OPTECH CONSULTING. World Market for Laser Materials Processing Systems - Growth Rates 2004, 2005...
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OPTECH CONSULTING W orld M arketforLaserM aterials P rocessing S ystem s - M arketTrend 1986 -2004 0 1 2 3 4 5 6 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004 EUR Bill O PTECH CO NSULTING
OPTECH CONSULTING. World Market for Laser Materials Processing Systems - Growth Rates 2004, 2005 2004 Growth Rate: + 27% - Laser Macro Processing:
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%
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OPTECH CONSULTING www.laserdeal.com
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OPTECH CONSULTING
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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
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Financing/Depreciation Company/Fixed Costs/Personnel Profit
Material/Variable Costs Investing in a Laser Cutting System
www.laserdeal.com
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Quality Price Processing time Financing/Depreciation
Company/Fixed Costs/Personnel Profit Material/Variable Costs
Choosing the optimal system: Orders p. Unit of Time
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0 5 101520 Thickness [mm] Main Material thick- ness Frequency
Steel [O 2 ]75 % Stainless [N 2 ]18 % Aluminum [N 2 ] 7 % Sheet
thickness and Materials 2 6mm
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Cutting Comparison Productivity I: Optimizing the
Investment
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4.4kW 5.2kW 2.2kW 3.0kW Electrical Power & Wear and Tear as
little as possible
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v in m/s t in s 1 s 30m/s 17m/s Acceleration is more important
than maximum speed! Workpiece time: Speed vs. Dynamic
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v in m/s t in s 1 s 30m/s 17m/s Axis speed (m/min.) 10 120 200
Start 10 20 30 t [s] StartEnd
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v in m/s t in s 1 s 30m/s 17m/s Axis speed (m/min.) 10 120 200
Start 10 20 30 t [s] StartEnd
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Machine Metal Sheet Spindle Y High Acceleration with DHM High
acceleration Direct Helical Motor (DHM) Without external cooling
With impulse decoupling With direct measuring Spindle X
www.laserdeal.com Cutting wagon
Thick metal & high-power Laser: Same Diameter (X2) optimal
Laser Cut Process quality: Beam Conditioning & ARC
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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
www.laserdeal.com
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- overlaps the moving running time -considers the cutting
direction -reduces positioning time -protects the machine Bow
positioning: Component time II: Cutting technologies and
piercing
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constant laser performance defined piercing time Oil fog and
blow away of scraps Large penetration hole Material heats up
Component time II: Cutting technologies and piercing conventional
piercing in metal > 8mm
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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) Component time II: Cutting
technologies and piercing
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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):
Component time II: Cutting technologies and piercing
less head improved cutting quality LeadIn reduces piece time up
to 35 % LeadIn: Reduced Positioned Drive Piercing, LeadIn-Drive
Cutting Parameters Component time II: Cutting technologies and
piercing
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Steel, 6mm: Standard :70s LeadIn :50s Time Advantage = 30%
Steel, 8mm: Standard: 109s LeadIn :76s Time Advantage = 30%
LeadIn:
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Well-tuned combination of leading technologies: Machine CNC
Drive technology & Servo Laser steering Programm Software 600
holes/min. (punching holes?) Steel: 1mm Diameter: 2mm Distance: 3mm
Highly Dynamic & smooth
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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?) Piece Time III:
Knowing the Technologies
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Quality Price Processing time Financing/Depreciation
Company/Fixed Costs/Personnel Profit Material/Variable Costs
Optimal System: Order per component time
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Sheet on cutting table Bridge Laser n Stationary Laser n
Constantly moving mass n Workpiece (large) steady n No clamping n
Continuous cutting n Less floor space Flying Optics
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Lens Nozzle Process Gas: O 2, N 2, Ar,... Workpiece Laser beam
Laser Cutting www.laserdeal.com
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Cutting small and oversize parts - no pratical parts limitation
Efficient 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
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Material flow Visualization + manual control of exchange table
sheet loader ByTrans tube loader PLC - Handling
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n Automatic sheet supply n Automatic restoring of cut parts
parts n Visualization and manual control of Sheet extraction Sheet
restoring Restoring of cut sheets n Communication ByStore PLC -
Store
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FMS requires n Good laser and beam delivery n Fast and dynamic
machine and CNC n Efficient material handling n Process oriented
programming software Flexible - Manufacturing - System
www.laserdeal.com
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78,7% 15,1% 1,3% 1,5% 3,4% 79,4% 15,2% 1,3% 0,6% 3,4% Plate
thickness 3 mmPlate thickness 12 mm Machine costs and overhead
Laser gas Labor costsCutting gas Electricity Bild 1
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Machine costs and overheadLaser gas Labour costs Cutting gas
Electricity 75,3% 14,5% 1,2% 5,8% 3,3% 71,6% 13,7% 1,1% 10,4% 3,1%
Plate thickness 3 mmPlate thickness 6 mm Bild 2
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0 0,5 1 1,5 2 2,5 0246810 O 2 2.5 O 2 3.5 Plate thick- ness mm
Cutting costs [/m] www.laserdeal.com
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Cost accounting LASER-Cutting System Investment E 600.000,-
from RV1 shift2 shifts3 shifts Machine hourly net rate
152,8584,0061,07 Manufacturing costs rate 187,85123,00101,07
Investment E 400.000,- from RV 1 shift2 shifts3 shifts Machine
hourly net rate 106,2759,0143,25 Manufacturing costs rate
141,2798,0183,25 Investment E 200.000,- from RV 1 shift2 shifts3
shifts Machine hourly net rate 59,7033,3925,45 Manufacturing costs
rate 94,7072,9965,45 Investment E 100.000,- from RV 1 shift2
shifts3 shifts Machine hourly net rate 36,3921,5116,54
Manufacturing costs rate 71,3960,5156,54
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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!
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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 Deal offers, if desired, machine
overhaul and maintenance, and also production warranty for 2000
hrs. or 6 months!
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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!
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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! www.laserdeal.com
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Conclusions n Laser technology has matured and shows continuous
rapid growth n Proven tool for modern industrial sheet metal
fabrication n Precision and quality n Beneficial side-effects
reduce costs Laser technology for higher profit
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Thank you for your interest! Contact: Laser System Deal,
www.laserdeal.com www.laserdeal.com E-mail: [email protected]
Postal address: Bgm. Schallenkammer Weg 7, D-82402 Seeshaupt,
Germany