CNC Cutting Solutions 2017 / 2018CNC controller for cutting machines

Laser

Oxy-fuel

Water

Plasma

CNC Cutting Solutions by Eckelmann

More and more cutting machine manufacturers worldwide trust in CNC Cutting Solutions by Eckelmann. In addition to technical and economic factors, the cooperative partnership and economic stability in particular are decisive when choosing Eckelmann.

Supporting all current processing methods and their combination: Thermal and water jet cutting, drilling, thread cutting, labelling and marking.

We offer interfaces to all technology providers and thus a free choice of cutting equipment.

Free choice of Eckelmann’s scope of delivery: One-stop-shop from procurement of the pure control core to complete control and drive equipment. Optionally also inclusive nesting software with macro library.

The same control platform for all machine designs allows for streamlined procure-ment and warehousing as well as training and service.

Control technology with long-term avail-ability independent of short innovation cycles (in contrast to PC technology).

Developed and produced for the use in harsh environmental conditions. Compli-ance with all relevant national and inter-national standards. Also with UL-certified switch cabinet construction as per UL File E233027.

Oxy-fuel / plasma cutting machine: ERL Automation GmbH

Germany

Oxy-fuel / plasma cutting system: Sato

Germany

The Eckelmann Engineering Documenta-tion Platform E°EDP provides 24/7 current and quick online access to all technical information.

Comprehensive know-how protection for the machine manufacturer. Thus, your competitive edge is always secured.

Machine manufacturers can quickly and easily modify or extend the application programs of the controllers.

No anonymous hotline, but personal customer service, including technical support, ensure quick problem solving.

For customer care and support abroad, we have Eckelmann branches or representations in export markets such as China, India and Russia.

Eckelmann is a medium-sized company group with more than 400 employees. Our head office is in Wiesbaden, near Frankfurt/Main (Germany).

Our company was founded in 1977 and we have almost 40 years of experience in the development and production of CNC controllers. Continuity and exten-sive know-how in NC technology make Eckelmann a reliable partner for long-term cooperation.

Eckelmann’s virtual 3D machine simulator offers machine manufacturers new possibilities in product development and training.

Retrofit of oxygen cutting machines: SAEHSEN Industrie-Service

Germany and global

Dual oxygen cutting machine: Stako B.V.

The Netherlands

Features

Interpolation types

Staight line, circle

Spline and polynomial interpolation

Transformations

6-axes transformation (RTCP)

Cylinder mantle transformation

Transformation for rotation-axis

Transformation for hexapod and tripod kinematics

Transformation for robots kinematics

6-axes transformation for rotary table kinematics (RTCP)

Cartesian polar transformation

Tool path correction

Tool radius compensation (WRK)

Special modules for intermittent operation

Axis correction

2D and 3D correction, sag compensation

Directional height correction

Spindle pitch error compensation

Backlash compensation

Programmable axis configuration

Program interruption or termination

Interrupt program call

Storing of the abortion position

Block scan and reverse for random access to the contour

Technology functions

Inclined axes (e.g. grinding)

Height control (e.g. cutting)

Pairing of axes path and rotation (e.g. grinding)

Programming of tool spindles (e.g. grinding, milling)

Non-cylindrical grinding

Track in and move back strategies (e.g. measuring machine, eroding)

Own CNC core

Complete access to all functionalities

Individual firmware extension, also exclusive

Router: FlexiCAM GmbH

Germany and United Arab Emirates

Cutter + Plotter: Lasercomb GmbH

Germany

Switching function on the path

depending on:

Distance before M function

Time before M function

During acceleration or breaking

Before and after a corner

User Interface Cutting HMI

Pipe profile cutting machine: Müller Opladen GmbH

Germany

Multifunctional cutting machine: Lind GmbH

Germany

Furthermore, special cutting technology pages with inter-active graphical user guidance and comprehensive help functions support the user when operating the machine.

The design of the user interface fully covers all cutting requirements and is based on Eckelmann Framework E°Tools HMI. Design and functionality are entirely separated, allowing the machine manufacturer to adapt and expand the user interface individually.

Eckelmann’s image processing software allows for a camera image to be superimposed for sheet positioning detection, with automatic offset calculation and angle correction in the cutting program. Further options are: Offcut sampling, scanning of contour templates, or reading of product codes and plain text markings.

The user interface offers a fully integrated CAD/CAM basic system with a comprehensive macro library and geometry import in various file formats as well as automatic nesting for generating cutting programs at the machine.

