Cutting and Welding Solutions

Automation & Robotics

Heavy Engineering Fabrication

AUTOMATION SIMPLIFIED

DRUPEAutomation in Cutting & Welding

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CNC Oxyfuel Plasma Cutting Machine (Hi-Cut)

Laser Cutting Machine

Heavy Engineering Servo Column and Boom

Servo Positioner Gantry for Welding

7th Axis for Robot

CNC Oxyfuel Plasma Cutting Machine (Jambo)

About Us

Drupe is a young company with a dream for worldwide operations including sales

and service network with a high standard product quality and delivery.

The country is witnessing rapid advance in new millennium in various fields. The

development in mechatronics field stands out for transforming the pace of industry

from the dumped technology to next century.

“Automation Solutions for Demanding Conditions”

The demand of products in the country thus

growing at rapid pace. To contribute to the

industry, DRUPE stepped in to provide local

manufacturing. With assembly base, Local

Service and High quality are made with indigenous manufacturing facilities, upto

international standards at affordable prices which is the hallmark of our company.

Drupe tends to become an influential world player in development, design and use

of linear axis, gantry and Robotic solutions for factory automation and Foundry

Machineries.

Drupe Attitude

n We sell satisfaction, not just machines.

n Every machine, system, product and spares must deliver and satisfy what it was

purchased for.

n The Customer must recover his investment very fast.

n Satisfy the customers to such an extent that

they unknowingly become our sales

promoters.

n Distributors are our arteries, without them we are lifeless.

n Our most important advisor is the actual floor level operator using our machine.

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Introduction

Do you need a cutting tool for occasional repair and maintenance work? Have you recently embarked on a new project that

requires higher cutting volumes? Or, are you looking for a new alternative to your current mechanical saw? All of these

scenarios provide great reasons to investigate plasma cutting. With the cost of machines on the decline, smaller-sized,

portable machines flooding the market and technology offering increased benefits and easier usage -- it may be time to take a

serious look at plasma for your cutting applications. The benefits of plasma cutting include ease of use, higher quality cuts and

faster travel speeds.

Oxyfuel Cutting

In this method of metal cutting, a torch is used to heat metal to

kindling temperature. The stream of oxygen that is trained on the

metal reacts with the metal in a chemical process, oxidizing the

steel and blowing it away to form the cut. Heat is actually a

byproduct of the process.

Oxyfuel cutting is primarily used for cutting mild steel in

thicknesses from 3/8 in. to 12 in. The technology is not

considered practical for aluminum or stainless steel, but can be

used for titanium.

The technology has a very large heat-affected zone when

compared to the other metal cutting technologies and is not as

accurate, typically ± 1.6 to ±3.175. Although careful process control can result in much tighter tolerance parameters.

The technology has improved greatly in recent years with technical advancements. High-speed torches have resulted in

cutting speeds that are 20 percent faster the previous generations'. Height-sensing probes and CNC gas regulation keep

Oxyfuel cutting operations running efficiently.

Plasma Cutting

When a gas is heated to an extremely high temperature, it ionizes. At this

point, the electrically conductive, ionized gas can be called plasma.

When a high-velocity jet of plasma is delivered to a metal workpiece, an

electrical arc is delivered with it. The heat of the arc melts the metal to be cut,

and the stream of ionized gas blows the molten metal away.

For the sake of this comparison, high-density plasma systems, also known as

high-definition systems, were used. This technology produces a much better

cut on metal because the latest nozzle technology dramatically constricts the

arc to deliver much more energy density.

Plasma cutting can yield a variety of cutting speeds and quality, depending on

the material to be cut, the material thickness, the quality of the cut desired,

and the cutting speed required. The ability to dial in the machine's amperage,

from 30 to 260, allows for this flexibility.

A simple rule of thumb: The more power you throw at it, the faster you will

plasma-cut the metal. Cutting speeds are less affected by material thickness than other processes. In fact, plasma cutting is

effective for aluminum, particularly thick aluminum. Because plasma cutting is not as precise as other metal cutting

technologies, it may not be able to deliver a series of functional holes. The wider kerf width affects part definition.

