DRUPE AUTOMATION SIMPLIFIED

Automation in Cutting & Welding Cutting and Welding Solutions Automation & Robotics Heavy Engineering Fabrication

CNC Oxyfuel Plasma Cutting Machine (Jambo)

CNC Oxyfuel Plasma Cutting Machine (Hi-Cut)

7th Axis for Robot

Laser Cutting Machine

Heavy Engineering

Servo Column and Boom

Servo Positioner

Gantry for Welding

1

About Us Drupe is a young company with a dream for worldwide operations including sales and service network with a high standard product quality and delivery. The country is witnessing rapid advance in new millennium in various fields. The development in mechatronics field stands out for transforming the pace of industry from the dumped technology to next century. “Automation Solutions for Demanding Conditions” The demand of products in the country thus growing at rapid pace. To contribute to the industry, DRUPE stepped in to provide local manufacturing. With assembly base, Local Service and High quality are made with indigenous manufacturing facilities, upto international standards at affordable prices which is the hallmark of our company. Drupe tends to become an influential world player in development, design and use of linear axis, gantry and Robotic solutions for factory automation and Foundry Machineries.

Drupe Attitude n We sell

satisfaction, not just machines.

n Every machine,

system, product and spares must deliver and satisfy what it was

purchased for. n The Customer

must recover his investment very fast.

n Satisfy the

customers to such an extent that they unknowingly become our sales promoters.

n Distributors

n Our most

are our arteries, without them we are lifeless.

important advisor is the actual floor level operator using our machine.

2

Introduction Do you need a cutting tool for occasional repair and maintenance work? Have you recently embarked on a new project that requires higher cutting volumes? Or, are you looking for a new alternative to your current mechanical saw? All of these scenarios provide great reasons to investigate plasma cutting. With the cost of machines on the decline, smaller-sized, portable machines flooding the market and technology offering increased benefits and easier usage -- it may be time to take a serious look at plasma for your cutting applications. The benefits of plasma cutting include ease of use, higher quality cuts and faster travel speeds.

Oxyfuel Cutting In this method of metal cutting, a torch is used to heat metal to kindling temperature. The stream of oxygen that is trained on the metal reacts with the metal in a chemical process, oxidizing the steel and blowing it away to form the cut. Heat is actually a byproduct of the process. Oxyfuel cutting is primarily used for cutting mild steel in thicknesses from 3/8 in. to 12 in. The technology is not considered practical for aluminum or stainless steel, but can be used for titanium. The technology has a very large heat-affected zone when compared to the other metal cutting technologies and is not as accurate, typically ± 1.6 to ±3.175. Although careful process control can result in much tighter tolerance parameters. The technology has improved greatly in recent years with technical advancements. High-speed torches have resulted in cutting speeds that are 20 percent faster the previous generations'. Height-sensing probes and CNC gas regulation keep Oxyfuel cutting operations running efficiently.

Plasma Cutting When a gas is heated to an extremely high temperature, it ionizes. At this point, the electrically conductive, ionized gas can be called plasma. When a high-velocity jet of plasma is delivered to a metal workpiece, an electrical arc is delivered with it. The heat of the arc melts the metal to be cut, and the stream of ionized gas blows the molten metal away. For the sake of this comparison, high-density plasma systems, also known as high-definition systems, were used. This technology produces a much better cut on metal because the latest nozzle technology dramatically constricts the arc to deliver much more energy density. Plasma cutting can yield a variety of cutting speeds and quality, depending on the material to be cut, the material thickness, the quality of the cut desired, and the cutting speed required. The ability to dial in the machine's amperage, from 30 to 260, allows for this flexibility. A simple rule of thumb: The more power you throw at it, the faster you will plasma-cut the metal. Cutting speeds are less affected by material thickness than other processes. In fact, plasma cutting is effective for aluminum, particularly thick aluminum. Because plasma cutting is not as precise as other metal cutting technologies, it may not be able to deliver a series of functional holes. The wider kerf width affects part definition. That's why the technology is often paired with punching tooling. However, high-density plasma cutting can yield tolerances of ± 0.25mm to ±0.3mm in closely monitored processes.

