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OPTECH CONSULTING

OPTECH CONSULTING. OPTECH CONSULTING. OPTECH CONSULTING. World Market for Laser Materials Processing Systems - Growth Rates 2004, 2005. 2004 Growth Rate: + 27% - Laser Macro Processing: + 23% - Laser Micro Processing: + 42% Growth Rates for market measured in Euro.

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OPTECH CONSULTING

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  1. OPTECH CONSULTING

  2. OPTECH CONSULTING

  3. OPTECH CONSULTING

  4. World Market for Laser Materials Processing Systems - Growth Rates 2004, 2005 2004 Growth Rate: + 27% - Laser Macro Processing: + 23% - Laser Micro Processing: + 42% Growth Rates for market measured in Euro. 2004 World Market Volume: - Laser Macro Processing: EUR 3.45 Billion - Laser Micro Processing: EUR 1.20 Billion Expected 2005 Growth Rate (estimate May 2005): -5% … +5% OPTECH CONSULTING

  5. www.laserdeal.com OPTECH CONSULTING

  6. OPTECH CONSULTING

  7. OPTECH CONSULTING

  8. Laser Macro Processing Applications Cutting Welding Drilling Surface Treatment Marking, Coding Desk Top Manufacturing Laser Processes in the Tool & Die Industry Plastics Welding Laser Structuring … OPTECH CONSULTING

  9. OPTECH CONSULTING

  10. www.laserdeal.com Investing in a Laser Cutting System www.laserdeal.com Financing/Depreciation Material/Variable Costs Company/Fixed Costs/Personnel Profit

  11. Choosing the optimal system: Quality Price Financing/Depreciation Processing time Material/Variable Costs Company/Fixed Costs/Personnel Profit Orders p. Unit of Time

  12. Frequency Main Material thick-ness Thickness [mm] 10 15 20 0 5 Sheet thickness and Materials Steel [O2] 75 % Stainless [N2] 18 % Aluminum [N2] 7 % 2 – 6mm

  13. Productivity I:Optimizing the Investment Cutting Comparison

  14. 5.2kW 4.4kW 3.0kW 2.2kW Electrical Power & Wear and Tear  as little as possible

  15. v in m/s 30m/s 17m/s t in s 1 s Acceleration is more important than maximum speed! Workpiece time:Speed vs. Dynamic

  16. v in m/s 30m/s Axis speed (m/min.) 17m/s t in s 200 1 s 120 10 t [s] Start 20 10 30 Start End

  17. v in m/s 30m/s 17m/s t in s 1 s Axis speed (m/min.) Start End 200 120 10 t [s] Start 20 10 30

  18. www.laserdeal.com High Acceleration with DHM • High acceleration Direct Helical Motor (DHM) • Without external cooling • With impulse decoupling • With direct measuring Spindle „X“ Cutting wagon Spindle „Y“ Metal Sheet Machine

  19. Mirror Process quality:Beam conditioning & ARC Laser beam Divergent light: Beam quality changes

  20. Process quality: Beam Conditioning & ARC Same Diameter (X2) optimal Laser Cut Thick metal & high-power Laser:

  21. www.laserdeal.com • Laser beam - • 25mm 22mm 20mm 18mm 16mm Results ARC, example on steel 20 mm Optimal beam: Diameter 21 mm Differences influence cut quality  ARC: best quality,all materials and thickness

  22. Component time II: Cutting technologies and piercing Bow positioning: -overlaps the moving running time-considers the cutting direction -reduces positioning time -protects the machine

  23. Component time II: Cutting technologies and piercing conventional piercing in metal > 8mm • constant laser performance  defined piercing time • Oil fog and blow away of scraps • Large penetration hole • Material heats up

  24. Component time II: Cutting technologies and piercing CPP: Controlled Pulsed Piercing • Controlled Pulsed Piercing • Cuts directly after piercing • Reduces the size of the initial hole • Reduces scraps • Reduces heat affected areas •  Time and process optimized piercing (Automation)

  25. Component time II: Cutting technologies and piercing • Total Piercing Time = 2s • Piercing (Oil fog 0.3s / Piercing 0.6s / Vertical Blowing 0.9s/ Lifting & Lowering 0.2s) • Diameter of the initial hole = 4mm • Total Piercing Time = 1s • Diameter of the initial hole = 1mm Piercing with CPP (Controlled Pulsed Piercing):

  26. CutControl Mirror Lens Nozzle I I 8mm 0.6-2mm Metal sheet 1. Step: 2. Step:

  27. Component time II: Cutting technologies and piercing ① Reduced Positioned Drive② Piercing, „LeadIn“-Drive③ Cutting Parameters LeadIn: • less head • improved cutting quality • „LeadIn“ reduces piece time up to 35 %

  28. LeadIn: • Steel, 6mm: • “Standard” : 70s • LeadIn : 50s •  Time Advantage = 30% • Steel, 8mm: • “Standard”: 109s • LeadIn : 76s •  Time Advantage = 30%

  29. Steel: 1mm • Diameter: 2mm • Distance: 3mm •  Highly Dynamic & „smooth“ • Well-tuned combination of leading technologies: • Machine • CNC • Drive technology & Servo • Laser steering • Programm Software •  600 holes/min. (punching holes?)