Laser cutting

Important components of any laser-cutting machine are the laser beam source (resonator), the laser beam guide and the cutting head (focusing optics) including the cutting nozzle.

For laser cutting, a focused laser beam is absorbed at the cutting front and thus applies the required cutting force to the material. Gases push the ablated material from the cutting kerf.

The most important laser-specific functions of the Eckelmann CNC:

Control of the cutting components and the cutting peripherals:

Laser beam sources from IPG, Coherent-ROFIN, SPI Lasers, TRUMPF

Laser cutting heads from Precitec, HIGHYAG und Laser Mech

Shuttle table of varying designs

Gas and exhaust control, nozzle cleaning etc.

Interfaces for conveyor lines and sheet bearing connection

Technology table for storing all relevant cutting parameters:

Material thickness, type and quality of material, cutting speed, laser power, cutting gas type

Track speed dependent analogue output and PWM signal for the laser power control:

The pulse-width modulated output has a maximum frequency of 10 MHz and a resolution of 16 bit. Thus, the laser power can be controlled extremely precisely depending on the material to be processed and the track speed of the guiding axles.

period

duty

Laser cutting system Proteck Machinery Pvt. Ltd.

India

Laser cutting machine: Motofil Equipamentos de Corte, Lda

Portugal

The fly-cut option reduces cutting time significantly.

During the scanning of all horizontal and vertical cuts with a consistently high speed, the laser beam is switched on and off “on the fly” by activating and deactivating the signal directly in the fine interpolation cycle of the control. Here switching times are in the microsecond range.

© Kjellberg Finsterwalde Plasma und Maschinen GmbH

Laser marker: Baublys 7000

Germany

Laser cutting system Lasercomb CLS 2115

Germany

Frog-jump function for the parabolic traversing of the laser cutting head between the beginning and end of the new contour section in z-direction

This prevents any collision between the laser head and the cut parts and reduces the traversing time compared to a separate z-axis movement.

Quick height adjustment for a constant distance between the workpiece surface and the cutting nozzle by recording the analogue distance signal using characteristic linearization.

CNC-controlled compensation mechanism for an optimal laser focus position with directional correction. Compensation of deformations in the focus geometry by corresponding corrections. Integration of manufacturer specific laser diagnostic tools directly into the CNC user interface.

Further universal functions for cutting applications:

Sheet position detection and offsetting, kerf compensation, reverse travel and returning to the contour

Consumables monitoring, operating data acquisition and order management, error log etc.

Sheet thickness

Laser

Plasma

Oxy-fuel

Cut

ting

spee

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Frog-Jump

Height adjustment

Plasma and oxy-fuel cutting

For oxy-fuel or flame cutting, the metal sheet containing carbon is first heated to ignition temperature and then burned in the oxygen jet.

For plasma cutting, the sheets are cut using a conductive gas (plasma), which is generated by an electric light arc.

Often plasma and oxy-fuel cutting are used in one machine. The control system must manage both cutting processes and must be able to support additional units:

Drilling and thread cutting heads with or without automatic tool change

Marking devices with pin marker, inkjet printer or plasma marker

Additional rotary axis on flatbed machines for tube cutting

Standard functions for all cutting applications:

Sheet position detection and offsetting

Kerf compensation with automatic overcut

Reverse travel and returning to the contour

Throttle control at the extraction table

Consumables monitoring

Operating data acquisition and order management

Error log

Operation with multi torch carriages:

Individually motor-driven, with automatic band clamping or both on one machine bridge

2 or more bridges on one track are possible thanks to multichannel CNC and collision monitoring

Oxy-fuel bevel cutting machine: Lind GmbH

Germany

Oxy-fuel / plasma cutting machines: Hollysen

China

© Kjellberg Finsterwalde Plasma und Maschinen GmbH

Basic quality features and control requirements for plasma cutting are:

Burr-free cut

Reduced roughness of cutting edge

Rectangular cutting edges

Plasma power sources and automatic gas consoles of the manufacturers

Kjellberg

Hypertherm

Thermal Dynamics

are supported. For an automatic communication with the plasma power source, the associated databases of the manufacturers are integrated into the CNC control.

The distance between the plasma torch and the metal sheet surface can be adjusted using external height control systems, for example from

IHT Automation, Kjellberg

or by using arc voltage inside the CNC; with corner signal and other special functions.