3

Introduction to Plasma What is Plasma? The Fourth State of Matter One common description of plasma is to describe it as the fourth state of matter. We normally think of the three states of matter as solid, liquid and gas. For a common element, water, these three states are ice, water and steam. The difference between these states relates to their energy levels. When we add energy in the form of heat to ice, the ice melts and forms water. When we add more energy, the water vaporizes into hydrogen and oxygen, in the form of steam. By adding more energy to steam these gases become ionized. This ionization process causes the gas to become electrically conductive. This electrically conductive, ionized gas is called a plasma

How Plasma Cuts Through Metal The plasma cutting process, as used in the cutting of electrically conductive metals, utilizes this electrically conductive gas to transfer energy from an electrical power source through a plasma cutting torch to the material being cut. The basic plasma arc cutting system consists of a power supply, an arc starting circuit and a torch. These system components provide the electrical energy, ionization capability and process control that is necessary to produce high quality, highly productive cuts on a variety of different materials. The power supply is a constant current DC power source. The open circuit voltage is typically in the range of 240 to 400 VDC. The output current (amperage) of the power supply determines the speed and cut thickness capability of the system. The main function of the power supply is to provide the correct energy to maintain the plasma arc after ionization. The arc starting circuit is a high frequency generator circuit that produces an AC voltage of 5,000 to 10,000 volts at approximately 2 megahertz. This voltage is used to create a high intensity arc inside the torch to ionize the gas, thereby producing the plasma. The Torch serves as the holder for the consumable nozzle and electrode, and provides cooling (either gas or water) to these parts. The nozzle and electrode constrict and maintain the plasma jet.

Sequence of Operating a Plasma Cutter The power source and arc starter circuit are connected to the torch via interconnecting leads and cables. These leads and cables supply the proper gas flow, electrical current flow and high frequency to the torch to start and maintain the process. 1. A start input signal is sent to the power supply. This simultaneously activates the open circuit voltage and the gas flow to the torch (see Figure 2). Open circuit voltage can be measured from the electrode (-) to the nozzle (+). Notice that the nozzle is connected to positive in the power supply through a resistor and a relay (pilot arc relay), while the metal to be cut (workpiece) is connected directly to positive. Gas flows through the nozzle and exits out the orifice. There is no arc at this time as there is no current path for the DC voltage.

2. After the gas flow stabilizes, the high frequency circuit is activated. The high frequency breaks down between the electrode and nozzle inside the torch in such a way that the gas must pass through this arc before exiting the nozzle. Energy transferred from the high frequency arc to the gas causes the gas to become ionized, therefore electrically conductive. This electrically conductive gas creates a current path between the electrode and the nozzle, and a resulting plasma arc is formed. The flow of the gas forces this arc through the nozzle orifice, creating a pilot arc.

4

3. Assuming that the nozzle is within close proximity to the workpiece, the pilot arc will attach to the workpiece, as the current path to positive (at the power supply) is not restricted by a resistance as the positive nozzle connection is. Current flow to the workpiece is sensed electronically at the power supply. As this current flow is sensed, the high frequency is disabled and the pilot arc relay is opened. Gas ionization is maintained with energy from the main DC arc.

4. The temperature of the plasma arc melts the metal, pierces through the workpiece and the high velocity gas flow removes the molten material from the bottom of the cut kerf. At this time, torch motion is initiated and the cutting process begins.

Applications ? Art work, Signs & ornamentation.

?

? Automotive

?

? Construction

?

? Demolition & Scraping

?

? Engineering industries.

?

? Metal fabricators.

?

? Ship building

?

? Earth moving equipments.

?

? Aviation

?

? Infrastructure.

?

5

CNC- OXYFUEL / PLASMA CUTTING MACHINE. The Machine frame is designed as heavy- Case structure using TATA tubes, with stress relieved processing. Excellent workmanship ensures outstanding Rigidity, operational balance and reliability. The cross and straight drive is equipped with Servo gear box & rack-pinion transmission. Gas hose and Cable supplied on the machine is via cable Drag chain.

Specification. Model No. JUMBOCUT-130 Main Body

Gantry Bridge with Double Crive

Operate Console

Right Side / Left Side

Drive Method

Rack - Pinion & Servo gear box drive for X and Yaxis

Effective Cutting Width

Standard 3000mm, also customer's requirement

Effective Cutting Length

Standard 6000mm, also customer's requirement

Torch mounting system

Wire rope connection systems

Maximum rapid Speed

12000mm/min

CNC Control Systems

Edge-Pro/ Micro Edge

Servo Motors and Drives

Panasonic, Mitsubishi and other popular brands of your choice

Nesting Software

SNX 102/ MX 1000/ MX 1250 Sigma Nest USA and Turbonest MTC USA

No. of Torch block

As per customer's Requirement

Oxy-Fuel Cutting Capacity

6 to 300 mm

Power Supply

Plasma Source as per customer requirement

Hose & Cable carrier

Polymer Energy chain system for longitudinal & Traverse (IGUS)

Optional accessories for Oxyfuel

Torch height Control (IHT). Tanaka Torch & Nozzles (LPG/Acetylene), Gas hose pipes, Pressure regulators, Flow regulators & Solenoid Valves

Optimal accessories for

Auto ignition , Fume extrator, Consumable spares & Grit box

LPG/Osyacetylene. Optimal accessories for Plasma

Plasma Source, Plasma torch height control, Grit box, All types & series of consumables.

