CNC Machinery Online Information

intelligent laser cutting and profiling systems feature an automatic torch changer and a CNC based on read-ahead theory to achieve high accuracy cutting

Yamazaki Mazak’s newest laser cutting machines were exhibited at EMO 2005, Hannover, Germany. It is Yamazaki Mazak’s most important mission to build and offer machines, which will completely meet our customers’ requirements so that they will realise considerable success in their business. Innovative success can only be achieved through creating and utilizing innovative technologies.

When we started the Hyper Gear development project, our main goal was to make it possible for one machine to cut ultra-thin worksheets including painted steel plate up to thick worksheets without stopping the machine for complex and time consuming setups.

Such a machine that can accurately cut most of the materials and thickness required by our customers would provide unsurpassed productivity.

Additionally, other types of machines, such as punch presses, would not be required resulting in minimum investment cost for our customers.

With this considerable theme as our goal, Mazak has challenged a variety of unprecedented technologies.

Not only engineering, but a wide variety of talents, even including those of our customers joined the Mazak Hyper Gear development team to strive to achieve ‘unprecedented’ technologies.

Our determination and efforts are confirmed by the fact that we have applied for more than 20 patents.

Our development of unprecedented technologies includes: * The innovative Mazak PreView 640 CNC based on read-ahead theory to achieve high accuracy cutting in ultra high-speed operation.

* Mazak Hybrid linear motor to realize high accuracy cutting in ultra high-speed operation with a long service life.

* Considerably complex computer algorithms to support a variety of sensors and digital image analysis technology.

* Technologies for extended hours of automatic operation and a long machine service life.

* Laser features automatic torch changer - Mazak’s new HyperGear laser system can automatically change its own torch, lens, nozzle and beam mode in seconds, enabling fabricators to use the ideal set-up for every application.

The HyperGear can automatically change set-ups when switching to the next material or thickness.

No time consuming manual torch changes or other adjustments required.

The system also automatically performs focal point and beam adjustments.

This dramatically reduces idle time while enabling optimum cutting performance.

The automated features of the HyperGear make it well suited for an FMS or other automated material handling system.

Because the HyperGear automatically chooses the ideal torch and for every job, cutting performance is not compromised for efficiency.

The system can work with maximum performance and efficiency while running unattended 24/7.

* Laser’s control enables unmatched speeds - Mazak’s new HyperGear laser system features the Nanosecond PREview 640 PC Control and Hyperlinear Drives.

These patented features let the HyperGear laser cut at unmatched speeds yet with the precision to maintain perfect corners, tight dimensional accuracy and roundness on contours.

The control’s new ‘read-ahead’ system is able to calculate a part’s cutting path with 8X greater resolution than the ‘feedback’ system found in other laser controls.

In addition, the software automatically calculates the laser’s optimum cutting speed and acceleration for each contour of the part’s shape.

This means the control can send more accurate instructions to the newly engineered Hyperlinear Drives, enabling the laser to achieve Hyper-fast speed while accurately staying on course.

In addition, the linear-style magnets in the drive motor are machined so precisely that they serve as positioning scales.

They feature a unique cooling technology, which uses clean shop air for cooling instead of water.

An innovative vertical box frame design enables the Hyperlinear Drives to be more accurate and generate less heat than traditional linear motors.

* ‘Intelligent’ laser spots and fixes cutting problems - Mazak’s new HyperGear laser cutting system features an intelligent maintenance notification system.

This maintenance system can spot cutting problems as they are happening and automatically make self-adjustments, such as replacing a dirty lens or reconditioning a nozzle.

In addition, sensors throughout the system alert operators in advance of needed maintenance.

Before every cutting job, sensors check to make sure the nozzle is centred and the lens is clean.

If not, the system switches the torch or nozzle.

It can also grind a nozzle to remove contamination.

If cutting problems occurs during production, an intelligent sensor signals the HyperGear to recheck the nozzle.

The system can also check the focal point and power levels and perform the necessary automatic adjustments or alert the operator.

These automatic features can significantly reduce downtime and the need to reprocess jobs.

The maintenance system also helps prevent expensive downtime and machine damage by notifying operators before maintenance is due.

Pre-notification enables operators to schedule labour and order parts in advance.

Sensors keep an eye on parts and processes throughout the system, including all filters and even the internal and external beam delivery systems.

* Laser’s piercing torch eliminates manual set-up - Mazak’s new HyperGear laser system features an automatically changed piercing torch with spatter removal.

The fast automatic torch changes en able fabricators to use the optimum torches for bath piercing and cutting without incurring time-consuming manual set-ups.

For most lasers, the lengthy manual set-up time involved in switching back and forth between torches negates any time saved by using a specialized piercing torch.

With its ability to change torches in only seconds, HyperGear can use the ideal torch set-ups without compromising accuracy, cut quality or speed.

The system can achieve maximum productivity even while processing unattended 24/7 (24h/7-day working).

In addition, the piercing torch’s ‘intelligent’ features enable the system to avoid heat accumulation, which often results in poor cut quality.

Taking a nest from a Mazak Smart System, the HyperGear’s Nanosecond PREview 640 PC Control can automatically determine the best method of piercing the entire sheet so that no area on the sheet becomes too hot.

* Space gear MarkII - versatile and affordable 2D and 3D CO2 laser machines - the Space Gear is a genuine Mazak innovative concept to offer a multi function laser cutting machine.

There is no compromise made on the cutting accuracy and feedrate.

The Space Gear cuts in 2D with the same speed and accuracy than a normal 2D laser cutter.

But Space Gear offers also the possibility to bevel cut, and to cut 3D cubic components, tubes and profiles as well.

A new generation of laser resonator plus a proven constant-beam length delivery system provides unsurpassed cutting performance - anywhere on the table.

The laser resonator is integrated into the machine base casting to ensure reliable and stable cutting performance.

The cutting torch is equipped with a non contact 3-dimensional profiler which together with off-line teaching delivers exceptional productivity.

Several sizes and laser power are available depending of the customer application.

* Cuts accurate tubes with 6-axis - thanks to the 6-axis cutting torch and NC controlled rotary table the Space Gear cuts a wide variety of accurate pipe joints.

Space CAM generates also the programs to make the jigs.

The appropriate software is particularly required for cutting 3D parts.

Space CAM was especially developed for this application.

Space CAM generates the 3D cutting programs but also the programs to cut the jigs for supporting the parts during the cutting operation.

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