TECHNICAL DESCRIPTION FOR AN
ULTRASONIC
CNC CARPET CUTTING EQUIPMENT
MODEL US-15 50’ STATIC
PRESENTED BY:
AMERICAN GFM CORPORATION
1200 CAVALIER BLVD.
CHESAPEAKE, VA. 23323
April 25, 2013
CONTENTS
1. INTRODUCTION 3
2. SPECIFICATION 3
3. MACHINE DESCRIPTION 6
3.1. Machine Structure 6
3.2. Work Support 6
3.3. Cutting Head 6
3.4. X-Axis 8
3.5. Y-Axis 8
3.6. Z-Axis and C-Axis 8
3.7. Machine Finish and Guarding 9
3.8. Control System 9
4. OPTIONS 15
4.1. Pattern Identification 15
4.2. NS2-Software 15
1. INTRODUCTION
AGFM is providing the following proposal for a CNC controlled system AGFM model US--15 for prepregs, technical textiles or similar material. The system described is based on the ultrasonic cutting technology which has a proven track record in the various industries.
2. SPECIFICATION
Work envelope static table:
Length (X) 600”
Width (Y) 72”
Z-axis-stroke max. 3.14”
Note: Z-Axis clearance is reduced if automated dispensing is used. A material clamping device is located under gantry in order to clamp material to belt for material advance.
C-axis-stroke n x 360°
Cutting speed max. 2400 inches/min
Acceleration/deceleration max. 2.5 m/sec²
Accuracy:
Absolute positioning accuracy ± 0.012”
Repeatability ± 0.006”
Profiling accuracy (in Mylar) ± 0.02”
(The accuracies specified assume a draught-free working
environment within a temperature range of 18 - 22 ° C.)
Position feed back system encoders, directly on the motor
Supply 400 V ± 10 %,
3 phase, 50 Hz
Cutting machine appr. 12 kVA
Vacuum aggregate star-delta start,
1 x 29 kVA
Cutting head:
Ultrasonic generator GFM-Ultrasonic Technology
Output power max. 800 Watt
Frequency 20 000 Hz
3. MACHINE DESCRIPTION
3.1. Machine Structure
The machine frame is a rigid welded design of hollow steel profiles.
Special foundations are not required, as the machine is positioned by its own leveling feet on a solid concrete floor.
3.2. Work Support
The work support system consists of a static cutting table with a non-metallic vyon cutting surface. The cutting surface is in connection to the vacuum chamber, thus allowing vacuum hold down of the workpiece.
The vacuum table has multiple individually controlled vacuum zones.
The vacuum aggregate is supplied with the machine. Because of the noise level the vacuum aggregate should be located in a separate room and the exhaust should be to the outside of the building.
3.3. Cutting Head
The machine will be supplied with a single ultrasonic knife cutting head, which together with suitable solid carbide blades is capable of cutting various materials. The achievable cutting quality has to be checked prior a contract by performing cutting tests at AGFM. The results of such cutting tests are part of the contract.
3.3.1 Principles of Ultrasonic Operation
Ultrasonic energy is simple mechanical vibratory energy which by definition operates beyond audible sound. This means the broad range of frequencies which are beyond 18000 Hz, the generally accepted upper threshold of human hearing. During activation large amounts of power/energy are imparted to a work-piece without large displacements or amounts of force.
Generating ultrasonic energy starts with conversion of standard electrical frequency to 20000 Hz by a solid state power supply. The high frequency electrical energy is conducted to a piezoelectric transducer (converter) for conversion to unidirectional mechanical vibrations. These vibrations are in turn amplified by an amplitude transformer (booster) and/or the acoustic tool (sonotrode) before being applied to a work-piece. The maximum available amplitude (blade stroke) is determined by the horn and/or booster design.
The operating amplitude of a stack (converter, booster/sonotrode assembly) is controlled and regulated by adjustments in the power supply. Ultrasonic vibratory energy is then employed to activate the cutting medium (blade) approximately twenty thousand times per second.
The ultrasonic vibrations significantly reduce friction between the blade and the material being cut for faster, easier, more precise cutting.
3.4. X-Axis
The X-axis is the movement of the gantry along the length of the machine. The gantry is able to "park" outside the cutting area to allow free access for material to load and unload.
The drive along the machine is by racks on the sides of the base and pinions on both ends of the crossbeam. The pinions are driven by separate ACservomotor/ encoder units linked together electronically to prevent crabbing.
3.5. Y-Axis
The Y-axis is the movement of a carriage along the crossbeam of the gantry carrying the ultrasonic knife cutting head. The carriage runs on linear bearings and is driven by one timing belt unit powered by an AC-servomotor/encoder unit.
3.6. Z-Axis and C-Axis
The Z-axis is the vertical movement of the cutting tool. The position of the cutting blade tip relative to the table top is automatically measured and this in combination with the low amplitude of the cutting blade's vibrations makes sure that on one hand during cutting the table top surface will only be scratched and that on the other hand cutting blades can be refurbished.
The C-axis which maintains tangentiallity to the cutting path is belt driven from an AC-servomotor with encoder feedback and is vector controlled from the CNC and associated electronics.
3.7. Machine Finish and Guarding
The machine is designed to comply with OSHA.
AGFM's experience has shown that laser safety scanners to prevent access to the cutting zone and emergency stop buttons are sufficient.
Additional safety precautions can in detail be discussed with the customer and/or his safety supervisor and can be offered as an option.