6

Features of Mechanical structure n 2 Axis Gantry n Heavy-Wall

system with Rack-and-Pinion Drive mechanism.

Reinforced Box Beam Design.

n Machined

Mating Surfaces for high stiffness and accuracy

n Digital AC

Servo Drive for years of maintenance free operation.

n AC Brushless

Motors for smooth & accurate motion.

n Precision

Backlash free Servo Planetary Gearboxes for accuracy and long life.

n Precision

Linear Rail Drive arrangement for X Axis & Precision machined tracks for Y Axis

n Maximum

Rapid Machine Speed: (14000 mm/min).

n Positioning

accuracy: ± 0.2mm; Repeatability: ± 0.1mm.

n Heavy-duty,

precision machined floor mounted track rail system.

n Machined

top and side surfaces.

n Machined

rack mounting groove for precise rack alignment.

n Precision

drive rack mounted directly to machined surface. 2 Axis Gantry system with Rack-and-Pinion Drive mechanism.

Gear Box

Rack and Pinion

Servo Motor and Driver

Guide LFR

7

CNC Plasma / Oxy-Fuel Cutting Machine

Specification. Model No. TABLECUT -200 Main Body Grid box for placing of sheets Operator Console Drive Method Effective Cutting Width Effective Cutting L ength Torch mounting system Maximum rapid Speed CNC Control Systems Servo Motors and Drivers. Nesting Software No. of Torch block Oxy-Fuel Cutting Capacity Power Supply Hose & cable carrier Optional accessories for Oyfu el Optional accessories for Plasma

Table Type with Double Drive Included- 1.6m X 3.1 m Right Side / Left Side Track roller with hardened shaft drive for X and Y axis 1500 mm 2500 mm Wire rope connection systems 10000mm/min Edge-Pro/ Micro Edge Panasonic (JAPAN) SNX102/ MX1000/ MX1250 Sigma Nest USA and Turbonest MTC USA 2 torches. Can be increased 6-300mm Plasma Source Polymer Energy chain systems for Longitudinal & Traverse(IGUS) Torch Height Control (IHT), Tanaka Torch & Nozzles (LPG/Acetylene), Gas hose pipes, Pressure regulators, Flow regulators & solenoid valves. All types & series of consumable. Plasma Source, Plasma torch height control.

Features: n Light beam

design with Track roller & shaft leads to high accuracy & stable transmission. speed, high accuracy, low cost. High quality Hypertherm plasma power, Can cut any conductive metal with high efficiency. n Equipped with Tanaka make gas system. n Advanced numerical control system for stable & uninterrupted performance. n Specialized Hypertherm plasma system. n High cutting

8

MECHANISED PLASMA CUTTING SYSTEMS We offer a wide range of Hypertherm Plasma cutting systems for our cutting Machines.

Machine Torch

Fetures of Plasma system Features ? Fast cutting speed increases productivity. ? Superior cut quality limits rework. ? Maximized productivity improves profitability. ? High duty cycle for industrial performance. ? Easy maintenance reduces machine idle time. ? Unmatched reliability.

Comparison Subject Method of imparting energy Source of energy Materials able to cut by the process T ypical process uses Initial investment required Operating cost

Plasma Gas transmitter DC power supply All electric conductive materials Cutting, welding, marking, drilling(True hole technology) Low to medium Low

9

Laser Light(far infrared range) Gas laser All materials like metals, wood, PU etc Cutting, welding, marking, drilling etc Very high Medium

Waterjet Water High pressure pump All materials Cutting, marking, drilling etc. Very high Medium

Torch Height Control Sensor PHC The sensor PHC is an easy to use and reliable voltage sensing height control for the conventional plasma applications. The benefits reliazed are in terms of n Consumables life improvement. n Improved cut quality. n Reduced opertaors intervention. The sensor PHC offers easy installation on new or existing plasma cutting table with any CNC and a broad range of plasma systems. Available in several applicationspecific configurations. The sensor PHC delivers improved performance at a reduced cost compared to other plasma height control solutions.

