Transcript ｽﾗｲﾄﾞ ﾀｲﾄﾙなし - Komatsu Plasma

60KW TWISTER
Confidential
ADVANTAGE OF 60KW TWISTER
Especially in Mild Steel 9mm-25mm plate cutting,
60KW TWISTER improves PRODUCTIVITY and
PRECISION drastically.
Laser
TWISTER
Precision
High
SS400 t9 - t25
Low
Plasma
Gas Cutting
(Multi Torches)
Low
Productivity
High
Confidential
NEW TECHNOLOGY
60KW Twister Unit
Linear Guide ＆
High Solid Carriage
Twister Gas
High Current
Electrode
Other technology
・ Torch Oil Jet
・ Quick Piercing
・ Auto Gas Control
・ Arc Marker
・ Gas Flow Pattern
・ Quick Arc Change
・ Spatter Shield
・ Fumes Elimination Room by Damper
・ Light Sensor
・ Cantilever Frame
・ Technology Table
・ Life Manager
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting
Accuracy & Quality
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
4．Lower Running
Cost
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
5． Clean & Safety
Work Environment
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
6． Easy Operation
Improved
Production
Costs
Improved Order
Response Capability
Confidential
WIDENED CUTTING RANGE
60KW High Power Twister Unit widens cutting
range up to 36mm thickness and achieves
TWISTER cutting quality up to 28mm thickness
Cutting Speed (mm/min)
5000
4000
3000
More than 28mm, difficult to
cut by Laser Cutting in stable
quality.
2000
1000
Gas Cutting
0
5
10
15
20
25
30
35
Mild Steel (mm)
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting
Accuracy & Quality
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
4．Lower Running
Cost
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
5． Clean & Safety
Work Environment
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
6． Easy Operation
Improved
Production
Costs
Improved Order
Response Capability
Confidential
IMPROVED RODUCTIVITY
Drastic improvement in cutting speed,
thanks to High Power Unit (60KW)
High speed cutting, 2 times faster than 6kW Laser
*5 to 10 times faster than Gas Cutting
3000
6kW Laser
2000
1000
0
60KW TWISTER
2500
1800
More than 28mm, impossible to
Laser cutting in stable
1500
1200
1000
Gas
Cutting Speed (mm/min)
3000
t16㎜
t19㎜
ｔ25㎜
ｔ28㎜
ｔ32㎜
ｔ36㎜
Confidential
IMPROVED PRODUCTIVITY
“TWISTER” Ultra Velocity Gas achieves High
Speed & High Precision Cutting
High Speed &
Vertical
“TWISTER” Gas
Arc
Gas Speed
TWISTER
Conventional
Assist Gas
Ultra-Velocity
“TWISTER” Gas
Only cutting speed
results in bevel
Cutting Speed
Confidential
IMPROVED PRODUCTIVITY
Unique technology; TORCH OIL JET
Spray non-spatter liquid in gas flow.
Adjustment for spray nozzle is unnecessary
KPCL 300A
Spray Nozzle
Spatter prevention device is PATENTED
TWISTER 60KW
Confidential
IMPROVED PRODUCTIVITY
Thanks to QUICK PIERCING,
far reduced total piercing time
Reduce air-cut time
Total one piercing time
KPCL
300A
Torch
moving
TWISTER
60KW
0
Non spatter
spray
Initial height sensing
Touch sensing
Gas flow
Non spatter jet
Torch
moving
2
4
Gas Flow
Piercing
13.5 sec
4.5 sec
-65%
6
8
10
12
14
Total Time (sec)
Confidential
IMPROVED PRODUCTIVITY
Thanks to speed up of Traverse Speed
Reduce air-cut time
TWISTER 60KW
KPCL 300A
44.7 m/min
18 m/min
25.5 m/min
40 m/min
1.8 Time Faster
18 m/min
20 m/min
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting Accuracy
& Quality
Improved
Production
Costs
4．Lower Running
Cost
5． Clean & Safety
Work Environment
6． Easy Operation
Improved Order
Response Capability
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
Thanks to Linear Guide, High Solid Carriage,
High Cutting Quality & Accuracy achieved
Dual driving
system
causes
・Pitching
・Yawing
Y axis: 2 Linear Guide
High Solid Carriage
Rail
X axis: 2 Linear Guide
Gantry Type
TWISTER TFPL Series
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
Thanks to dismounting 60KW Twister Unit,
Lightweight Y axis Carriage achieved.
Enable cutting accuracy to keep for a long time.