Unless otherwise specified, the machine will be supplied in zinc-yellow (RAL1018)/brilliant-blue (RAL 5007). Vacuum aggregates, motors and standard sub-supplied machine parts are delivered in the standard color of the sub-supplier. Aluminum and galvanized parts will be not painted.
3.8. Control System
The machine will be supplied with a computer numerical control, type GFM "CNC 6000".
The CNC-6000 is a powerful system which is especially designed for optimal support of the ultrasonic cutting technology. The control allows to operate an ultrasonic cutting machine at significantly higher speeds in comparison to commercially available control systems.
The control is offered with five axes (X1, X2, Y, Z and C).
System Architecture:
- Man-machine interface, based on an integrated personal computer with 15"-colour TFT-display running under Windows 7 Ultimate
- Industrial hard disc-drive with high capacity for storage of part programs, and DVD R/W-drive
- Modern operators interface with operators guidance and online-help
- Highly-reliable real-time control system based on VME-bus with standard components of high quality
- Integrated Programmable logic interface (PLI)
- Standard Network Interface (Ethernet, TCP/IP, …)
General control functions of the CNC-6000:
- Automatic speed optimization:
Calculation of the maximal achievable machining speed with automatic consideration of velocity and acceleration limits in all axes and with consideration of user-defined feed rates. (feed rates may be programmed but need not to be programmed).
This feature allows a machine to operate at significantly higher speed in comparison to systems equipped with commercially control systems.
- Unlimited look-ahead
- Bell-shaped velocity-profile for highest contour accuracy or trapezoidal velocity-profile for time optimal operation
- G-Code functions according to DIN 66025
- Automatic check of complete part program before execution
- Download of part programs via network interface
- “Select“-Function for graphical selection of single parts out of a complete nest and for automatic generation of a corresponding part program
- Effective support for program-restart after interruption
- Graphical display of part programs (programmed path of tool-tip is displayed in XY-plane with additional information)
- Graphical online-display of actual machining-path
- Software support for “Laser Part Alignment” (translation and rotation of part-programs in XY-plane to fit to the actual position of a workpiece)
- Dynamic supervision of machining-range
- Continuous supervision of all machine movements
- Software-support for optional peripheral-devices like label-printers, inkjets, inkjet-markers, pen-markers, barcode-scanners, digitizing-equipment, …
- Automatic recording of Production-logfile
(in csv-format, compatible to standard programs like MS-Excel)
- Part History software (as an option)
- Automatic recording of Error-logfile
- High-precision axis-calibration (screw-error compensation)
- Axis-backlash compensation
- Advanced gantry-control for X1-X2 axis
- Software-Support for table-mapping
- Powerful servo-controller (cycle-time less than 1 ms)
Control functions for ultrasonic-cutting:
- Linear, circular or spline interpolation in XY-plane with simultaneous automatic tangential alignment of the knife angle (knife-alignment needs not to be considered at program generation)
- Automatic vertical positioning of the knife
- Technology-functions for ultrasonic-cutting like automatic creation of overcuts at corners, smoothing-radii, adjustment of cutting-direction, enlargement of parts, mirroring of parts, …
- Automatic measurement and vertical alignment of knife
- Automatic measurement and angular alignment of knife
- Programmable check of knife-length
- Programmable amplitude for ultrasonic-system
- Powerful features for diagnoses of process
All files needed to operate the machine are stored safely on hard disc, so that loss of power to the machine will not cause any loss of memory.
Complete electrics are of European origin according to the EN-standards.
3.9 Support for remote diagnosis
The machine will be equipped with a secure software for remote diagnosis. For the connection to the machine we suggest to use internet/VPN. If necessary GFM can also provide a modem for remote diagnosis via telephone line (which is less effective).
3.10 Network adapter
For integration into the customer’s network the machine control will provide a network port (Ethernet, RJ-45) for “mounting” of drives within the network. In case of an order details to the integration of the machine into the network shall be clarified with the customer.
4. OPTIONS
The machine can be upgraded with optional equipment which will be discussed in detail with the customer to obtain the best and most suitable system.
4.1. Pattern Identification
The machine can be equipped with either a labeler or inkjet printer. In the case of the labeler, the system will print and deposit an self-adhesive alphanumeric barcode label.
The labeler is mounted on a separate undriven slide on the cutting cross beam and when needed will automatically be coupled to the carriage with the ultrasonic cutting head.
The inkjet is also gantry mounted and will print alphanumeric characters on coversheet (keytone based ink) or directly on the prepreg material (pigmented ink). If the ink is placed directly on the prepreg, the customer must speicfy the acceptable ink type. A special pigmented inkjet is required for this application.
4.2. NS2-Software
The nesting system includes the software to input and import data from a CADsystem, to manipulate individual ply shapes into a nest and to process this information into commands suitable for the CNC of the cutting machine.
It thus provides full integration of design, production planning and manufacturing. The nesting system links definition on and documentation related to parts needed with the cutting process, providing optimal utilization of material and man-hours resulting in reduction of production waste, production time and thus cost.
Generally the GFM nesting package consists of several modules to create part programs - using CAD-data and order lists - in a way to make optimal use of GFM-Ultrasonic cutting machines.
The modules included in this option are, the Preprocessor module, the Automatic and Interactive Nesting module and the Postprocessor module for installation on a customers PC with Windows operating system.
For information on the nesting system please see attached description (appendix).
2