss of public trust in the company.

Building Sustainability Through Local Manufacturing

According to Eric Bruggeman, CEO at SACEEC, part of the Council’s mandate is to organise outward selling and inward buying missions.

“We identified a need to showcase the offerings of the SADC region’s local manufacturers in an interactive manner. The result is the inaugural Local Southern African Manufacturing Expo (LME) being held at the Expo Centre, Nasrec from 21 to 23 May 2019.”

“Endorsed by the Premier of Gauteng, David Makhura, we believe that the exhibition will enable exhibitors to meet with top decision makers from the inward buying missions already committed to the event. As Industry 4.0 continues to transform the way that manufacturers do business, LME 2019 will provide them with an opportunity to grow their customer base, with the knock-on potential for fostering job creation,” says Charlene Hefer, portfolio director for Specialised Exhibitions Montgomery.

“It is critical for the sustainability of local manufacturing operations that they aggressively pursue opportunities to increase their market share. Not only is this relevant to their increased permeation of the overseas market, but furthermore, they need to capture market share that is currently being monopolized by importers. Recent statistics indicate that South Africa currently imports products to the value of a staggering $83.2-billion. If we were able to shift this demand to the local manufacturing sector, we could realistically create 1.329-million jobs,” says Bruggeman.

LME 2019 will give local manufacturers from South Africa and other SADC regions a chance to not only display their capabilities and capacities to a captive audience, but furthermore it creates a forum for the exhibitors to network with their peers.

“We are excited about the prospect that local manufacturing operations have to evolve and expand by interacting with the inward buying mission representatives. Added to this are the benefits derived by the support of SACEEC, together with AREI (Association of Representatives for the Electronics Industry) and the dti (Department of Trade & Industry). We urge local manufacturing companies throughout southern Africa to capitalise on the unique marketing opportunities of exhibiting at LME 2019,” says Hefer.

Jo’burg To Host Doyens In Africa’s PVP Sector

The largest and most comprehensive African trade show dedicated to industries involved in the conveyance of liquids, gases and slurries will in June bring together key buyers, engineering professionals, leading manufacturers, suppliers and agents to exhibit, network, learn and do business.

INDUTEC Africa recently announced that for the first time ever, its 11th edition of Pumps, Valves & Pipes Africa, taking place 11-13 June, will now be co-located with African Construction Expo and Totally Concrete Expo – both part of the Big Five portfolio of construction events under the umbrella of dmg events.

Says Project Manager, Nico Loretz: “The event will feature and showcase latest technologies and innovations in pump, valve and pipe manufacturing, engineering, installation, maintenance, refurbishment and all else related.”

According to Sales Manager, Dale Magaya, leading manufacturers, suppliers and service providers for pumps, valves, pipes and all related equipment within the following industry sectors will exhibit at the event:

Extractive industries (mining and minerals), construction (infrastructure), energy (oil, gas and petrochemicals), water and wastewater, power generation (solar thermal, hydropower, nuclear, geothermal), agriculture, food and beverage and pulp and paper.

Loretz adds that the event will not only feature a trade exhibition, but will also include a free-to-attend joint keynote session, workshops and interactive panel discussions that will provide practical, applicable knowledge sharing – not only for visitors to gain knowledge and improve their skills, but also to expand their professional network for years to come.

“Africa has enormous growth potential in all the growth and investment areas as mentioned by Dale Magaya. Not only are terms like Internet of Things (IoT) and Big Data on everybody’s lips these days, but localization and skills developments are just as important in order for Africa’s economy to elevate to the next level. These issues will form part interactive panel discussions among technical case studies during the event”, he concludes.

SA Government Prioritizes Investment In The Mining Sector And Mineral Beneficiation

The Minister of Trade and Industry, Dr Rob Davies says the South African government has prioritized investment and mineral beneficiation due to its capacity to grow the economy and create jobs. Minister Davies was speaking at the South African Mining Investment Roundtable that took place on the margins of the Mining Indaba in Cape Town.

The purpose of the roundtable which was organized by the South African government was to provide potential investors from targeted countries with the opportunity to interact with the South African political and business leadership in order to obtain firsthand information on the issues relating to the South African mining environment. Investors from various countries including Canada, United States of America, India, Japan, China, Saudi Arabia, Australia, United Kingdom and Russia attended the roundtable.

“The beneficiation of our minerals is one of the most critical issues that we as government have prioritized because value-addition will go a long way in creating jobs and growing our economy. We can no longer afford to export raw minerals so that they can be beneficiated in other countries. Beneficiation increases the value of our minerals and if we are stuck on exporting raw minerals we will not be able to build an economy that will enable us to create jobs and develop our country and the continent in general,” said Davies.

He added that there were opportunities for investment in the beneficiation of the South African minerals and invited investors attending the session to take advantage of them.

“As a department we are engaged in various initiatives that are aimed at adding value to our minerals. There is a variety of beneficiation projects that offer opportunities for investment,” said Davies.

He listed the development of hydrogen fuel cell-powered busses and vanadium batteries as some of the initiatives aimed at beneficiating South African minerals. The Minister of Mineral Resources, Mr Gwede Mantashe and the Minister of Science and Technology, Ms Mmamoloko Kubayi-Ngubane also addressed the session.

Mantashe spoke about the deepening of stakeholder relations between government, business, labour and communities and the opportunities the policy certainty provided by the mining charter. Kubayi stressed the importance of technology and skills and developing a sustainable mining sector.

Meanwhile, Exxaro Resources Limited committed to investing R20 billion in Limpopo and Mpumalanga, while Vedanta Zinc International committed to phase 2 and to conduct a feasibility to develop a zinc smelter in the Northern Cape.

SEIFSA Welcomes President Ramaphosa’s Inspiring Sona

The Steel and Engineering Industries Federation of Southern Africa (SEIFSA) welcomes President Cyril Ramaphosa’s inspiring State of the Nation Address. SEIFSA Chief Executive Officer Kaizer Nyatsumba said the President’s speech was both rich in content and much welcoming of the important role that business plays in the country.

“After nine frustrating years of terrible leadership, during which the Government had a very hostile stance towards business, it feels very good to be able to say that South Africa has solid leadership again. We are very encouraged by the President’s grasp of the serious challenges facing South Africa and more importantly, his acknowledgement of the obvious fact that the Government alone does not have all the answers to the country’s problems. We are very encouraged by the fact that he understands that all stakeholders have an important role to play and that he places such a welcome emphasis on the need for a meaningful partnership with business, Nyatsumba said.

He said like other business organizations, SEIFSA – which is part of the manufacturing sector – stands ready to partner with the Government in an effort to grow South Africa’s economy. “We hope that the President will ensure that his Ministers also come to the party.”

In conclusion Nyatsumba said the Federation commended the President for his war on corruption and fully shared his desire to see the country’s law enforcement agencies rigorously prosecuting all those who have been implicated in State capture and other forms of corruption and malfeasance.

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