ESAB Welding and Cutting Products will exhibit a number of its latest equipment offerings to enhance productivity for fabricators at IMTS 2006. On display at booth #B6157 will be a Hydrocut waterjet/plasma combination cutting machine, ESAB's new m3 plasma system, Columbus software, a CaB automated welding system and the new hybrid laser welding process. ESAB will also sponsor the Battlebots competition and offer attendees an opportunity to win Jesse James Signature Series welding and cutting equipment.
COMBINATION WATERJET/PLASMA CUTTING MACHINE COMBINES SPEED AND ACCURACY
The Hydrocut LR multi-process waterjet cutting system uses ESAB's patented waterjet/plasma combination to produce cut parts using the speed of plasma and the accuracy of waterjet. The waterjet process can also be combined with many other cutting or marking process tools, including oxyfuel cutting, plasma marking, ink-jet marking, routing, drilling or scribing.
The advantage of combining waterjet and plasma on the same machine is that both tools can be used on the same parts. Contours requiring high precision can be cut with waterjet, while other contours can be cut with plasma. This system allows users to produce the precision contours they need without sacrificing speed on every cut. The
machine at IMTS will demonstrate the use of the waterjet cutting head with ESAB's m3plasma system, an oxyfuel torch station for cutting carbon steel up to 12 inches thick, and a router spindle for high-speed aluminum cutting.
The Hydrocut LR is a precision gantry on floor mounted rails, featuring digital AC drives, brushless AC motors and precision planetary gearboxes. The machine delivers smooth, accurate motion for the most precise cuts on a wide variety of materials.
Hydrocut LR features positioning accuracy of ± 0.010" over 3' in each axis, and repeatability of ±0.002". A maximum positioning speed of 600 inches per minute keeps
traverse time to a minimum. Combined with ESAB's high-speed lifters and integrated process control, this speed delivers maximum throughput and low cost per part.
The Hydrocut LR is available with cutting widths of 8' to 20'. It can be equipped with up to four waterjet cutting stations, along with a wide variety of other cutting and marking process tools. When combined with ESAB's m3 Precision Plasma system, the Hydrocut LR provides the ultimate tool for maximized production and precision cutting.
Automatic height control for both waterjet and plasma processes allows underwater cutting with the waterjet and plasma tools. This reduces noise, fumes, plasma glare and abrasive spray. The automatic height control also allows unattended cutting. Operators can perform other jobs while the Hydrocut LR is working and not worry about the waterjet nozzle or plasma torch crashing. Large parts can be produced with minimal supervision because the height will remain constant.
The Hydrocut LR can be equipped with waterjet systems from 30 to 100 HP and with plasma systems from 100 to 600 amps. ESAB's m3 Precision Plasma system provides high precision cutting on carbon steel, stainless steel, and aluminum from gauge material up to 6" thick.
NEW ESAB m3 PLASMA SYSTEM COMBINES HIGH SPEED AND HIGH PRECISION PLASMA CUTTING IN A SINGLE SYSTEM
ESAB's new m3 Plasma System combines multiple plasma cutting and marking features in a single easy-to-use system, taking plasma cutting productivity to new heights. The m3 system produces high-speed, low-cost standard plasma cutting; high-quality precision cutting and marking; and high-current, thick-plate cutting all with a single
plasma torch. When configured for 600 amp operation, the system can quickly and accurately cut and mark material from 20 ga. to 6.25 inches (1mm to 160mm) without sacrificing cut quality.
The key to this new system is the new state-of-the-art PT-36 torch design. Instead of setting a fixed cutting current and adjusting other parameters to achieve the desired cutting result, ESAB starts with the desired result and then determines the best parameter settings, including current, needed to achieve it. This design allows ESAB to achieve superior cutting and marking results over a wide range of materials and thicknesses while using the fewest consumable parts in the industry. The new PT-36 torch replaces up to three single-purpose torches (heavy plate cutting, precision cutting and marking) and produces a superior cut face with low dross, requiring little secondary clean up. The end result is superior cutting functionality and productivity, with minimal set-up time, downtime and consumable cost. The new torch can function in both dry and water injection modes.
The m3 system features the most advanced gas control system in the industry, fully automated by ESAB's Vision CNC. Great flexibility in selection and mix of shield gases allows an operator to produce the best cut quality on any material. The operator simply selects the material type and thickness, and the Vision CNC automatically selects and mixes the optimal start, cut and shield gas combination. Process parameters for most plasma cutting and marking applications are preloaded in the Vision CNC, and custom parameter files can be easily created as needed.
ESAB's Columbus Programming and Nesting Software is an advanced software package designed specifically for plasma, oxyfuel, laser, and waterjet cutting. The first cutting software package developed and maintained by a cutting machine manufacturer, Columbus supports straight and bevel cutting as well as all current marking devices.
