Characteristics of the equipment
1. High speed cutting ability, 1.5g acceleration, high cutting efficiency.
2. The minimum tail material is 40mm, saving more material cost.
3. Have independent research and development system, remote upgrade for customers, and fault diagnosis.
4. Automatic processing of material head and tail, eliminating secondary manual material picking.
5. Selecting slag extraction component, it can automatically remove residue from inner wall of pipe when cutting pipe.
6. With left and right models, saving factory space and turnover area, one person can operate 10 sets of equipment.
7. Semi-automatic feeding system, high rigidity material frame design, refueling, feeding, feeding speed, good stability.
8.The bed is welded with high-strength rectangular tubes and steel plates, and is completed by two processes of rough machining and finishing in the machining center.
9.The bed is relatively thicker and stronger, with stronger rigidity. The machine is more stable in fast running and has a longer service life.
Cutting sample
2、Technical parameters
Model： | CTK-X2 round tube high speed laser cutting machine |
Tube cutting working area | Round pipe diameter: 10mm-65mm L=6000mm |
Cutting Length | 15~1000mm(Other length can be customized) |
Automatic loading range | Loading way：Semi-Automatic loading system |
Loading diameter：Φ10mm-Φ65mm |
Straightness requirements：≤ 0.2% /m |
Quality requirements of pipe: no burr at pipe end, roundness requirement ± 0.2mm |
Cutting material | Stainless steel, iron (copper, aluminum customized) |
Mechanism speed | 1.Y axis | 1300mm/s |
2.W axis | 1.6rpm/s |
3.X axis | 1800mm/s |
4.Z axis | 500mm/s |
Cutting speed | 12m/min（based on material and thickness） |
Cutting gap | 0.1-0.2mm |
Y axis accuracy | ±0.15mm/m |
Tailing length | ≥40mm |
Control system | CTK professional cutting system |
Voltage/power | 380V/50HZ / 3.3KW（exclude laser and cooling system） |
Machine Weight | Main cutting machine：1300kg | Loading system：580kg |
Machine size | Whole machine：8000×1800×2225mm |
3、Machine configuration
No. | Name | Specification/Model | Brand/Original |
1 | Fiber laser generator | 1000-3000W | BWT/RECI（China） |
2 | Laser cutting head | several | OSPRI/GANGCHUN （China） |
3 | Control system | intelligent cnc | CTK（China） |
4 | Laser cutting process database | several | CTK（China） |
5 | Pipe welding machine tool | CTK | CTK（China） |
6 | Servo motors and Drives | 4 set | Delta(Taiwan) |
7 | Precision reducer | 3 set | Wanxin（China） |
8 | Precision guide rail | several | Taiwan |
9 | Precision rack | several | Taiwan |
10 | Standard electrical element | several | Schneider(French) |
11 | Cooling system | 1 set | Jizhi/Blue penguin(China) |
12 | Feeding system | several | CTK（China） |
13 | Automatic oil filling system | 1 set | CTK（China） |
4、Introduction of machine parts
Fiber Laser Generator (BWT)
1.Fiber laser generator, using imported chips, with higher photoelectric conversion efficiency, lower power consumption
2.Deep research and development of core components: pump source, with 19 years of industry experience
3.High stability, low light decay, long service life
4.Its predecessor is the core supplier of most domestic laser manufacturers
OSPRI Laser Head
1.Cutting more sensitive: the highest support 4000W power laser, sensitive sensor. Optimized optical design with digital height sensor.
2.Cutting more durable: three pieces of protection mirror closely dust-free, more durable.
3.More efficient cutting: Dual water cooling design allows the cutting head to work continuously and steadily at high power for a long time.
Laser head structure
1.The Z axis refers to the direction in which the laser head moves up and down
2.Structural composition: 1. Servo motor; 2. Guide rail slider; 3. Mounting seat; 4. Laser head, etc.
3.Structure introduction: It can adapt to different specifications of pipes by adjusting the up and down movement of the laser head.
4.Structural advantages: the mechanism is simple, stable and easy to operate.
5.CTK Intelligent Pipe Cutting System
1. This machine adopts man-machine interface control, touch screen, easy to operate.
2.Software independent design and development, more humane! (The software can be upgraded later according to customer needs)
3.Length digital display, a single material can be set to 5 different lengths, reducing waste of excess material.
4.The parameter setting is simple, the operation is simple and easy to adjust; the material pulling servo can be digitally operated; the head and tail material can be selected whether to cut off or not, and the tail material can be automatically calculated; it has the functions of direct feeding and pinch feeding.
5. The I/O screen can display various input and output monitoring, and is equipped with an automatic detection alarm information system, which is convenient for users to troubleshoot.
Industrial Cooling System:
1. The high quality stainless steel cold water circulating pump has the advantages of large flow, high head, low noise and long service life;
2. The control system adopts liquid crystal full Chinese (or English) computer controller, CPU fully automatic control, simple and intuitive operation. The control precision is as high as ± 0.1 ℃; it has the function of automatic fault diagnosis, and the fault point is directly displayed on the screen to prompt the user to deal with it quickly. The fault signal can be directly transmitted to CNC system through data line to avoid damage to components and equipment;
3. It provides multiple protection functions, passive alarm terminal and remote control terminal, which is easy to realize centralized control and monitoring of CNC; The "double temperature" precision water cooler not only provides stable and accurate water temperature control for the laser, but also provides a water temperature similar to the ambient temperature for lens cooling, which solves the problem of lens damage caused by condensation when cooling with low-temperature water, and is the best choice for laser equipment cooling.