Unit
Lightweight &
High Solid
Carriage
Mount heavy Plasma Unit or
Laser Oscillator on Y axis Carriage
⇒ Results in early abrasion of
driving system
Gantry Type
Dismount 60KW Twister Unit
from Y axis Carriage
TWISTER 60KW
*TFPL 30KW Series mount Lightweight Unit on Y axis carriage
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
Optimized driving balance of Y axis carriage
achieves High Quality & Accuracy Cutting.
Center of Gravity
High Solid Y axis Carriage
Rack
Center of Gravity is located on
the center of rack & pinion on X axis
Linear Guide
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
Thanks to High Solid Carriage, the accuracy of
of locus and roundness of small hole at high
speed cutting, improved
Gantry Type
TFPL Series
Response time 0.1 sec
Cutting Speed
Cutting Speed
Response time 0.3 sec
In case of 16mm cutting (F=1,000mm/min)
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
The arc mode has been optimized by MAIN GAS
FLOW CONTROL. Improves cutting quality of holes(Roundness)
Reduces finish by drilling, reamer
TWISTER
Main Gas Flow
Main Gas Flow
KPCL 300A
Arc mode is modified to
match configuration
Hole
Outline
Hole
Outline
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
TWISTER GAS eliminates dross
Reduces finish process
Patent No.2689310
No.2997224
TWISTER 60KW
KPCL 300A
SS t6～t25
Ultra High
Velocity Gas
Arc
Assist Gas
Arc
Dross
ULTRA
HIGH SPEED
TWISTER GAS
LESS DROSS
( Small hole with dross )
Confidential
IMPROVED CUTTING QUALITY & ACCURACY
Thanks to ARC MARKER, enable to take
Marking and Punching in cutting process
Positioning for drilling
⇒ Punching
Positioning for welding, bending ⇒ Marking
Marking
Punching
Patent
No.2641043
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting
Accuracy & Quality
Improved
Production
Costs
4．Lower Running
Cost
5． Clean & Safety
Work Environment
6． Easy Operation
Improved Order
Response Capability
Confidential
LOWER RUNNING COST
By optimizing tip shape and inside for cooling of Electrode
results in improved Long Life of Consumables
The life of Electrode, two times longer than ever
Coolant
Optimized
Inside
Optimized
Hafnium
Section of Electrode
Accumulated Arc Time (H)
Output Currant 220A
3
2
1
0
KPCL 300A
TWISTER 60KW
Confidential
LOWER RUNNING COST
Thanks to MAIN GAS FLOW PATTER, QUICK ARC
CHANGE, the heat shock on ignition has been curbed
The life of TIPS, 1.5 - 2 times longer than ever
TWISTER 60 KW
Main Gas
Main Gas
KPCL 300A
Oxygen
Air
Cutting
Finish
Plasma Current
Time
The current overshoot
shortens Nozzle life
Start
Cutting
Finish
Time
TWISTER Current
Start
Oxygen
+
Nitrogen Air
Start
Cutting
Finish
Start
Cutting
Finish
Time
Time
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting
Accuracy & Quality
Improved
Production
Costs
4．Lower Running
Cost
5． Clean & Safety
Work Environment
6． Easy Operation
Improved Order
Response Capability
Confidential
CLEAN & SAFETY WORK ENVIRONMENT
SPATTER SHIELD COVER has greatly curbed
spatter splash during piercing
Clean working environment
KPCL 300A
TWISTER
Spatter Shield Cover
Confidential
CLEAN & SAFETY WORK ENVIRONMENT
Thanks to Push & Pull Fumes Collecting System,
prevent blowing up of Fumes.
Clean working environment
TFPL Series
KPCL 300A
Pushing
by Fan
Dust
Collector
Pulling
By Twister
Original
Dust Collector
Confidential
CLEAN & SAFETY WORK ENVIRONMENT
Thanks to Fumes Elimination Room by Damper
and Twister Original Dust Collector (2 set),
prevent blowing up of Fumes.
Clean working environment
Fumes Elimination Room by Damper
Twister
Original
Dust Collector
Twister
Original
Dust Collector
Confidential
CLEAN & SAFETY WORK ENVIRONMENT
The machine shall be stopped when interrupting
Light Sensor and colliding with Tape Switch
during cutting operation.
Light Sensor
Tape Switch
Confidential
FEATURE AND OPERATIONAL EFFECT
FEATURE
MERIT
・ High Power Unit
・ Twister Gas
・ Torch Oil Jet
・ Quick Piercing
・ High Traverse Speed
・
・
・
・
・
・ Linear Guide
・ Lightweight Carriage
・ Auto Gas Control
・
・
Main Gas Flow
Twister Gas Flow
・ Arc Marker
・
・
・
・ High Current Electrode ・
・ Gas Flow Pattern
・
・ Quick Arc Change
・
・ Spatter Shield
・
・ Push & Pull Fume Collecting System・
・ Fumes Elimination Room by Damper・
・ Light Sensor
・
・ Cantilever Frame
・ Technology Table
・ Life Manager
・
・
・
EFFECT
1．Widened
Cutting Range
2． Improved
Productivity
3． Improved
Cutting
Accuracy & Quality
Improved
Production
Costs
4．Lower Running
Cost
5． Clean & Safety
Work Environment
6． Easy Operation
Improved Order
Response Capability
Confidential
EASY OPERATION
Cantilever Flame enables operator to take
easy of access to cutting table
Easy of access for mounting material sheet,
picking work, dismounting scrap
Gantry Frame
1 access
And difficult of
of access, because
of Rails
TFPL Series
3 access
Confidential
EASY OPERATION
Optimal work conditions automatically set
by TECHNOLOGY TABLE
Troublesome adjustment is unnecessary
TWISTER
KPCL 300A
・GAS
Flow ①②③④
Pressure ⑤⑥
Type ⑦
⑦
・CURRENT
・CUT SPEED
・CUT HEIGHT
・PIERCE HEIGHT
・OFFSET
・PILOT CURRENT ⑧
⑥
⑤
Adjustment
8 places
①
②
③ ④
材料選択
画面
A
A
A
A
A
A
A
A
A
A
21
22
23
24
25
26
27
28
29
30
材質
板厚
（ ㎜）
ﾉｽﾞﾙ
ｶﾞｽ 上昇量
（ ㎜）
SS4 0 0 1 2 .0
1 .7
SS4 0 0 1 6 .0
1 .7
SS4 0画面No．
0 1 9 .0 ： A12.75
SS4 0 0 2 2 .0
1 .7
材質
： SS4 0 0
SS4 0 0 2 5 .0
1 .7
板厚
： 2 5 .0
SS4 0 0 2 8 .0
1 .7
Without
Adjustment
ﾉｽﾞﾙ径
： 1 .7
A 21
電流
速度
切断高さ
ﾋﾟｱｽ高さ
補正番号
ｱｼｽﾄ流量
ﾒｲﾝｶﾞｽ
混合窒素
1
1
1
1
1
1
T0
220
1500
4 .0
2 .5
17
30
0 .6 5
5
速度
ﾄﾞｩｴﾙ
（ se c ）
5000
5000
5000
5000
5000
5000
1 .0
1 .5
1 .5
1 .5
2 .0
2 .0
5 .0
7 .0
8 .0
1 0 .0
1 2 .0
1 2 .0
T1
220
1200
4 .0
2 .5
18
30
0 .6 5
5
T2
220
1000
4 .0
2 .5
18
25
0 .6 5
5
ﾉﾝ
ｽﾊﾟｯ ﾀ
有効
有効
有効
有効
有効
有効
T3
220
1000
4 .0
2 .5
19
20
0 .6 5
5
Confidential
EASY OPERATION
LIFE MANAGER manages consumables life
Easy to make a decision for replacement
LIFE MANAGER DISPLAY
Size of Nozzle
Rate of Usage
0
0．6
0．8
1．1
1．3
25
50
75
100
125
**********************************
*************
Arc Time
Piercing Time
Reset Time
Alarm
：
：
1．7
2．2
50%
： 0001h 13m 18s
： 148 Times
： 04/07/11 12：34：56
： Invalid Valid （100%）
Note: Manages the life of Electrode & Nozzle only
BENEFIT OF TFPL 60KW
In comparison with
6KW Laser & Gas Cutting
Confidential
NESTED PARTS FOR SIMULATION
6,100 mm
Thickness
6 mm
9 mm
12 mm
16 mm
19 mm
22 mm
25 mm
28 mm
Yield Weight
705 kg
1,057kg
1,409kg
1,879kg
2,231kg
2,583kg
2,936kg
3,288kg
Total Parts No.: 73
Total Cutting Length：137.6m
Confidential
WIDENED CUTTING RANGE
60KW High Power Twister Unit widens cutting
range up to 36mm thickness and achieves
TWISTER cutting quality up to 28mm thickness
Cutting Speed (mm/min)
5000
4000
3000
More than 28mm, difficult to
cut by Laser Cutting in stable
quality.
