FEATURE ON PROFILING

Wippro invests in Salvagnini production line

With the investment in a new Salvagnini S4 + P4 production line, Wippro GmbH, a specialist in attic ladders and door systems, is paving the way for future success. Equipped with an upstream single-sheet store-tower and a stacking robot, the system punches, bends and optimally sorts metal sheet for subsequent processes in a fully automatic manner. This new flexible processing solution makes economic batch size 1 production a reality.

“We’ve been working with a punching-bending combination S4 + P4 from Salvagnini since 1998, providing excellent service,” explains managing partner Robert Wipplinger. “The extremely flexible and fully-automated production concept was the reason we decided again in favour of Salvagnini’s S4+P4 production line.Furthermore, the co-operation with Salvagnini has always worked smoothly.”

Based on Salvagnini‘s MD sheet metal storetower, the S4 punching machine is fed automatically with single sheets from the rows of trays. Thanks to fully automated multi-press punching up to the finished part head in combination with the angle shears, the machine punches parts individually. Subsequently, the MCU device brings parts into the correct position for the P4 panel bender.

Wipplinger is extremely excited about the high degree of flexibility provided on the Salvagnini line: “We have no longer to think about which parts will be scheduled subsequently in the line,” he says.“Depending on the order, the system retrieves the corresponding material with the respective sheet thickness out of the storage tower and manufactures the part without any manual set up in a completely automatic manner and sorts them onto pallets. I call this the perfection of batch size 1 production.”
For further information www.salvagninigroup.com

Flow releases two new waterjet cutters

Flow International, a developer and manufacturer of ultra-high-pressure waterjet cutting systems, is releasing two ground-up waterjet systems, the Mach 200c and the EchoJet, highlighting a flurry of customer-focused innovation. The latest cutting-edge waterjet solutions showcase Flow’s continued commitment to advancing waterjet technology and expanding product lines to meet the evolving needs of customers.

“Like the other advancements from Flow, the Mach 200c and EchoJet are designed based on intense research of customer needs and real-world applications,” says Tim Fabian, vice president of product management and marketing at Flow.

The Mach 200c provides unprecedented operator access to the waterjet table and delivers improved speed and accuracy at an affordable price point. Featuring Pivot+ waterjet technology, the Mach 200c enables bevel and five-axis cutting of virtually any material, hard or soft, with up to 60° of motion to achieve more complex part cutting needs.

The EchoJet’s design is a fully enclosed and highly flexible waterjet solution. Easy-to-open doors make it a good addition to any shop floor, says Flow, containing spray and reducing cutting noise. Additionally, the EchoJet’s compact design allows it to fit in smaller spaces, where a smaller footprint is required.

“We’re thrilled to be introducing not just one, but two cutting-edge waterjet systems,” says Brian Sherick, president of Flow.“It’s an incredibly exciting time for the Flow team, as we’ve been working tirelessly to bring this much innovation to our customers. This focused effort is all about delivering true value back to our customers and we can’t wait to see the impact these machines will have on their businesses.”
For further information www.flowwaterjet.com

kerf unleashes ‘the beast’ at AJS Profiles

When it comes to heavy engineering, few names hold a torch to the prestige of AJS Profiles. The West Midlands manufacturer has the world’s largest reciprocating grinder and the world’s largest Lumsden grinder. So, it comes as no surprise that when this steel profiling business needed a large heavy-duty cutting machine, it turned to long-standing supplier Kerf Developments.

Steve Harris, director at AJS Profiles,says: “It was 2011 when we bought our first Kerf machine, an RUR3500G, which was soon followed by an RUR2500P plasma machine. So, when it came to making a shift to more advanced technology, the service, support and quality provided by Kerf stood out. Over the years, we gradually moved from the old technology, employing Kerf flame and plasma cutting machines with CNC controls that drastically simplified, modernised and improved our cutting capabilities.”

In total, AJS Profiles installednine Kerf machines over 11 years. Notable among them is ‘the beast’, an RUM3000G with an oxy-arc lance capable of cutting through steel up to 1 m thick. The RUM3000G is a gas cutting machine with a reinforced gantry extending beyond 1.5 m high, making it the only machine of its type in the UK. This extended bridge height accommodates the 1m thick steel plate that AJS frequently cuts, while providing thermal protection with its through coolant design that protects the integrity, repeatability and stability of the bridge during heavy-duty cutting.

The company’s latest acquisition, arriving in September 2022, is its fourth RUR3500G cutting machine, which is the sixth gas cutting machine from Kerf at AJS Profiles.

“The latest RUR3500G can cut plate up to 250mm – and for everything beyond we have ‘the beast’,” concludes Harris.
For further information www.kerfdevelopments.com

Robot assists large-scalelaser cutting cell

A suite of automation solutions from FANUC has proved integral to the delivery of an industrial-scale laser cutting cell commissioned by the UK’s Manufacturing Technology Centre (MTC). Constructed bysystem integrator Cyan Tec Systems, the demonstration cell comprises a 12 x 4m cutting table and, from FANUC, a six-axis robot, a CNC system for the flatbed, and the laser, all contained within a laser-secure enclosure.

FANUC was the clear choice for automation partner on this project, as Cyan Tec’s project co-ordinator Grant Copson confirms: “The main reason for working with FANUC was the fact that they could offer a seamless automation solution incorporating not just the robot but also the laser and motion system.”

The system sits at the upper end of industry expectations in terms of scale to show those visiting the MTC what is possible within automated laser cutting. There is real scope for using the cell within the aerospace and automotive industries, or any sector that requires large-scale pre-cut profiles. The construction sector could also benefit from cells of this size, in particular for precision cutting of profile sections used in prefabricated buildings.

The cutting table and robot sit inside a large enclosure measuring 15.5 x 9m, but the space requirements go even further. The cutting table slides out an additional 13m, ensuring that if an operator wants to load a 12 x 4m product, he or she has adequate access to do so, even if this requires the use of a crane or forklift truck.

The laser cutting bed handles flat plate, while the FANUC M-20iB robot cuts tubular sections. Notably, the robot’s six axes siton a floor track and drive synchronously with a FANUC seventh axis, allowing it to move up and down the tube in cut.
For further information laser@the-mtc.org

Bystronic provides retail therapy for Crown

Founded in the late 1990s, Crown Manufacturing has evolved into a true manufacturing success story, overcoming adversity and growing to become a business with a presence at two locations in Somersetand a team of over 60 staff. Bystronic has travelled this journey with Crown Manufacturing almost since its inception.

Disaster struck the business in 2018 when a fire caught hold of the paint department, creating catastrophic damage. However, one thing that the fire did provide, was an opportunity to review processes, workflow and production equipment.

“The fire also gave us the realisation that we could work smarter with the people and suppliers that we have,” says Paul Read, works manager at Crown Manufacturing.

Since the fire, Crown Manufacturing has invested in three machines from Bystronic, the latest of which is a ByTube 130. This machine features a fully automatic set-up, bundle loading, six-axis control and high-speed and precision cutting that allows Crown Manufacturing to take on and efficiently complete high-quantity orders to a high standard.

“The tube laser takes away our dependency on a third-party supplier that we ended up struggling with,” states Read. “Integrating the ByTube 130 into our arsenal of machinery has been revolutionary, as it removes bottlenecks in the manufacturing process by allowing us to schedule and prioritise tube laser work in-line with due dates and urgency.”

In conclusion, Read says: “As much as the fire was a disaster, we bounced out of that to create far more productivity from being better organised. Having a new factory layout will help us to move onto the next level.”
For further information www.bystronic.co.uk