AMADA’s most advanced laser/punch combination: the ACIES 2515T AJ
While all AMADA’s laser/punch combination products have that distinctive AMADA look, the ACIES 2515T AJ carries with it some important distinctions in capabilities. This 33-ton rated laser/punch is unique in that it essentially guarantees a scratch-free surface because of the design of its ZR turret puts it below the brush table. ACIES 2515T AJ also offers one of the most automated machine tools in the market today. Additionally, the capacity and the design for tool changing means continuous operation and minimal downtime.
Scratches don’t exist
It is a victory when engineers can design a problem away. AMADA engineers have a big win with the ACIES 2515T AJ and the problem of scratched material. How is this possible? The ZR turret design (see Figure 1) for this machine has the lower turret recessed under the brush table, disallowing the possibility of scratches.
The selected die is rises through an adjustable window in the brush table, and the die height is compensated for grinding; no shimming is necessary. Down forming is now possible with no concerns about forms catching in the lower turret. Also, forming tools can be raised and lowered while material moves into position—again avoiding the possibility of scratching. Two other key points about this design: a new track structure takes away restrictions on tool location (inner/outer track or forming tool location); and this system offers the smallest tool dead zone. When tools are not in use, they are retracted below the brush table, and are raised only when in punching position.
High-capacity tooling system
A unique design once again increases the performance of the ACIES 2515T AJ. The system features a high-capacity tool storage unit (see Figure 2) that houses 300 tools, and two dies for each tool (thus up to 600 of them). Tools are stored and automatically loaded into the turret. A buffer turret (see Figure 3) with 24 spots interfaces with the auto-loader, and allows for rapid insertion into the ZR turret.
Because the tools are identified and their use is noted, any tool that reaches its hit count is automatically replaced with a backup tool for continuous operation. Tools are changed while the system processes parts. These changes occur during laser cutting/processing. Additionally, up to seven tapping tools can be rotated into the four existing tapping stations.
Tool ID system
Speaking of the tool set used with this machine, AMADA has laser-etched QR codes (see Figure 4) on the side of each tool. These identify each specific punch and die, which are tracked for number of hits (compared to the duty cycle), sharpening amount, and remaining life. The system will know if a tool or die is out of place before proceeding further with a job—even the tool angle and appropriate die selections are confirmed upon installation.
AC servo direct twin drive
ACIES 2515T AJ features an AC servo direct twin drive system (see Figure 5), which consists of two AC srvo motors directly connected to the ram through an eccentric shaft. The system yields three times the torque and five times the starting torque than conventional servo motors. In line with other power saving features in the ACIES 2515T AJ, the servo drive includes a power storage device that stores energy at the end of each stroke for use in starting the next cycle. The result is about a 60% reduction in power consumption per hit when compared to conventional hydraulic machines. Power consumption does not rise as hit rate increases, so the running cost per processed sheet can save fabricators anywhere from 45% to 75% of the cost of sheets processed on comparable hydraulic turret punch presses.
Other advantages come with the ACIES 2515T AJ because of this advanced drive system:
- Fast response
- Shortest stroke required
- High stroke rate
- Improved positioning accuracy
- No hydraulics, therefore no sensitivity from hydraulic oil contamination and no oil requirements
- With a 0.197” stroke, and a 1” feed, it offers 430 HPM (1,850 HPM in marking mode)
The flexibility and speed of fiber
The laser cutter that is included with the ACIES 2515T AJ is a 3 kW fiber laser model that is tried and true, and engineered by AMADA. A number of technologies make the process easier, more continuous, and better managed.
The first of these technologies is the V-Monitor camera technology. It is located inside the laser cabin to record and store program execution. Process details (certain types of cuts, for example) can be monitored, stored, and called up later. If something occurs to trigger an alarm, the alarm triggers a video recording for later viewing. This is invaluable information in the case of service personnel trying to diagnose a problem. These videos can be viewed over the network as well as at the AMNC control. In addition, a table cabin (see Figure 6) protects the operator from laser reflection by sealing the moving sheet inside. It can be moved forward or backward for accessing clamps or other areas of the table. When manually loading material, the carriage will move forward under the table cabin, exposing the clamps for easy loading of material.
The laser system also features automatic focus control, a four-station automatic nozzle changer, and auto-conveyance of laser scrap. A cutting data library also automates the setup of cuts based on material type and thickness.
Automation
The ACIES 2515T AJ already has many built-in features that represent system automation. However, there are a number of additional ways to automate the system, such as a parts conveyor, simple sheet load/unload devices, multi-shelf material towers (for example the ASR NTK material racking system), and automatic part picking devices (see Figure 7). Some or all of these solutions help to prepare fabricators for the present and future of automated fabricating.