2000
1000
Gas Cutting
0
5
10
15
20
25
30
35
Mild Steel (mm)
Confidential
PRODUTION TIME PER 1 SHEET: 19mm
577
300
Picking, Dismounting
Setting
Air Cutting
240
Production Time (min)
20
10
16
82% Reduction
43% Reduction
188
20
10
16
180
120
Cutting
F330
20
417
120
10
Cutting
F1200
Cutting
F1500: 150A
105
144
60
Preheating
Piercing
143
Piercing
29
0
Gas Cutting
10
6KW Laser
In case of 200A
F2600, 63min
Total 78 min
4
TWISTER 60KW
Confidential
RUNNING COST PER 1 SHEET: 19mm
12,500
11,532
Running Cost (JPY)
521
72 Consumables
Fuel Gas
10,000
11,914
Maintenance
charge
1,699
102
1,174
163
2,876
7,500
1,142
4,870
395
7,651
5,000
58% Reduction
Electricity at idling
Gas
In comparison with Laser
325
Consumables
Nozzle life
1,648
600 piercing time
2,500
5,537
1,160
423
49
57
77
Electricity at air cut
1,703
1,643
0
Oxygen / Nitrogen
Electricity at cutting
Gas Cutting
6KW Laser
Precondition: 1)Machine operating rate 75% 2) Gas cutting by single torch
TWISTER 60KW
Confidential
PRODUCTION TIME PER 1 TON
9.5
8
6.3
6
5.4
4.7
0
4.0
3.7
3.5
2.0
6
1.7
1.7
1.1
0.9
9
12
1.4
0.9
0.8
16
1.7
1.6
1.5
1.4
1.2
TWISTER
2
4.3
6KW Laser
4
Gas Cutting
Production Time (hour)
10
19
22
0.7
0.7
0.6
25
28
Thickness(mm)
Confidential
PRODUCTION COST PER 1 TON
50
45.3
30.2
30
25.6
23.4
19.8
18.7
17.6
14.2
12.5
0
6
7.1
12.3
10.6
7.1
5.8
TWISTER
10
21.3
6KW Laser
20
Gas Cutting
Production Cost (JPY 1,000)
40
9
12
10.6
5.3
16
5.8
5.6
19
12.3
11.1
22
Precondition: 1) Production Cost = Running Cost + Operator Charge (Cutting, Setting, Dismounting)
2) Machine operating rate 75% 3) Gas Cutting by single torch
12.6
6.3
6.1
25
28
Thickness (mm)
Confidential
BENEFIT
100 ton / month
Thickness(mm)
Material Weight (ton)
Cutting Sheet
Gas
Cutting
Material Weight
ton
Production Time
hour
Material Cost
50
Total Cutting Cost
Operator Charge
3
JPY 1000/h
Production Cost
Sales
75 JPY/kg
Profit per Month
Profit per Year
12
10%
10
7.0
16
25%
25
13.0
82
-66
354
5,354
1,397
6,751
5,000
444
5,444
444
5,888
261
5,261
245
5,506
-183
7,500
1,612
19,347
80,000
4.1
7,500
1,994
23,929
50,000
2.1
4,095
7,500
749
8,990
Year
Reduction of Investment: JPY30 million
Additional Annual Profit: JPY4.6 million
19
25%
25
11.0
22
20%
20
8.0
25
15%
15
5.0
Benefit
466
Initial Investment
Return on Investment
60KW
TWISTER
9
5%
5
5.0
100
148
JPY/kg
Cutting Cost
6KW
Laser
6
0%
0
0.0
vs 6KW Laser
-199
-382
382
4,583
-30,000
TOTAL BENEFIT: JPY34.6 million
PRECONDITION
Utility
Electricity
Gas
20 JPY/kW・H
TWISTER
Oxygen / Nitrogen
Liquid O2 for Laser
Laser Gas
Maintenance
TWISTER
Life fluctuates
according to each
customer
Maintenance
Nozzle
Electrode
Shielding Cap
Ring
200 JPY/m3
150 JPY/m3
25,000 JPY/7m3
600,000 JPY/Year
1800
JPY/PC.
2800
2,000 JPY/PC.
1,200 JPY/PC.
5KW Laser Maintenance
1,500,000 JPY/Year
Consumption Electricity (Main body with Dust Collector)
6KW Laser Cutting
90 kW
Idling
44 kW
TWISTER
Cutting
36/51/57/67 kW
Idling
6.2 kW
Operator Cost
Unit Charge
3,000 JPY/H
7m3 Cylinder
Est. JPY180/kg
Filter of Dust Collector, Crossbar of Table
t6：700 t9：650
t12：700 t16：650 ｔ19：600 t22,25：200
Life is x 4 times than Nozzle & Electrode
Life is x 10 times than Nozzle &
Electrode.
6,9㎜/12㎜/16,19㎜/22,25㎜