Page 21 - MetalForming July 2011

Laser-cut parts move to a robotic press brake for forming, and then are restocked and ready to move to assembly lines where welders (above) build specialty beds for pickup trucks.
The HyperGear, which runs nearly 24/7 at the shop, is fed by a 10-drawer FMS that accommodates a host of materials, material thicknesses and sheet dimensions. And Portenier points to additional automation features opti- mizing the system’s productivity.
“We opted for all of the extra automation features available,” he says, “such as an automatic torch changer and automatic nozzle changer. We also added a nitrogen generator to eliminate any oxide layers on cut edges.”
Unclamped
Another significant advantage of the HyperGear enjoyed by Bradford Built: It can process material unclamped, since the machine moves the laser rather than the worktable. This is a critical factor in how the shop runs its material.
“Rather than cutting deck plate material tread-side up,” says Portenier, “we can cut it tread-side down and use suction-cup automated material-han- dling systems to move parts from the laser to the press brakes.”
the firm struggled to consistently gen- erate perfectly round, accurately posi- tioned holes for assembly of mating parts, or holes that could be used for self-tapping screws. For these reasons, it turned to laser cutting.
The shop first installed one hybrid- style 2D laser-cutting system, a Mazak Super Turbo-X MK II Series machine, which cured its hole-tolerance issues. Then, as production levels increased, additional systems were needed to keep up with demand. Company co- owners Brad Portenier and his wife Donna added four more Mazak Super Turbo-X MK II laser-cutting systems, taking the shop’s laser count to five. Four of the machines became part of an FMS, while the shop kept one as a standalone for custom jobs.
Ramped Up
In the fall of 2010, Bradford Built made its next significant advancement in laser cutting, investing in an extremely fast linear-motor-driven, fully automated Mazak HyperGear FMS. The FMS features a two-pallet changer, and full hybrid linear motors in all five axes for 3G acceleration, high- speed cutting and optimum position- ing accuracy—±0.0004 in. Its work envelope: 19.7 by 19.7 in. x and y axes by 3.94 in. z axis.
“We ramped up our rapid-traverse capability to 5000 in./min. with the HyperGear, says Portenier, “and now that one machine produces the same amount of work we were getting out of our four older systems combined, in a shorter amount of time.”
Vac-Con manufactures machines for sewer flushing and cleaning, as well as industrial vacuuming and hydro-excava- tion machines. The firm fabricates tons of steel plate, from 20 gauge to 2.5 in. thick.
Vac-Con, Green Cove Springs, FL, manufactures sewer-cleaning and excavating equipment used by municipalities and contractors across North and South America, the Middle East and Europe. As such, the firm fabricates tons of steel plate, from 20 gauge to 2.5 in. thick.
In 2007, Vac-Con’s management team decided to add capacity to its
fabrication shop, outfitted at the time with a pair of large plasma-cutting cen- ters and a laser-cutting center. After attending trade shows and conduct- ing copious research, Vac-Con pur- chased a Platino 2D laser-cutting sys- tem from Prima North America, Chicopee, MA. Included is a 10-shelf TowerServer automated material-han- dling system.
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MetalForming/July 2011 19
Laser Line Spurs Productivity Gain