  30. Piece Time III:Knowing the Technologies • Steel: 1mm • Metal: 1 mm •  Highly Dynamic and „smooth“ Well-tuned combination of leading technologies: Machine, CNC, Drive Technology including Power Electronic,Laser steering, Programm Software  Cutting of 330 holes / min. (Punch Application?)

  31. Optimal System: Quality Price Financing/Depreciation Processing time Material/Variable Costs Company/Fixed Costs/Personnel Profit Order per component time

  32. Laser Bridge Sheet on cutting table Flying Optics • Stationary Laser • Constantly moving mass • Workpiece (large) steady • No clamping • Continuous cutting • Less floor space

  33. www.laserdeal.com Process Gas: I Lens O2, N2, Ar, ... Nozzle Laser beam Workpiece Laser Cutting

  34. Cutting small and oversize parts- no pratical parts limitationEfficient machine space utilisationConsistent cutting quality over the entire working area Working area - vertical cutting Y - axis, transver up to 5 meter in width X - axis, longitudinal pratical no limitation in length Z - axis, movement in height 260 mm Working area - vertical / bevel cutting - axis, transversal up to 4.5 meter C - axis 360 ° infinity rotating A - axis + / - 45 °

  35. PLC - Handling • Material flow • Visualization + manual control of • exchange table • sheet loader • ByTrans • tube loader

  36. PLC - Store • Automatic sheet supply • Automatic restoring of cut parts • Visualization and manual control of • Sheet extraction • Sheet restoring • Restoring of cut sheets • Communication ByStore

  37. www.laserdeal.com FMS requires • Good laser and beam delivery • Fast and dynamic machine and CNC • Efficient material handling • Process oriented programming software Flexible - Manufacturing - System

  38. 79,4% 78,7% 3,4% 3,4% 1,5% 0,6% 1,3% 1,3% 15,1% 15,2% Plate thickness 3 mm Plate thickness 12 mm Machine costs and overhead Labor costs Laser gas Cutting gas Electricity Bild 1

  39. 75,3% 71,6% 3,3% 3,1% 5,8% 10,4% 1,2% 1,1% 14,5% 13,7% Plate thickness 3 mm Plate thickness 6 mm Machine costs and overhead Laser gas Labour costs Cutting gas Electricity Bild 2

  40. www.laserdeal.com 2,5 Cutting costs [€/m] 2 1,5 O2 2.5 1 O2 3.5 0,5 Plate thick-ness mm 0 0 2 4 6 8 10

  41. Cost accounting LASER-Cutting System Investment E 600.000,- from RV 1 shift 2 shifts 3 shifts Machine hourly net rate 152,85 84,00 61,07 Manufacturing costs rate 187,85 123,00 101,07 Investment E 400.000,- from RV 1 shift 2 shifts 3 shifts Machine hourly net rate 106,27 59,01 43,25 Manufacturing costs rate 141,27 98,01 83,25 Investment E 200.000,- from RV 1 shift 2 shifts 3 shifts Machine hourly net rate 59,70 33,39 25,45 Manufacturing costs rate 94,70 72,99 65,45 Investment E 100.000,- from RV 1 shift 2 shifts 3 shifts Machine hourly net rate 36,39 21,51 16,54 Manufacturing costs rate 71,39 60,51 56,54

  42. Uncomplicated start in a new technology or reasonable production extension • Arguments pro: • lower manufacturing costs (see example cost accounting) • lower initial investment • cost effectiveness even in one production shift • output peaks can be worked off in-house, thus no need for outsourcing, no logistic delivery problems • installation of a more effective system for rise in output for meeting new material processing requirements • comprehensive service from one source, servicing machines of several manufacturers. We are your partner for service, modernization and resale!

  43. Arguments con: • higher energy costs for older lasers and machines and higher maintenance costs • no guarantees like with new systems • parameters differ from initial performance • machines are not state-of-the-art But, Laser System Dealoffers, if desired, machine overhaul and maintenance, and also production warranty for 2000 hrs. or 6 months!

  44. We do everything necessary to make your cutting system reliable. Have confidence in us, a business partner whose Service Technicians have installed more than 150 machines! • We can improve your laser processing results by: • replacing mechanical parts and optice • reworking of all the NC-axes • cleaning and painting • running acceptance tests You will produce higher quality after the Laser System Deal service!

  45. www.laserdeal.com • Qualification brings efficiency, efficiency brings profit • Why training? • economic, laser specific PC-programming • saving on material and cutting time • application optimization • maintenance and problem finding by your own personnel • the operator masters the machine after being trained by us • Your operator identifies himself with the job and works on his own!

  46. Conclusions • Laser technology has matured and shows continuous rapid growth • Proven tool for modern industrial sheet metal fabrication • Precision and quality • Beneficial side-effects reduce costs Laser technology for higher profit

  47. Thank you for your interest! Contact: Laser System Deal, www.laserdeal.com E-mail: h.d.ruebcke@web.de Postal address: Bgm. Schallenkammer Weg 7, D-82402 Seeshaupt, Germany

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