A coil feed laser blanking line is an advanced industrial manufacturing system used for high-speed and precision cutting of metal sheets or coils into specific shapes or blanks. It combines the advantages of coil feeding technology and laser cutting technology to achieve efficient and accurate production in various industries, such as automotive, aerospace, and appliance manufacturing.
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Here's a breakdown of the key components and processes involved in a coil feed laser blanking line:
Coil Feeding: The process begins with a metal coil, typically made of steel, being unwound and fed into the system. The coil may be stored on a reel or a decoiler, which allows for continuous feeding without interruptions.
Straightening and Leveling: To ensure the material is flat and properly aligned, the coil passes through straightening and leveling equipment. This process removes any distortions or imperfections in the coil.
Servo Roll Feed: The straightened coil is then fed into a servo roll feed, which precisely controls the movement of the metal sheet. This mechanism ensures accurate positioning and feeding of the material to the cutting area.
Laser Cutting: A high-power laser cutting system is employed to cut the metal sheet or coil into desired shapes or blanks. The laser beam is guided by computer numerical control (CNC) to follow a predefined cutting path, determined by the desired design or pattern.
Scrap Removal: As the laser cuts through the metal, the excess material or scrap is separated from the main sheet. Various methods, such as suction or magnetic systems, are used to remove the scrap from the cutting area.
Sorting and Stacking: Once the blanks are cut, they are sorted and stacked according to the production requirements. This can be done automatically using robotic systems or manually by operators.
Quality Control: Throughout the process, quality control measures are implemented to ensure the accuracy and integrity of the produced blanks. This may include automated inspections using vision systems or manual checks by operators.
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Coil Changeover: When the current coil is depleted, the system can be set up for a coil changeover. This involves stopping the line, removing the empty coil, and installing a new one.
The coil feed laser blanking line offers several advantages over traditional blanking methods, such as increased productivity, reduced material waste, improved flexibility in design, and enhanced precision. It allows for the production of complex and intricate shapes with minimal tooling requirements and faster production cycles.
With short setup times and high availability, you benefit from high efficiency over the entire system service life. The system is characterized by compact design, high speeds, higher process reliability, and short coil changing times. Laser cuts can be optimally nested on strip material, reducing scrap. This saves you up to 15% on material costs. Whether steel, stainless steel or aluminum – many different materials can be processed. Coils up to 20 t can be accommodated as standard, 25 t and a width of mm are possible as options.
The CoilMaster 50 precision leveler from ARKU delivers consistently good leveling results for robust laser cutting. Coil material from 0 up to 4 mm in thickness is supported as standard, whether steel, stainless steel or aluminum. Even higher-strength steels can be processed with the nine leveling rollers. During roller leveling, the coil material passes through alternating bends, flattening it and relieving tension. The component can then be cut safely and then removed from the scrap skeleton.
The hydraulically controlled strip storage bridge supplies the laser cutting cell with material, decoupling the material feed cutting process and the strip system. The belt speed in the strip system is reduced to a minimum, but never stopped. This avoids the risk of surface damage to the strip. The strip feed rollers integrated in the strip storage transport the strip material to the laser cutting cell at up to 40 m per minute.
The heart of the laser blanking system is a proven TruLaser cutting machine. The coil material is transported linearly through the machine, reducing non-productive times by a factor of up to 2.5. This is made possible by a support belt newly developed by TRUMPF. While the new material is transported in, the processed material – including scrap – simultaneously moves out. This increases the entire system productivity many times over.
One or, optionally, two robots enable parallel to production unloading and repeatable stacking. The complete integration of the robot kinematics into the control architecture eliminates the need for robot-specific programming expertise. The position of the components is already determined during programming or nesting of the cutting parts in TruTops Boost. This way, the robot immediately knows where the components to be removed are located.
Small separating cuts are already made in the scrap skeleton during the cutting process. In this way, the scrap skeleton breaks into smaller pieces during removal and can be disposed of in a cost-efficient manner. The scrap conveyor can transport scrap out of the machine in three directions as required - either directly out or via a transverse conveyor belt to the left or right. This way, scrap removal can be integrated into the customer's scrap logistics.
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