Amada marker punching machine

EuroBLECH 2006:
Hall 12, Stand D08
lnnovations for all technologies

EuroBLECH 2O06 is due to tempt many industry visitors to Hanover between 24th and 28th October. At this 19th international trade fair of inetal working technology, AMADA will be presenting its trend setting technologies and state-of-the-art manufacturing solutions in Hall 12, stand D08.

For example, the company will be presenting a revolutionary tool-changing system for the EM series of punching machines for the first time. Visitors interested in laser cutting technology will get their first glimpse of the ALPHA 1V, a new machine generation offering a significant boost in performance. To coincide with EuroBLECH, AMADA will be adding the HDS series to the wide range of press brakes that it already markets in Germany. These high-end machines are a perfect example of top-quality equipment, precision and speed. Another highlight: The bending robot now offers greater flexibility during loading and unloading operations and has a larger radius of action, to name only a few of the improvements. Consequently, AMADA's stand will take the form of a production hub in which all the different metal working technologies are networked. End-toend processing involving punches, lasers, forming and tapping cutting will be performed on an automated
EML Z punch-laser system combination. So-called "IT wagons" will connect the bending robot to the punch/laser process. End-to-end solutions in the metal working sector are opening up the possibility of a totally new type of production: the Virtual Prototype Simulation System (VPSS), a component of Digital Sheet Metal, will therefore be a core subject of the AMADA stand. The digital mapping of all manufacturing processes creates transparency and leads to high quality, shorter throughput times and lower costs. 

Efficient laser cutting for the most demanding requirements
AMADA`s new laser cutting machine, the offers high-quality cutting results coupled with the utmost reliabitity and precision throughout the entire process. This all-round machine boasts an extended range of convincing processing options: alongside all steel types, it is now possible to machine aluminum-magnesium alloys of up to 12 mm in thickness and stainless steel of up to 15 mm. The resonator stands out due to its excellent performance stability and optimized energy management. Thanks to the use of state-of-the-art machine engineering technoiogy, the Lc-3015 X1 NT continues to offer absolute precision even after many years of operation. clearest change to the LC-3015 X1 NT is the striking, modern machine design which visually emphasizes the innovative character of the product. On the one hand, the visual concept
gives the machine its own independent appearance. On the other, it helps
to optimize the functions of the laser cutting machine. For example, the automatic telescopic door of the protective cabin can be lowered right down to the level of the work table. The cross-gantry is located behind this. This design optimizes access to the working area across the whole width of the machine and simplifies adjustment operations and part removal. The machine operator also has good, all-round access to the pallet changer. High dynamic loads occur at laser cutting machines with flying optics, the LC-3015 X1 NT's solid construction can overcome any
vibratìons which occur on any stage of operation. The rigid cast machine
frame guarantees high manufacturing quality even after many years of use. Stability even in sensitive operating ranges. The CFX resonator is characterised by a closed laser system which offers a number of advantages. A laser with a slow lateral gas feed ensures very stable discharge coupled with optimum energy utilization. Compared to conventional laser cutting machines, the LC-3015 X1 NT is able to maintain a constant, top level of performance at all times and only minimal sensitive operating range. This capability is due to the resonator's HSP (High speed Power) sensor, which compares the nominal and actual values in a matter of milliseconds and is therefore able to monitor output control in real time. The extremely constant beam and output make the cutting process exceptionally stable. The laser therefore offers a particularly clean cutting profile which guarantees high cut quality. At a low laser gas speed of only 10 m/s, simple gas circulation is sufficient. This greatly simplifies the maintenance of the beam source. The closed laser system requires only a small volume which is cyclically filled with laser gas. This results in a reduced gas consumption of approximately three litres per hour A particularly energy-efficient standby mode also contributes to the considerable reduction in operating costs. The fact that the machine is ready for operation extremely quickly is an absolute novelty. This means that it is worthwhile to power the machine down completely whenever extended idle times occur. After a start-up period of just two minutes, the system has already reached 100 percent output capacity.
Fast lens changes
When it comes to guiding the laser beam, AMADA again employs state-of-the-art technology to ensure highquality cutting. The beam telescope keeps the optical beam length constant across the entire working area. In comb'ınation with the adaptive optícs, the beam properties are automatically adjusted to ensure that optimum cutting quality is achieved at every point on the table as well as for every material and material gauge. Since the cutting area is subdivided into a number of subsectors, suction removal is necessary onIy in the immediate working area. This reduces the volume for removal and improves efficiency. The cutting head possesses a capacitive sensor system. This keeps the nozzle gap constant even in the presence of plasma and also contributes to the consistent, high cutting quality. The quick-change cartridge at the cutting head considerably simplifies lens changes. It is not usually necessary to adjust the center of the nozzle. Non-productive times and the associated costs ace therefore reduced to a minimum.
Functions for perfection. The new AMADA LC-3015 X1 NT laser cutting system offers the greatest possible process reliability. This can be achieved thanks to a wide range of system tunctions such as
automatic nozzle cleaning, for example. Automatic sensor calibration ensures that the distance between the nozzle and the material remains
constant at all times. Intelligent Cut Control (ICC) simultaneously performs a number of different tasks: The function identifies the presence of plasma and scorching of the material and optimizes the focusing position for each individual material. In addition, ICC monitors the piercing operation and automatically starts the cutting process. This is not only faster than a fixed piercing time but also makes the process more reliable. Power Piercing permits a considerable reduction of piercing times, in particular in the case of high-gauge materials. An oil spray function prevents the formation of spatter during piercing. Another characteristic: Dross-Reduction. This special cutting routine which is stored in the cutting program also prevents dross formation on component corners. All the features of AMADA's LC-3015 X1 NT laser cutting machine have a single purpose: to achieve optimum cutting quality and the best possible process reliability at all times.