That's why the technology is often paired with punching tooling. However, high-density plasma cutting can yield tolerances of ±

0.25mm to ±0.3mm in closely monitored processes.

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Introduction to Plasma

What is Plasma? The Fourth State of MatterOne common description of plasma is to describe it as the fourth state of matter. We normally think of the three states of matter

as solid, liquid and gas. For a common element, water, these three states are ice, water and steam. The difference between

these states relates to their energy levels. When we add energy in the form of heat to ice, the ice melts and forms water. When

we add more energy, the water vaporizes into hydrogen and oxygen, in the form of steam. By adding more energy to steam

these gases become ionized. This ionization process causes the gas to become electrically conductive. This electrically

conductive, ionized gas is called a plasma

How Plasma Cuts Through MetalThe plasma cutting process, as used in the cutting of electrically conductive metals, utilizes this electrically conductive gas to

transfer energy from an electrical power source through a plasma cutting torch to the material being cut.

The basic plasma arc cutting system consists of a power supply, an arc starting circuit and a torch. These system components

provide the electrical energy, ionization capability and process control that is necessary to produce high quality, highly

productive cuts on a variety of different materials.

The power supply is a constant current DC power source. The open circuit voltage is typically in the range of 240 to 400 VDC.

The output current (amperage) of the power supply determines the speed and cut thickness capability of the system. The main

function of the power supply is to provide the correct energy to maintain the plasma arc after ionization.

The arc starting circuit is a high frequency generator circuit that produces an AC voltage of 5,000 to 10,000 volts at

approximately 2 megahertz. This voltage is used to create a high intensity arc inside the torch to ionize the gas, thereby

producing the plasma.

The Torch serves as the holder for the consumable nozzle and electrode, and provides cooling (either gas or water) to these

parts. The nozzle and electrode constrict and maintain the plasma jet.

Sequence of Operating a Plasma CutterThe power source and arc starter circuit are connected to the torch via interconnecting leads and cables. These leads and

cables supply the proper gas flow, electrical current flow and high frequency to the torch to start and maintain the process.

1. A start input signal is sent to the power supply. This simultaneously activates the open circuit voltage and the gas flow to the

torch (see Figure 2). Open circuit voltage can be measured from the electrode (-) to the nozzle (+). Notice that the nozzle is

connected to positive in the power supply through a resistor and a relay (pilot arc relay), while the metal to be cut (workpiece) is

connected directly to positive. Gas flows through the nozzle and exits out the orifice. There is no arc at this time as there is no

current path for the DC voltage.

2. After the gas flow stabilizes, the high frequency circuit is activated. The high frequency breaks down between the electrode

and nozzle inside the torch in such a way that the gas must pass through this arc before exiting the nozzle. Energy transferred

from the high frequency arc to the gas causes the gas to become ionized, therefore electrically conductive. This electrically

conductive gas creates a current path between the electrode and the nozzle, and a resulting plasma arc is formed. The flow of

the gas forces this arc through the nozzle orifice, creating a pilot arc.

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3. Assuming that the nozzle is within close proximity to the workpiece, the pilot arc will attach to the workpiece, as the

current path to positive (at the power supply) is not restricted by a resistance as the positive nozzle connection is. Current

flow to the workpiece is sensed electronically at the power supply. As this current flow is sensed, the high frequency is

disabled and the pilot arc relay is opened. Gas ionization is maintained with energy from the main DC arc.

4. The temperature of the plasma arc melts the metal, pierces through the workpiece and the high velocity gas flow

removes the molten material from the bottom of the cut kerf. At this time, torch motion is initiated and the cutting process

begins.

Applications

?? Art work, Signs & ornamentation.

?? Automotive

?? Construction

?? Demolition & Scraping

?? Engineering industries.

?? Metal fabricators.

?? Ship building

?? Earth moving equipments.

?? Aviation

?? Infrastructure.