Program details (mechanical part)
Clamp mechanism:
1. The equipment adopts Taiwan high speed rotary chuck, the speed of chuck can reach more than 150 RPM/min.
2. Each tube specification corresponds to a set of clamping die, easy and quick replacement, replacement time about 2 minutes
3.Compared with other companys, it has obvious advantages: easy installation, fast clamping speed, flexible adjustment of clamping force, and forced release clamping function, which can realize loading and unloading without stopping and improve efficiency.
Head and tail material separation device
Material head material tail separation advantage
Ensure that every workpiece is free from adulterated waste
1.When the length of the workpiece is similar to the length of the head and tail material, the manual labor time of secondary material selection can be saved
2.Especially suitable for high degree of automation equipment manufacturers.
Front positioning mechanism
This mechanism is mainly used to locate the pipe cutting length. Through the mechanical positioning method, when the pipe comes into contact with the front positioning mechanism through the feeding mechanism, the feeding is stopped, so as to achieve the set length of the cutting pipe.
The front positioning mechanism consists of: 1. It includes servo motor, screw rod, guide rail, and slider; 2. The front positioning plate and the material support mechanism are composed.
1. The front positioning adopts a low-voltage electric shock structure, and the pipe fittings can be clamped and cut by touching the front positioning electric shock board. Fast response speed, accurate positioning, fast cutting speed and high efficiency;
2. The front positioning electric shock plate adopts an adjustable structure, which has strong versatility. It does not need to be replaced when it is equipped with slag extraction, which reduces the cost of the mold and the time for replacing the mold (other companies need to replace the positioning plate when changing the pipe specifications, which is troublesome in material management and high in mold management costs
3、The front positioning is equipped with a supporting wheel, which prevents the pipe from sagging when cutting small pipe diameters or tailings, which affects the cutting accuracy, reduces the friction on the fixture, and improves the life of the fixture or chuck. Nozzle collision deformation.
Feeding and tailings handling advantages
1、Feeding: The servo motor is used for feeding, the feeding is stable and the feeding speed is fast;
2、Servo drive feeding speed can be set via touch screen. Easy operation, balanced butt joint of pipe fittings, small impact force and high cutting precision;
3、The tailings are processed by the rear ejection method, and the maximum laser head is set close to the fixture, and the fixture can hold a small length and keep it stable. At the same time, it is equipped with the tailing length detection function, so the shortest can be 40mm, which is much lower than similar machines in the market which is 160mm-220m
Semi-automatic feeding system of material line type
1. Automatic loading after material listing: the operator only needs to lay the pipe to the material waiting area, without manual intervention, one person can see ten machines
2. Exclusive design stable feeding: the pressing mechanism ensures that there is no material overlapping in the waiting area, and the small tubes below 16mm can be produced stably
3. Anti-scratch design of pipe surface: unique protection design can effectively prevent friction and scratch of pipe surface
Left and right machine customization
Advantages of left and right models:
1. Operators operate two machines in the same channel, improve work efficiency, one person can see more than one machine.
2. Reduce machine floor space and turnover area, save factory rent.
7. Cost analysis:
1、Consumption of parts
Name | Service life （hour） | Note |
Protective glasses | >=240 | The values are theoretical, that determined by working condition and environment |
Copper nozzle | >=240 |
Focusing lenses | >=2400 |
2、Total operating cost analysis：(for reference only,Taking an example of 1000w)
Project | 1000W（CTK-X2） |
Power consumption (Peak power consumption) | Laser generator | 3KW |
Main body | 6KW |
Cooling | 1KW |
Automatic rack | 1KW |
Total Power | 11KW |
Total power consumption (*0.6 power factor) | 11*0.6=6.6KW |
Consumable part | ≈RMB 0.3/H |
The cost of air | 0 |
Total operating cost (press 1 RMB/KW/H) | 6.6+0.3≈6.9
RMB/H |
3、Gas reference cost (1000W as an example)
Auxiliary gas type | Require | Cutting steel tubes | Gas price | Cost of gas per hour |
Air | Compressed air | Stainless steel and carbon steel | ...... | 5RMB/hour |
Liquid nitrogen filled with oxygen | recommended 99.9% | carbon steel | 360RMB/pot | 12RMB/hour |
A minimum of 99.5% |
Liquid nitrogen filled with oxygen | 99.99% | Stainless steel | 720RMB/pot | 24RMB/hour |
8. Operating environment requirements
Item | Name | Requirement | Note |
Power | Installed capacity | ≤50kva |
|
Installed voltage | 380V±5% | Automatic voltage stabilizing device must be installed |
Grounding resistance | ≤4Ω |
|
There shall be no strong electromagnetic signal interference near the installation equipment by radio transmitting station or relay station. |
Water | Cooling system | It is recommended to use purified water, deionized or distilled water, and add specified antifreeze in winter. |
Gas | Nitrogen, oxygen | Purity≥99.99% | Depending on the material, process, etc. |
Air compressor | Pressure≥2.5mpa |
Work environment | Temperature | 5-40 degree |
|
Humidity | ≤70% |
|
Foundation | Standard：500kg/m2 Amplitude≤50um， Amplitude acceleration≤0.05g. It is required that there is no large stamping vibration equipment nearby |
The working environment shall be no smoke and dust without metal polishing and grinding. The anti-static floor must be installed and the shielding wire must be connected. |