At the core of the Columbus system is the Vision PLUS® Desktop. This base module contains numerous functions that conveniently enable the creation of machine programs from geometrical information. A set of integrated modules can be combined as a seamless package to provide exactly the features and capabilities needed for a given application. Included with the standard Vision PLUS Desktop is a comprehensive set of modules that provide basic programming capabilities and serve as the foundation for additional optional modules.
The Automatic Nesting module adds fully automated true shape nesting to the Vision PLUS Desktop system, providing Part-In-Part Nesting, Multiple Torch Nesting, Common Line and Bridge Cutting, and many other powerful features. The user can control all aspects of the nesting process, such as the number of cutting heads to be used, priority of each part in the nest, cutting sequence or material grain limitations. Parts can also be selected by weight or size to ensure the best optimization possible.
The Data Management Module (DMM) provides part management and tracking capabilities, converting the nesting system into a powerful tool for production control. Delivery date, material required, and nesting priority of a part can all be specified. This module allows a user to automatically track the part/order through the entire process and track what plate was used to cut the part.
The Plate Management Module adds plate inventory and remnant tracking capabilities to accurately track plate inventory and utilize every scrap of plate, maximizing profits through maximum plate utilization.
The 3D Transition Programming Software allows quick and easy development of three-dimensional transitions. Graphical selection of the shape and graphical 3D displays make it easy to create the desired transition. The software automatically unfolds the 3D shape into a 2D program for cutting.
When used in conjunction with ESAB's Vision PLUS CNC package, Columbus software allows machine operators to post DXF files and draw parts right at the Vision
PC or Vision NT controller. Vision PLUS CNC includes many features that simplify creation of a CNC program from geometrical information.
ESAB INTRODUCES NEW HYBRID LASER WELDING SYSTEM
ESAB Cutting Systems will introduce its new hybrid laser arc welding (HLAW) process at IMTS 2006. This new product line is the first commercially available mechanized laser-welding systems utilizing laser only, laser with cold wire fill, or hybrid laser arc welding in a 2D gantry, 3D robotic or custom mechanized solution with closed-loop weld process control. All the components of these systems are available from a single source and are supported and serviced by ESAB. A video presentation at IMTS will highlight the process and show it in use ESAB's test laboratory. Experts will also be on hand to discuss the process and answer questions.
Hybrid Laser Arc Welding (HLAW) combines the deep weld penetration and low heat input associated with laser welding with the power efficiency and superior gap tolerance of GMAW to create a new welding alternative. The deep penetration and fast weld speeds of laser welding reduce heat infusion into the part and reduce the associated distortion that causes plates to buckle and warp, making fit-up unpredictable and often costly to repair. This deep penetration, however, can limit laser welding's ability to produce acceptable weld fusion in weldments with wide gaps between parts.
Adding GMAW in tandem with the laser, with the addition of a relatively modest amount of filler metal, creates a wider weld bead capable of bridging much larger weld gaps, up to four times as wide as conventional laser processes can handle. Adding
GMAW to the welding mix also enhances a finished part's metallurgical stability, and with GMAW's slower cooling rates, produces welds with greater strength and less brittleness. This is especially beneficial for higher alloyed steels sensitive to hot cracking.
The hybrid process improves process efficiency and overall productivity, improves weld quality, lowers production costs and offers more versatility than conventional welding processes, setting new standards for productivity, cost efficiency and flexibility in heavy fabrication applications.
ESAB'S AUTOMATED COLUMN & BOOM COMBINES FLEXIBILITY AND PRECISION
ESAB's application-oriented Column & Boom (CaB) series for automated welding with integrated modular functions meets individual application demands for flexibility, reliability and precision in modern production equipment.
Three basic models are offered: CaB 300, CaB 460 and CaB 600. Each has a different profile and working range from 2 m x 2 m (6.56' x 6.56') up to 10 m x 8 m (32.8' x 26.2'). Equipped with different components and accessories, CaB systems suit the most varied production needs and provide maximum flexibility to any production line, fully customized to the customer's unique application.
Positioned for maximum productivity and safety, CaB offers short set-up times and fast, exact work piece positioning. Travel speeds are pre-programmable and the column is capable of ±180o rotation. ESAB A2 or A6 welding heads are mounted to the boom with a swiveling mounting bracket, allowing the welding heads to perform external and internal longitudinal and circumferential welding in various weld joints and work pieces.
ESAB Welding & Cutting Products is one of the world's largest and most experienced manufacturers of welding and cutting equipment and welding filler metals. Recognized as the technological leader in the industry, ESAB is committed to providing customized solutions for its customers. For more information, call 1-800-ESAB-123.