Almost any TCP and non-TCP kinematics for 3D- processing (bevel cutting)

Several bevel units on one machine are possible, also together with rotary axles for round tube and section tube cutting

Oxy-fuel cuttingPlasma cutting

Technology tables for oxy-fuel cutting

Configurable speed reduction at cutting start and end

Variable control of the gas technology depending on valve arrangement and valve type:

Switching valves

Proportional valves with pressure rampus

Height control of the oxy-fuel torch using external height control systems or CNC-integrated height control through recording and linearization of a capacitive measuring signal.

Bevel cutting with 3 torches arrangement:

Automatic motorised torch angle and lateral adjustment

Several oxy-fuel bevel cutting units are possible on one machine

Cross section of the thermal cutting processes

Plasma Laser Oxy-fuel

Oxy-fuel / plasma cutting machine: Swayambhu Engineering

India

Oxy-fuel / plasma cutting machine: Rate

China

Waterjet cutting

One differentiates between the pure water cutting for cutting soft materials and the abrasive cutting with added abrasives for cutting hard materials such a glass, stone and metal.

For waterjet cutting, water is pushed through a nozzle with a pressure of 4000 to 6000 bar and accelerated to twice the speed of sound.

Important control requirements for water jet cutting:

Avoiding bevel cuts and maximising cutting speed are important challenges. Here, the control requirements are material parameter management using a technology table and bevel cut adjustment through supporting relevant axle kinematics.

A precise cut requires accurate and quick distance control between the cutting nozzle and the workpiece surface. For this, the height of the workpiece is scanned using displacement sensors, configurable in the control, and various measuring strategies.

Special speed ramp functions for minimising the “whip effect”, in particular for corners and small radii

Water jet only and abrasive water jet cutting support with parameterisable abrasive dosing

Connection of high pressure pumps using varying interfaces and protocols

Freely programmable sequential control for water preparation can be integrated

Several cutting heads on one machine bridge and several machine bridges on one track are possible

3D workpiece processing thanks to supporting various cutting heads kinematics

Pure water cutting Abrasive cutting

Waterjet cutting system: STM GmbH, www.stm.at

Austria

Waterjet cutting system: Sato

Germany

© Luca Fabbian/Shutterstock.com

Glass cutting machine: Hegla

Germany

There are several other material-specific separation proces-ses, in addition to water jet and thermal cutting. For this, varying tools, requiring specific control properties, are used.

Brass wire for wire-cut EDM or graphite electrodes for electric discharge machining for tool and mould making

Discharge gap control

Reverse retraction

Rotation-symmetric tools for milling and engraving machines for the processing of wood, metal and plastics

Tool radius compensation

Length compensation

Heating wire for cutting EPS materials (polystyrene)

Special thermal functions

Revolving band knives for foam cutting of upholstery, mattress, packaging and insulation materials

Tangential tool tracking

Turning points on the contour

Jigsaws and knives for cutting clothing products and technical textiles

Tangential tool tracking

Compensation of knife regrinding

Special strategies for corners

Cutting wheels for scratching glass in preparation of the subsequent breaking of the glass

Tangential tool tracking

Control of cutting pressure

Special strategies for corners

Electric discharge

machining - EDM

Wire-cut EDM

Textile cutting machine: Kuris

Germany

Additional cutting / separation processes

Range of products and service

Example of complete equipment for a 4 axis-cutting machine (CNC supports up to 16 axes)

Custom operating panelwith E°Tools HMI

Connection of peripheral and auxilia-ry units, for example, plasma power source, marking system etc.

CNC controller E°EXC 66and I/O modules E°LBM

Box PC E°PC B0101

Camera E°CAMBOX

Drive controller E°Darc

Safety logic controller E°SLC 204Safety I/O module E°SLC SIO084 and CAN bus coupler E°SLC CAN

Motors E°SL3 compact

Water jet cutting system: Atech

Germany

Oxy-fuel / plasma cutting machine: Proarc

India

Embedded controller E°EXC 66

Includes drive interfaces CANopen®, EtherCAT®, Sercos® III or analog; ports for Ethernet, RS232, USB as well as SD card slot and watchdog.

Its powerful CNC operating system offers new cutting specific additional functions.

Machine manufacturers can independently extend its SPS application software for all cutting methods.

Local bus modules E°LBM

Provides activation of the machine signals (digital, analogue, serial, PWM) as well as an interface for a separate machine operating panel and fieldbus modules for a distributed I/O structure.