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CNC- OXYFUEL / PLASMA CUTTING MACHINE.

The Machine frame is designed as heavy- Case structure using TATA tubes, with stress relieved processing.Excellent workmanship ensures outstanding Rigidity, operational balance and reliability. The cross and straight drive is equipped with Servo gear box & rack-pinion transmission. Gas hose and Cable supplied on the machine is via cable Drag chain.

Specification.

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Model No. JUMBOCUT-130

Main Body Gantry Bridge with Double Crive

Operate Console Right Side / Left Side

Drive Method Rack - Pinion & Servo gear box drive for X and Yaxis

Effective Cutting Width Standard 3000mm, also customer's requirement

Effective Cutting Length Standard 6000mm, also customer's requirement

Torch mounting system Wire rope connection systems

Maximum rapid Speed 12000mm/min

CNC Control Systems Edge-Pro/ Micro Edge

Servo Motors and Drives Panasonic, Mitsubishi and other popular brands of your choice

Nesting Software SNX 102/ MX 1000/ MX 1250 Sigma Nest USA and Turbonest MTC USA

No. of Torch block As per customer's Requirement

Oxy-Fuel Cutting Capacity 6 to 300 mm

Power Supply Plasma Source as per customer requirement

Hose & Cable carrier Polymer Energy chain system for longitudinal & Traverse (IGUS)

Optional accessories for Oxyfuel Torch height Control (IHT). Tanaka Torch & Nozzles (LPG/Acetylene),

Gas hose pipes, Pressure regulators, Flow regulators & Solenoid Valves

Optimal accessories for Auto ignition , Fume extrator, Consumable spares & Grit box

Optimal accessories for Plasma Plasma Source, Plasma torch height control, Grit box, All types & series of

consumables.

LPG/Osyacetylene.

Gear Box

Rack and Pinion

Guide LFR

Servo Motor and Driver

Features of Mechanical structure

n 2 Axis Gantry system with Rack-and-Pinion Drive mechanism.

n Heavy-Wall Reinforced Box Beam Design.

n Machined Mating Surfaces for high stiffness and accuracy

n Digital AC Servo Drive for years of maintenance free operation.

n AC Brushless Motors for smooth & accurate motion.

n Precision Backlash free Servo Planetary Gearboxes for accuracy and long life.

n Precision Linear Rail Drive arrangement for X Axis & Precision machined tracks for Y Axis

n Maximum Rapid Machine Speed: (14000 mm/min).

n Positioning accuracy: ± 0.2mm; Repeatability: ± 0.1mm.

n Heavy-duty, precision machined floor mounted track rail system.

n Machined top and side surfaces.

n Machined rack mounting groove for precise rack alignment.

n Precision drive rack mounted directly to machined surface. 2 Axis Gantry system with Rack-and-Pinion Drive mechanism.

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CNC Plasma / Oxy-Fuel Cutting Machine

Specification.

Features:n Light beam design with Track roller & shaft leads to high accuracy & stable transmission.

n High cutting speed, high accuracy, low cost. High quality Hypertherm plasma power, Can cut any conductive metal

with high efficiency.

n Equipped with Tanaka make gas system.

n Advanced numerical control system for stable & uninterrupted performance.

n Specialized Hypertherm plasma system.

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Model No. TABLECUT-200 Main Body Table Type with Double Drive

Grid box for placing of sheets Included- 1.6m X 3.1 m Operator Console Right Side / Left SideDrive Method Track roller with hardened shaft drive for X and Y axis Effective Cutting Width 1500 mm Effective Cutting Length 2500 mm

Torch mounting system Wire rope connection systems Maximum rapid Speed 10000mm/min CNC Control Systems Edge-Pro/ Micro Edge

Servo Motors and Drivers. Panasonic (JAPAN)

Nesting Software SNX102/ MX1000/ MX1250 Sigma Nest USA and Turbonest MTC USA

No. of Torch block 2 torches. Can be increased Oxy-Fuel Cutting Capacity 6-300mm

Power Supply Plasma Source Hose & cable carrier Polymer Energy chain systems for Longitudinal & Traverse(IGUS) Optional accessories for Oyfuel Torch Height Control (IHT), Tanaka Torch & Nozzles (LPG/Acetylene), Gas

hose pipes, Pressure regulators, Flow regulators & solenoid valves.

Optional accessories for Plasma All types & series of consumable. Plasma Source, Plasma torch height

control.

MECHANISED PLASMA CUTTING SYSTEMS

We offer a wide range of Hypertherm Plasma cutting systems for our cutting Machines.

Fetures of Plasma system

Features

?Fast cutting speed increases productivity.?Superior cut quality limits rework.?Maximized productivity improves profitability.?High duty cycle for industrial performance.?Easy maintenance reduces machine idle time.?Unmatched reliability.

Comparison

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Subject Plasma Laser Waterjet Method of imparting energy Gas transmitter Light(far infrared range) Water

Source of energy DC power supply Gas laser High pressure pump Materials able to cut by the process

All electric conductive materials

All materials like metals, wood, PU etc

All materials

Typical process uses Cutting, welding, marking, drilling(True hole technology)

Cutt ing, welding, marking, drilling etc

Cutt ing, marking, drilling etc.

Initial investment required Low to medium Very high Very high

Operating cost Low Medium Medium

Machine Torch

Torch Height Control

Sensor PHC

The sensor PHC is an easy to use and reliable voltage sensing height control for the

conventional plasma applications.

The benefits reliazed are in terms of

n Consumables life improvement.

n Improved cut quality.

n Reduced opertaors intervention.

The sensor PHC offers easy installation on new or existing plasma cutting table with

any CNC and a broad range of plasma systems. Available in several application-

specific configurations. The sensor PHC delivers improved performance at a reduced

cost compared to other plasma height control solutions.

Arc Glide THCThe Arc Glide THC offers optimal cut quality substantially improved productivity &

reduced operating cost for plasma cutting applications.

Specific advantages include

n Optimal consumable life & superior cut quality through arc voltage sampling and

control.

n Upto 80% improvement in parts cut per hour by minimizing cut-to-cut cycle time.

n Extremely robust mechanized backed by a 2 year warranty.

n Easy to use HMI (Human Machine Interface) for fast job set under a minute.

n True hole technology capable for HyPerformance Plasma HPRXD installation.

Performance advantages are achievable with minimal operator input, eliminating the

need for extensive training and allowing you to get the best performance across any shift with any operator at any plant.

Torch Height Control System – M4000 CapAutomatic clearance control for oxy-fuel cutting machines

Advantagesn Small ring electrodes means optimised yield from the workpiece.

n Highly accurate control of the clearance distance for more precise cuts.

n Adjustable cutting and piercing height.

Visit: www.iht-automation.com for more details.

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Features of Nissan-Tanaka Oxyfuel Torch SystemThe New Dimension of Nozzle Mix Technology for Gas Cutting Used in Nissan- Tanaka Torch.

Introduction

To understand the importance of Nozzle Mix Technology in Industry today, it is necessary to understand the process of

Oxy-Fuel cutting and safety hazards associated this traditional but most popular & cost effective metal cutting process.

Oxy-Fuel CuttingIn spite of great progress in plasma cutting, laser cutting, waterjet cutting, Oxy-fuel cutting process still dominate 80% of the

global mild steel fabrication today because of:

1. Lower investment cost in the equipment.

2. Capability to cut from 5mm to 200mm with a standard torch just by changing nozzles.

3. Long service life of nozzles.

4. Easy availability of Oxygen and fuel gases like Acet., LPG, Propane & Hydrogen.

Actually Oxy-fuel cutting is a simple chemical process in which the preheating flame created by a mixture of oxygen with the

fuel gas heats up the plate to red hot condition. As we allow the cutting oxygen jet to pass through the central hole of the nozzle

to the red hot zone, it reacts with iron & convert it to iron oxide through an exothermic reaction generating more heat to sustain

the process. Since the iron oxide has a lower melting temperature than the iron, the Oxygen jet pierces through molten area of

the thick plates separating into two parts as long as cutting continues.

Backfire, Sustained Backfire & Flash BackThe mixing of preheat oxygen with the fuel gas, however creates an explosive gas mixture which often cause safety hazards.

During cutting operation as long as preheat flame gets adequate supply of fuel gas at the cutting nozzle tip, there is nothing to

worry and uninterrupted cutting is possible. However, if there is a drop in fuel gas supply pressure for whatever reasons

(clogging of nozzle holes due to rusted plates, improper seating of the nozzle, dropl in input pressure of fuel gas), the flame

often goes inside the nozzle in search of fuel gas and create a pop sound.

If the flame repeatedly stops with a pop sound and after few moments restarts again, we call it simple “Backfire” which can be

prevented either by cleaning the holes of nozzle with proper tip cleaner or replacing the nozzle altogether. Backfire is therefore

is very common phenomena. Though it creates an irritating sound & may interrupt cutting, it does not cause any major damage

otherwise.

However, if neglected for long, Backfire can lead to “Sustained Backfire” where the flame enters further inside the torch to

burn the fuel mixture available inside the metal pipes of the torch. Sustained Backfire therefore is very dangerous for

conventional Injector Mix cutting torch (Conventional 2 pipe torch) where the preheat oxygen and fuel gases get mixed inside

the torch near the handle and travel through the gas pipe. The explosive mixture thus available inside the preheat gas supply

pipe of the torch with fast catch fire & burn with a hissing sound until perhaps the pipe explodes with a big bang, if not attended

by an alert operator. Apart from severe damage to the gas cutting torch, Sustained Backfire often cause injury to the operator

if he is not very prompt to cut off the gas supply.

However, the most horrific incident is “Flashback” in which the flame after burning the explosive mixture inside the torch,

travels reverse with a lightning speed further towards the sources i, e high pressure gas cylinders. In case the Oxygen & fuel

gas regulators are not protected by Flash Back Arrestor, the flame accompanied by heat, dust and smoke can enter the

cylinder causing huge explosion and damage to men & machines.

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“ NOZZLE MIXING IS SAFER THAN TORCH MIXING”

Nozzle Mix Technology:In order to minimize the incidence of Sustained Backfire and Flash Back in the new generation gas cutting torches, the

preheat oxygen and fuel gases flow independently through separate pipes only to mix in very small quantity inside the

specially designed nozzle (3 seat nozzle) in extremely small quantity thereby limiting the scope of accident to a very great

extent. The sectional photo of Nozzle Mix nozzle & torch head where this nozzle is fitted is given above to explain the

technology.

Nozzle Mix Technology perfected in Japan few decades back, has now spread to major parts of the world. It entered India in a

big way a decade back after government adopted policy of globalization. While Cutting torch based on Injector Mix cutting

technology is the decline stage of product life cycle and has been phased out in most countries in the world for safety

reasons , those based on NM technology is the growth stage.

However, shortage of good quality imported nozzles is slowing the growth of this much superior and safer technology.

Are all NM Cutting Nozzles the same?Unfortunately the quality of all imported NM nozzles are not same. The major source of NM cutting nozzle in the world today

is Japan, UK, Italy followed by Taiwan & China.

While Chinese nozzles are cheap, the performance is very poor. The main feature of a superior NM cutting nozzle, which make

the Japanese nozzles superior to other NM nozzles are the following:

1. Superior Acetylene NM nozzles is made in Japan out of a Brass top and Copper bottom. The two dissimilar metal parts

are then micro-brazed together by a unique patented process. As the cutting torch head is also made of brass, the torch

head and nozzle seat, under continuous cutting, expand by same degree thereby maintaining although air tight contact at

all the 3 seats. This feature does not allow any leakage from seat even after prolonged use. This is not possible in All

copper Acetylene nozzle made in U. K., Italy, Taiwan & China.

2. The other major feature is the “positive suction” property of Japanese cutting nozzles. To check this property one can

allow the preheat oxygen to flow through the nozzle and connect a vacuum gauge on the fuel gas inlet. Suction shows for

fuel gas not only under normal preheat condition; the suction improves once the cutting jet starts cutting. This feature

greatly eliminates any occurrence of backfire. Hence these nozzles smoothly operate even if supply pressure of fuel gas is

a pipe line fluctuates.

3. The Japanese NM nozzle is longer in length compared to British style nozzle and give a more streamlined flow of gases.

The cut quality is therefore always better.

For machine cutting application Japanese NM nozzle are given a special chemical coating to work under extreme working

condition. Hi-speed machine cutting nozzles have small stainless steel ring at the central Oxygen hole to improve

straightness of cutting jet and wear due to repeated piercing operation. They produce superior cut quality as per

Japanese standard WES 2801 and have long life

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CNC Control Systems

EDGE Pro Shape Control

The EDGE Pro offers multiple back-door interfaces for table manufacturer integration.

Providing three analog choices and one SERCOS version, the EDGE Pro interfaces

allow the table manufacturer to configure the CNC to match the table design. Designed

to be flexible and easy to use, the EDGE Pro delivers reliable performance for improved

profitability and application performance such as True Hole technology. Using Phoenix

software, this CNC improves cut quality and productivity by delivering our expertise

directly to your factory, making it as if you have your best operator on every shift.

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Micro EDGE

Consumables for Plasma cutting system.

Hypertherm offers a wide range of consumables depending upon the type & series of plasma system. The consumables

like shield, retaining cap, nozzle, electrode, Torch body are designated by unique code no. This can beordered in single

unit or in kit.

Operating system Microsoft W indows XP® - embedded;

Processor Intel 2.5 GHz

Memory 512 Megabytes RAM

Hard drive 80.0 Gigabyte hard drive

Communication 1 x RS232; programmable to 230K baud.

Floppy drive 1.44 Megabyte f loppy drive

CD-ROM/DVD drive Standard

RFI / EMI shielding Machine side Opto-Isolation: grounding

Input / output 24 Lines of user definable Interface signal (12 in / 12 out)

No. of Axes 3 Axes

MBoard Interface PS2 keyboard & mouse with USB ports.

Optional networking On-board RJ-45 network port

Dimensions 14.38" (365.252 mm) W, 20.00" (508 mm) D, 9.35" (237.49 mm) H

Weight 14 Kg.

Operating environment

0 to 50°C; 95% relative humidity (non-condensing).

Display 15” Touch screen- SAMSUNG/SIEMENS

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Welding Automation

Automated welding has improved upon manual welding by increasing speed, quality and throughput. Top-notch

weldments are easily repeatable with robots. Robot welding automation is much safer and more cost-effective.

Welding is a process where two materials are fused together through heating, intermixing, and then

cooling the materials and/or a filler to form a strong join. Robots are capable of performing several types of

welding processes, including arc welding, spot welding, and laser welding. They are typically used in welding

processes where the weld required is repetitive and quality and speed are crucial.

Quality - Welds are more consistent and thorough when performed by robots.

Productivity - Robots produce effectively because they can work inexhaustibly and consistently.

Speed - Robots move from one weld to the next very quickly, making the entire process much faster.

Less Waste - Robotic welding uses fewer consumables than its human counterparts. Material is saved and more

product produced because of this exact welding.

Reduced Costs - Investing in robotic welding saves money. One robotic welding cell has the potential to

complete the work of four human welders.

DRUPE ENGINEERING PVT.LTD.

Plot No.B29/2 MIDC Taloja

Dist Raigad - 410208 Navi Mumbai

Tel: 0227411922 / 27401153

Fax: 022-27411933

Email: / Web:

saeed@drupeengg.com sales@drupeengg.comwww.drupeeengg.com

AUTOMATION SIMPLIFIED

DRUPE

Application Examples

Locomotive Engineering

Offshore Rigs

Heavy Fabrication

Ship building

Steel Manufacturing

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