Arc Glide THC The Arc Glide THC offers optimal cut quality substantially improved productivity & reduced operating cost for plasma cutting applications. Specific advantages include n Optimal consumable life & superior cut quality through arc voltage sampling and control. n Upto 80% improvement in parts cut per hour by minimizing cut-to-cut cycle time. n Extremely robust mechanized backed by a 2 year warranty. n Easy to use HMI (Human Machine Interface) for fast job set under a minute. n True hole technology capable for HyPerformance Plasma HPRXD installation. Performance advantages are achievable with minimal operator input, eliminating the need for extensive training and allowing you to get the best performance across any shift with any operator at any plant.

Torch Height Control System – M4000 Cap Automatic clearance control for oxy-fuel cutting machines

Advantages n Small ring

electrodes means optimised yield from the workpiece. control of the clearance distance for more precise cuts. n Adjustable cutting and piercing height. n Highly accurate

Visit: www.iht-automation.com for more details.

10

Features of Nissan-Tanaka Oxyfuel Torch System The New Dimension of Nozzle Mix Technology for Gas Cutting Used in Nissan- Tanaka Torch. Introduction To understand the importance of Nozzle Mix Technology in Industry today, it is necessary to understand the process of Oxy-Fuel cutting and safety hazards associated this traditional but most popular & cost effective metal cutting process.

Oxy-Fuel Cutting In spite of great progress in plasma cutting, laser cutting, waterjet cutting, Oxy-fuel cutting process still dominate 80% of the global mild steel fabrication today because of: 1. Lower investment cost in the equipment. 2. Capability to cut from 5mm to 200mm with a standard torch just by changing nozzles. 3. Long service life of nozzles. 4. Easy availability of Oxygen and fuel gases like Acet., LPG, Propane & Hydrogen.

Actually Oxy-fuel cutting is a simple chemical process in which the preheating flame created by a mixture of oxygen with the fuel gas heats up the plate to red hot condition. As we allow the cutting oxygen jet to pass through the central hole of the nozzle to the red hot zone, it reacts with iron & convert it to iron oxide through an exothermic reaction generating more heat to sustain the process. Since the iron oxide has a lower melting temperature than the iron, the Oxygen jet pierces through molten area of the thick plates separating into two parts as long as cutting continues.

Backfire, Sustained Backfire & Flash Back The mixing of preheat oxygen with the fuel gas, however creates an explosive gas mixture which often cause safety hazards. During cutting operation as long as preheat flame gets adequate supply of fuel gas at the cutting nozzle tip, there is nothing to worry and uninterrupted cutting is possible. However, if there is a drop in fuel gas supply pressure for whatever reasons (clogging of nozzle holes due to rusted plates, improper seating of the nozzle, dropl in input pressure of fuel gas), the flame often goes inside the nozzle in search of fuel gas and create a pop sound. If the flame repeatedly stops with a pop sound and after few moments restarts again, we call it simple “Backfire” which can be prevented either by cleaning the holes of nozzle with proper tip cleaner or replacing the nozzle altogether. Backfire is therefore is very common phenomena. Though it creates an irritating sound & may interrupt cutting, it does not cause any major damage otherwise. However, if neglected for long, Backfire can lead to “Sustained Backfire” where the flame enters further inside the torch to burn the fuel mixture available inside the metal pipes of the torch. Sustained Backfire therefore is very dangerous for conventional Injector Mix cutting torch (Conventional 2 pipe torch) where the preheat oxygen and fuel gases get mixed inside the torch near the handle and travel through the gas pipe. The explosive mixture thus available inside the preheat gas supply pipe of the torch with fast catch fire & burn with a hissing sound until perhaps the pipe explodes with a big bang, if not attended by an alert operator. Apart from severe damage to the gas cutting torch, Sustained Backfire often cause injury to the operator if he is not very prompt to cut off the gas supply. However, the most horrific incident is “Flashback” in which the flame after burning the explosive mixture inside the torch, travels reverse with a lightning speed further towards the sources i, e high pressure gas cylinders. In case the Oxygen & fuel gas regulators are not protected by Flash Back Arrestor, the flame accompanied by heat, dust and smoke can enter the cylinder causing huge explosion and damage to men & machines.