AMADA has always been a trend setter in the field of automated metal working and is currently opening up new avenues in the development of automation. The combination of the EML Z-3610 NT metal working center and the ASTRO bending cell has made it possible to combine a variety of production technologies to form a production hub. This will be revealed to the public for the first time at EuroBLECH 2O06.
The EML Z-3610 NT is a combination machine which is able to handle large sheet formats of a thickness of up to six millimeters. Thanks to the punching technology with its patented servoelectric drive and the integrated hybrid laser with semi-flying optics, it is possible to complete extremely demanding manufacturiпg tasks at maximum operating speed. The metal working center allows users to choose between highspeed laser and high-speed punching technology. The reduction in non-productive times made possible by the Z revolver turret and the new laser cutting head make the EML Z-3610 NT even more productive. This system is, of course, equipped with the AMADA AMNC-F multimedia controller

The EML Z-3610 NT is also specifically characterized by the variety of strategies available for the removal of finished parts. Thus customers can choose between various parts removal options in order to react appropriately to the constraints of different components. The first of these is the large, high-speed work chute which is 1,525 x 400 millimeters in size and is especially suitable for small and medium-sized parts. If parts have to be set down reliably using an individual parts sorting system, then the EML Z-3610 NT can be optionally equipped with the ASR-510 NTK automation solution which compIements the production cell. Loading and unIoading is then performed via the tower which is located behind the system and which consists of a total of six shelves of three tons each for raw materials and finished parts. The shelves, which are mounted one above the other, take up very little space while simultaneously permitting a very high level of automation.

Taking the IT wagon to the bending robot
The EML 7-3610 NT's special capabilities include Punch & FormIng which permits high-quality forming to a height of up to 20 mm. It is sometimes not possible to stack parts with grills, beading or mounted assemblies reliably. To make it possible to store these parts securely and without deformation, AMADA developed the IT wagon. Every IT wagon possesses 38 drawers. The IT wagons therefore possess a total storage
area of up to 40 square meters. Thanks to this enormous capacity it is even possible to deposit preformed parts without scratching. Thanks to the IT wagon, the metal working industry possesses the ideal tool to meet the trend towards high-quality, brushed stainless steel or aluminum
surfaces and the exacting quality profiles associated with these.
AMADA IT wagons possess an additional advantage: They can be used
to ensure the flow of materials between a metal working centre and
an ASTRO bending cell. This is achieved by moving the IT wagon to
the bending robot where the final machining of the part is performed.
At the ASTRO bending cell, an optical measurement system equipped with a camera identifies the position of the part. An automatic position correction is performed if necessary. This production hub represents another impressive example of the performance that modern process automation can achieve. 