Safety Logic Controller E°SLC204

For safe connections and prefabricated components that are graphically programmed in the function chart. Interface connection to E°EXC 66 via CANopen®.

Foam contour cutting machine: Bäumer

Germany

EPS cutting system: Pantel + Brömser

Germany

Operating panel

Offers a large 21.5“ multi touch panel in 16:9 format with Full-HD resolution. Operating elements can be fitted as needed by the machine equipment. The panel can be placed up to 100 m away from the switch cabinet IPC at an ergonomic place on the machine.

Box-IPC

For panel mounting in various performance and equip-ment variants; in connection with operating panel (see above).

Servo controller and motor family

For a wide power range from 200 W to 16 kW. With different motor features, several encoder systems and types (also linear motors), designed for maximum energy efficiency with high dynamics.

Additionally, we offer integrated panel IPCs as alternative to the above remote solution.

Industry 4.0 – The path to an intelligent and flexible production

In industry 4.0, production and modern information and communication technologies are intertwined. This is due to digital networked systems, so that users, machines, plants, logistics and products can communicate and interact directly with each other..

© iStock.com/mstay

Eckelmann advises and accompanies you on the way to Industry 4.0 and to a Smart Factory.

During the cutting process, the CNC control systematically collects and analyses continuously generated data in the Big Data analysis. Thus, the complete production process can be monitored and controlled from an office. All relevant information, such as current cutting jobs, cutting times, cost calculations and machine state and machine utilisation, is available online.

Wire bending and forming machine: Post

Germany

Cylindrical and non-cylindrical grinding machine: CNC-Technik Weiß

Germany

Machine vision is an important catalyst for increasing the level of automation in production processes. It has become indispensable in quality control and for the identification of products as well as in process control and monitoring.

Image processing as automation tool

When using Eckelmann industrial cameras and image evalu-ation software, in addition to the pure process visualisation, the position of the sheets on the machine table and the offset and angle correction are also automatically calculated in the cutting program.

Furthermore, residue plates can be detected and thus reused. Additionally, it is possible to scan in cutting contours (sheet or drawing) and to read and verify product codes and markings in plain writing.

The following services are offered for machine integration into the end customer’s production environment:

CNC connection to higher level IT systems, a require- ment for Industry 4.0

Manufacturing Execution Systems (MES)

Control solutions for conveying and storage technology

Meyer Werft GmbH & Co. KG

Additional services

PCB processing: Asys

Germany

Depaneling machine: Systemtechnik Hölzer

Germany

Switch cabinet construction at Eckelmann

Furthermore, Eckelmann offers machine manufacturers electrical design and switch cabinet construction.

Our electrical design engineers use EPLAN, promis, ELCAD, RUPLAN …

As we are a UL-certified switch cabinet manufacturer, you do not require any expensive, on site UL-inspections.

Alternative compact controller E°EXC 880Plug-and-play ready all-in-one controller especially for series application. Price-optimised solution with precisely defined scope of service and reduced commissioning efforts at the machine. Also available as export variant (no BAFA export licence required).

Please contact us for detailed information about the E°EXC 880!

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Eckelmann Group – Source of inspiration

Networked intelligence – the Eckelmann Group

Thanks to continuous internal growth and investments, the engineering firm, founded by Dr.-Ing. Gerd Eckelmann,has grown into a leading medium-sized company group for automation technology.

Eckelmann AG Berliner Straße 161 65205 Wiesbadenwww.eckelmann.de

Your representative: Nils Scholbrock Telephone +49 611 7103-398E-Mail N.Scholbrock@eckelmann.de

Ferrocontrol Steuerungssysteme GmbH & Co. KGBodelschwinghstraße 2032049 Herfordwww.ferrocontrol.de

Your representative: Peter Schicker Telephone +49 5221 966-399 E-Mail PSchicker@ferrocontrol.de

Eckelmann Industrial Automation Technologies (Beijing) Co., Ltd.Fl. 3 of West PlantKangzhen Yuan, No. 69 of Yangzhuang StreetShijingshan District100043 BeijingP.R. Chinawww.eckelmann.cn

Your representative:Roland SimonTelephone +49 611 7103-157E-Mail R.Simon@eckelmann.de

Rex Automatisierungstechnik GmbHFichtenweg 3699098 Erfurtwww.rex-at.de

Your representative: Matthias Rex Telephone +49 36203 9591-200 E-Mail M.Rex@rex-at.de

Your local representative: