AMADA’s EML 2515 AJ proves innovation has tangible results
The EML 2515 AJ is a laser/punch combination product from AMADA that takes fabricators up to a new level in multiple ways. First, the capacity of 33 tons is 50 percent higher than others in the laser/punch line. Second, the speed increases to 500 HPM on 1” centers, or 1,850 HPM in marking mode. Third, the AC Servo Direct Twin Drive System (two AC servo motors directly connected to the ram through an eccentric shaft) generates three-times-higher standard torque and five-times-higher starting torque than conventional servo motors.
There are other advances in this machine, and we will explore them. First, here is more information on one of the ways this machine brings more speed and power—and with more efficiency and less operating costs.
The twin servo direct drive system
The EML 2515 AJ’s twin servo drive is responsible for the high hit rates mentioned above. Additionally, it is responsible for a faster response, shorter strokes, improved positioning accuracy, and reduced electrical consumption. The secret to the power savings is that the drive system uses regenerative braking to replenish electrical power to the capacitors in the system. In fact, this capability results in a 60% reduction in power consumption per hit when compared to hydraulic machines.
The running cost of a sheet is 45% to 75% less than the same sheet on comparable hydraulic equipment. The lower costs combined with the higher hit rate is demonstrated in cost per part. The fabricator’s savings can be measured with a timer and a balance sheet.
Higher capacity turret
The EML 2515 AJ features a Multi-Purpose Turret like the LC 2515 C1 AJ, but the capacity is larger, 55 stations vs. 44, respectively. The EML 2515 AJ’s turret features four auto-index stations (two of the latter are 1 ¼”, and two are 4 ½”). Four built-in tapping stations are also built in (see tapping photos at Figure 1 and Figure 2) and utilize the auto-index mechanism as well as the AMADA “drop-in” tapping tools. The tapping stations also work with standard 1 ¼” punches and dies. If a tap break occurs, a special die detects it and will stop the machine.
The turret is 4.7” thick, thick enough to fully guide the AMADA long body tooling and thus ensure alignment of tool and die. Because of the alignment, maintenance is minimized, and tool life is extended.
Time and unnecessary steps are reduced because the system uses AMADA’s Triple Track design, which provides a high tooling capacity without the hassle of some other systems that are based on multi-tool holders. Using Triple Track, split-second tool selection is possible between adjacent tracks. Individual tools can be changed in seconds without disassembly. An advanced pneumatic striker system, a high-powered AC motor, and bi-directional turret rotation mean that rapid indexing to any tool is the norm and saves time and ultimately, money.
One standard item that is shared among AMADA laser/punch combination family members is the power vacuum die system for ½” and 1 ¼” stations (see Figure 3). This system addresses the problem of slug pull by using the venturi effect to suck slugs through the die. A side benefit of this system is that the punch can travel a shorter distance into the die to ensure the slug is forced down. This positively affects tool life and yields higher hit rates. (It requires the use of Power Vacuum Dies.)
New designs, fewer operations
Because of the capabilities built into the EML 2515 AJ, fabricators can help customers improve their product designs for savings in production costs. A few examples:
- Rather than pushing operations further downstream, fabricators can use solutions like the lance clip (see Figure 4) to create a corner that locks together during the bending process—needing no rivets or spot welding to hold it together.
- The EML 2515 AJ can be used in thread forming operations (see Figure 5), again bypassing the need for secondary operations—no more passing the work forward.
- A Punch & Form option (see Figure 6) allows you to form ridges, special louvers, etc. utilizing a forming cylinder that is underneath the material. The die in this case is on top and as the work is held down so that the die is ready for the
punch. The bottom forming cylinder acts and the form is completed from the bottom up. (An example of the type of louvers you can create with this system is shown in Figure 7.)
The laser and its role
The laser in the laser/punch combo brings much to the equation. It does everything that a punch cannot, including process an infinite number of shapes and sizes. The combination of the two processes really delivers on the promise of less time and less cost. Each machine does what it does best, leaving the rest to its respective partner. The two processes are controlled on the same AMNC hardware, and on the same controller software. There is no need to learn two families of hardware and software.
Some of the main features of the 3kW laser include:
- Automatic focus control
- Auto scrap removal
- A four-station automatic nozzle changer
- Auto cutting plate cleaning
- A vast cutting data library for fast setups
- A capacitive, non-contact cutting head system to avoid contact with material
A built-in camera (the V-Monitor system) records and stores program execution by the laser cutter. This can be monitored on the machine control and recalled later to gain more insight into an action. The system features an alarm history logging function that records video when an alarm is triggered. It is also accessible remotely for determining the cause of an anomaly or to view machine operation.
Additionally, every AMADA laser/punch combination product includes a table cabin for operator protection. The moving sheet is covered with a solid table cabin during laser cutting for complete protection from laser reflection. It can be moved forward or backward for accessing areas of the table.
Automation options
The ASR 3015 NTK (see Figure 8) is AMADA’s automation solution that provides customized tower and shelf configurations to meet individual needs, with the ability to store a variety of material types and thicknesses. The gains of “masked time” are evident because sorted parts can be removed from the tower while the machine is processing. Automation also means consistent runtimes, from material to part.
The Punch & Die Changer (PDC, see Figure 9) is another major option for the EML 2515 AJ. It automatically replaces tools, allowing the machine to run continuously. The control can load the next program and change the tools while the laser processes the current program, again saving time with concurrent action. The PDC features a 220-station automatic punch & die changer, with two dies for each punch (440 dies total). Tools can be exchanged in 20 seconds per tool.
Like other laser/punch combinations from AMADA, this one is network ready and fully manageable via the AMADA IIoT software solution called Influent. It holds a place of excellence in the AMADA family of combination products. And the level of automation, while ample in the base product, is only more effective when the options are part of the equation.