LC-2415 ALPHA 1V NT
Laser cutting system
The fourth generation
The next generation with the LC-2415 ALPHA 1V NT, AMADA is presenting a new version of its laser cutting systems. The LC-2415 ALPHA 1V is remarkable for the new HS 2003 cutting head and the AMNC multimedia network controIIer. The optimisation of other features, all designed to achieve maximum productivity, underline the innovative character of the fourth generation.
The completely revised design of the ALPHA 1V laser cutting system is in line with AMADA's most recent innovations. Even the beam protection cover has been optimised. The new travel function lowers the cover vertically towards the work table to protect against reflections and sparking New HS 2003 cutting head. The LC-2415 ALPHA 1V NT, a new compact laser cutting machine with semi-flying optics, is remarkable not only for its extremely short piercing times but also for its high travel and cutting speeds. For example, when operating at top speed, the machine can travel up to 113 metres per minute and the cutting speed can reach up to 20 metres per minute depending on the material gauge. The high cutting speed has been achieved thanks to a number of adaptations to the laser optics. There is an optical element to compensate for any dispersion of the laser beam. In addition, the adaptive optics adjust the beam properties precisely to suit the material that is being machined.
This means that laser cutting can always be performed under optimum conditions. Even at high speeds and in the presence of plasma, the system always continues to cut reliably. Thanks to the HS 2003 and the nozzle and lens quick-change system, setup times are significantly reduced since considerably fewer adjustment operations are required overall. Teflon rollers for scratch-free workpieces
The LC-2415 ALPHA 1V NT offers customers the choice between a
2,000 W and a 4,000 W resonator. At the work table, a program allows the user to choose between steel and Teflon roller support, the latter guaranteeing particularly non-abrasive and therefore scratch-free machining. The table design with the existing bearing options represents one of the ALPHA series particular advantages. The defined material support and Final-Cut guarantee reliable parts removal and in this way increase process reliability while also providing the optimum conditions for parts sorting and more far-reaching automation. Process reliability is also supported by the Optical Measurement System (OMS). Sheet metal plates that have been pre-punched at a punching machine are measured and any differences in position are automatically compensated for by the machine itself. The advantage: Workpieces that before only were possible to be manufactured at a punch/laser combination system can now be produced at two different systems thanks to OMS.

AMNC controller included
The ALPHA 1V laser also belongs to the family of AMADA machines that
aгe equipped with the AMNC multimedia network controller. This innovative controller simplifies the operation of multiple machine combinations involving punching, laser and bending systems. Thanks to the uniform user interface and the touchscreen-based menu guidance, machine operators soon feel at home in all the different technologies, thus reducing both operating errors and training effort. Against precisely this background of multi-machine operation, companies benefit from increased efficiency on the part of their machine operators coupled with reduced payroll costs and are thus able to greatly boost their productivity using state-ofthe-art laser technology.

EM Z-3610 NT with 1T-TSU tool changer Revolver turret with access to 600 tools. When punching machines have to run through multiple shifts or exceptionally wide varieties of parts have to be manufactured, then the capacity of even the largest revolver turret is not enough. AMADA has come up with an innovative solution to meet this challenge: the 1T-TSU tool changer with a capacity of up to 600 tools.

