Consider the 80-20 Rule
How to choose the right thermal cutting machine for your application.
P
Is the machine control easy to operate? Look
urchasing a new thermal cutting machine can
•
seem complicated. It cal Is for striking a balance
for a machine that is user-friendly. Touch-screen controls,
between price, productivity and the machine's
such as Messer's Global Control Plus, make it easy for new
capabilities. Following are some simple questions
lo consider to help narrow down the choices and
choose the right equipment for your needs:
operators to learn how to run the cutting equipment.
•
How advanced is the software?
Software used
on a cutting machine is the most critical component of the
system.
Software
per­
forms two distinct func­
tions: designing the piece
to be cut and controlling
the
cutting
The
best
equipment.
sofh,vare
wi 11
maximize the character­
istics of the cutting ma­
chine on which it's run­
ning.
use
Messer
machines
OmniWin software
for thermal cutting with
oxyfuel, plasma and la­
ser CNC machines. Om­
niWin offers a wide range
of
functions,
including
easy export and import of
drawings and plans, and
What is the thickness of the material most
frequently cut? There are several methods to cut mild
•
steel, aluminum and stainless steel using plasma, oxyfuel
or laser. Yet it's cost-prohibitive for most shops to invest in
a II the various cutting options. For most, it's about the 80-20
rule. If 80 percent of the jobs involve cutting mild steel in
nesting for special appli­
cations. It is effective and economical for small production
runs, as well as fur just-in-time manufacturing with changing
quantities and custom cutting.
What are the material-handling and storage
options? Sometimes companies make a large investment
•
in automated plasma and oxyfuel cutting machinery only to
gauges of 2 inches or less, then a plasma process is prob­
find they do not see the expected savings in the true cost per
ably the best choice. The other 20 percent of heavier parts,
part. What many fail to consider is the importance of material
best cut using an oxyfuel process, could be outsourced to
hand I ing. The time it takes to move plate on and parts off the
a local fab shop. If 80 percent of the work is gauge to half­
cutting table can have a significant effect on productivity and
inch, then it becomes a choice between plasma or laser.
Plasma is generally more economical than laser. However, if
tight tolerances are required, laser may be the best solution.
If you're still not sure what process will work best, ask suppli­
ers to cul samples for comparison.
Messer Cutting Systems, Inc., Menomonee
Falls, Wis., offers a wide range of CNC cutting
equipment and accessories. For more information,
call 262-255-5520 or visit www.messer-cs.com.
Editor's note: This article was contributed by the experts at Messer Cutting Systems.
18 The Cutting Edge f Fa/12015
!Messer Cutting Systems
return on investment. The latest plasma and laser technology
parts to a sorting table, then load the next plate into position
offer impressive cut speeds, but that gain is often lost 1,vhen
for cutting, before sorting the parts . Shuttle tables or pass­
removing the parts and moving the next plate into cutting
through conveyor systems also can be used to move plate in
position. It takes two tu three times longer tu unload cut parts
and out. Storage towers allow plate tu be stacked in a vertical
than it does to load a full plate onto the cutting table, assum­
retrieval system until the system calls for a particular piece.
ing the crane is well positioned and available.
Smart cranes allow plate to be moved from storage towers to
Material storage is another troublesome area. Some com­
cutting tables \".•ilh no crane operator. Robotic pick-and-place
panies lack the floor space and are forced to stack different
systems can be used to remove cut parts from the cutting
sized pieces of plate on top of one another. To get to the plate
table. Use of a self-cleaning cutting table to remove slag can
that needs to be cut, all those on top have to be moved. As
help to minimize downtime.
an alternative, plate should be stacked vertically whenever
On a bigger scale, review the true material flow of the
possible so each piece is accessible. Consider installing a
plant. Consider where material comes in, goes out, and how
•
material handling could be used to expedite it.
large magnet that can be used to move an entire plate of cut
Cutting & Sa1Ning Products
Koike's KARMAC Controller Aids Automation
K
oike Aronson lnc./Ransume, Arcade, N.Y., introduces
pipe rotation, the company claims.
its new KARMA( CNC controller (Koike Aronson Ran­
The new KARMA( CNC and its new electrical assem­
some Motion And Control). Many types of CNC controllers
bly are designed to run in harsh environ­
are available today, most developed for a
ments. It features an easy-to-use operator
specific cutting process, such as
interface, 64 editable shapes in the shape
a CNC for plasma and oxyfuel
library, CAD import, touch-screen tech­
cutting, a CNC for laser cutting,
nology, real-time graphics, multi-axis
or a CNC for waterjet cutting.
control, productivity monitoring, a re­
Because these controllers are de­
mote help service tool, built-in cutting
signed for a particular cutting sys­
process database, and a high-speed
tem, they have limitations when it
reliable
EtherCAT interface.
CAM
comes to automation. KARMAC is
software can be installed at the CNC
designed to offer users a single solu­
giving an operator the flexibility to
tion for intelligent motion and control
create and edit programs at the con-
no ma lier what the cutting process. Au­
trol station. The current design runs on a Win­
tomated systems such as material han­
dows 7 32-bit platform. Future models will be available with
dling, plate stackers, shuttle systems and
automated
slag removal cutting tables and fume collectors are easily
integrated, as well as options such as drilling, marking and
a current Windows format and a 64-bit platform.
For more information, call 800-252-5232 or visit
www.koike.com.
Cosen Mechalogix Monitors Blade Life
C
osen Saws USA, Charlotte, N.C., introduces Mecha­
remaining useful life, the technology provides advance notice
Logix Cosen Predictive Computing, a cloud-based sys­
of required saw blade replacement. The system also provides
tem that monitors the performance of a sawing operation and
real-time analysis of individual components and overall ma­
can accurately forecast the number of cutting hours remain­
chine health status. It can send notification of abnormal con­
ing before the blade dulls or breaks.
ditions from motors and bearings. It also alerts on frequent
Mechalogix offers real-time performance data and can
consumable items like hydraulic and cutting fluid. The ad­
report issues like excessive vibration, overheating and chang­
vanced monitoring and notification system alerts the operator
es in fluid I ine pressure. The technology is intuitive and user
when machine maintenance is needed, which aids in sched­
customizable. Adjustable alert notification sellings work
uling needed down Lime.
seamlessly with a mobile app.
For more information, call Cosen at 877-729-4641 or
visit www.MechaLogix.com.
By monitoring and alerting the operator of a saw blade's
The Cutting Edge
f Fa/12015
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