The modern metal working industry has to cope with ever
smaller parts runs. To make sure that the program required at any given time is immediately available it is necessary, at the technical level, to network the various metal working machines. Automated loading and unloading processes result in a continuous material flow. Consequently, it is only logical to pursue this trend towards automation in the tools field and thus make punching machine throughput times even more independent of human operators and setup times. 100 tools per module
To permit the automatic extension of tool revolver capacity, AMADA has developed a revolutionary, innovative, external tool changer. The guiding principle behind this development was to achieve a modular design which would give customers the greatest possible flexibility in adapting systems to their precise requirements. The construction of the 1T-TSU tool changer resembles that of a small rack system. The smallest
1T-TSU variant can handle 100 tools. However, the system can be extended by modules of 100 tools each to a maximum capacity of 600 tools!

300 kN punching machine for large formats. For automatic tool changing to be possible, unobstructed tool access must be guaranteed as in the socalled Z revolver turret with which the EM Z-3610 NT is also equipped.
lnnovative AMADA punching machines such as the EM Z-3610 NT meet the most exacting customer requirements. The 300 kN punching unit for large format operations is capable of machining large material gauges or executing large-scale punch geometries in a single workstroke. This series of AMADA punching machines also benefits from the unique servo-electric and practically maintenance-free drive solution. High workstroke frequencies and travel speeds make the system extremely productive and capable of producing complex components rapidly and at an outstanding level of quality. A large-format work chute is available for parts removal. Alternatively, an automatic individual parts sorting system is also available for scratch-free, sorted part removal. The EM Z-3610 NT combines top product quality with an extended service life and allows metal working companies to considerably increase their competitiveness.

Manipulators in use
Alongside the new tool revolver turret, the EM Z-3610 NT, which
possesses 41 stations seven of them revolving specifically in order to handle such appIications, is also equipped with a quick-change station
which again consists of a revolver and multiple stations. The quickchange station always contains the tools that are to be mounted during the next tooIing operation and therefore acts as a buffer. While the punching machine is doing its work, a manipulator which travels along a linear axis retrieves the required tools from the rack system. The actual transfer from the quickchange station to the operating revolver is again performed by a manipulator. This achieves impressive cycle times of approximately 15 seconds per tool change. A number of different dies clearances are available for the different metal qualities and gauges.

Optimum tool maintenance
The 1T-TSU tool changer also possesses a terminal at which the
machine operator is able to call up all the necessary information concerning the available tools. Punch stroke counters record the number of punch strokes performed by each tool. This represents a valuable statistic which permits optimum tool maintenance. Once a tool has reached its predefined usage level, it can be withdrawn from the process. Users are able to access the tools during machine production time and do not have to wait until the machine stops and the tool revolver is accessible again. It is well-known that good maintenance prolongs tool service life. The longer a tool remains present in the punching process, the more its service life tends to be reduced. Sharp tools also prevent any negative impact on the punching process. With the 1T-TSU automatic tool changer, AMADA is able to offer not only greatly increased tool availability but also eliminates manual tool changing operations as a potential source of error. The 1T-TSU represents an additional advance towards automated manufacturing processes for unmanned production.

The HAZET factory, Remscheid Quality triumphs
Remscheid is a traditional centre for the engineering industry: it is here that two of HAZET's three factories are located. This tools specialist uses AMADA technologíes for its metal working operations.

The company, which was founded in 1868 by Hermann Zerver, has been family-owned for five generations. Experienced employees and state-of-the-art technology ensure unwaveringly high quality and have helped HAZET's standard and special tools acquire an outstanding reputation. Alongside tools, HAZET also manufactures tool cabinets including the patented "Assistant" which is predominantly used in vehicle workshops. For nearly 20 years, HAZET possessed its own in-house, end-to-end metal working facilities where sheet metal components were manufactured primarily on punching machines, press brakes and deep drawing presses. However, two trends were to result in a fundamental change in HAZET's approach to the production of inetal parts: Over the last 10 years, tool cabinets with drawers have been consistently increasing their market share. During the same period, the number of variants has grown in response to the special adaptations demanded by both car manufacturers and specialist dealers. Deep drawing presses were no longer economical in view of the short operating periods, the high set-up times and the enormous stock of tools that was required, In addition, parts had to be machined more than once and stored