11

“ NOZZLE MIXING IS SAFER

THAN TORCH MIXING”

Nozzle Mix Technology: In order to minimize the incidence of Sustained Backfire and Flash Back in the new generation gas cutting torches, the preheat oxygen and fuel gases flow independently through separate pipes only to mix in very small quantity inside the specially designed nozzle (3 seat nozzle) in extremely small quantity thereby limiting the scope of accident to a very great extent. The sectional photo of Nozzle Mix nozzle & torch head where this nozzle is fitted is given above to explain the technology. Nozzle Mix Technology perfected in Japan few decades back, has now spread to major parts of the world. It entered India in a big way a decade back after government adopted policy of globalization. While Cutting torch based on Injector Mix cutting technology is the decline stage of product life cycle and has been phased out in most countries in the world for safety reasons , those based on NM technology is the growth stage. However, shortage of good quality imported nozzles is slowing the growth of this much superior and safer technology.

Are all NM Cutting Nozzles the same? Unfortunately the quality of all imported NM nozzles are not same. The major source of NM cutting nozzle in the world today is Japan, UK, Italy followed by Taiwan & China. While Chinese nozzles are cheap, the performance is very poor. The main feature of a superior NM cutting nozzle, which make the Japanese nozzles superior to other NM nozzles are the following: 1. Superior Acetylene NM nozzles is made in Japan out of a Brass top and Copper bottom. The two dissimilar metal parts are then micro-brazed together by a unique patented process. As the cutting torch head is also made of brass, the torch head and nozzle seat, under continuous cutting, expand by same degree thereby maintaining although air tight contact at all the 3 seats. This feature does not allow any leakage from seat even after prolonged use. This is not possible in All copper Acetylene nozzle made in U. K., Italy, Taiwan & China. 2. The other major feature is the “positive suction” property of Japanese cutting nozzles. To check this property one can allow the preheat oxygen to flow through the nozzle and connect a vacuum gauge on the fuel gas inlet. Suction shows for fuel gas not only under normal preheat condition; the suction improves once the cutting jet starts cutting. This feature greatly eliminates any occurrence of backfire. Hence these nozzles smoothly operate even if supply pressure of fuel gas is a pipe line fluctuates. 3. The Japanese NM nozzle is longer in length compared to British style nozzle and give a more streamlined flow of gases. The cut quality is therefore always better. For machine cutting application Japanese NM nozzle are given a special chemical coating to work under extreme working condition. Hi-speed machine cutting nozzles have small stainless steel ring at the central Oxygen hole to improve straightness of cutting jet and wear due to repeated piercing operation. They produce superior cut quality as per Japanese standard WES 2801 and have long life

12

CNC Control Systems EDGE Pro Shape Control The EDGE Pro offers multiple back-door interfaces for table manufacturer integration. Providing three analog choices and one SERCOS version, the EDGE Pro interfaces allow the table manufacturer to configure the CNC to match the table design. Designed to be flexible and easy to use, the EDGE Pro delivers reliable performance for improved profitability and application performance such as True Hole technology. Using Phoenix software, this CNC improves cut quality and productivity by delivering our expertise directly to your factory, making it as if you have your best operator on every shift.

13

Micro EDGE Operating system

Microsoft W indows XP® - embedded;

Processor

Intel 2.5 GHz

Memory

512 Megabytes RAM

Hard drive

80.0 Gigabyte hard drive

Communication

1 x RS232; programmable to 230K baud.

Floppy drive

1.44 Megabyte floppy drive

CD-ROM/DVD drive

Standard

RFI / EMI shielding

Machine side Opto-Isolation: grounding

Input / output

24 Lines of user definable Interface signal (12 in / 12 out)

No. of Axes

3 Axes

MBoard Interface

PS2 keyboard & mouse with USB ports.

Optional networking

On-board RJ-45 network port

Dimensions

14.38" (365.252 mm) W, 20.00" (508 mm) D, 9.35" (237.49 mm) H

Weight

14 Kg.

Operating environment

0 to 50°C; 95% relative humidity (noncondensing).

Display

15” Touch screen- SAMSUNG/SIEMENS

Consumables for Plasma cutting system. Hypertherm offers a wide range of consumables depending upon the type & series of plasma system. The consumables like shield, retaining cap, nozzle, electrode, Torch body are designated by unique code no. This can beordered in single unit or in kit.

14

15

16

17

Welding Automation

Automated welding has improved upon manual welding by increasing speed, quality and throughput. Top-notch weldments are easily repeatable with robots. Robot welding automation is much safer and more cost-effective. Welding is a process where two materials are fused together through heating, intermixing, and then cooling the materials and/or a filler to form a strong join. Robots are capable of performing several types of welding processes, including arc welding, spot welding, and laser welding. They are typically used in welding processes where the weld required is repetitive and quality and speed are crucial. Quality - Welds are more consistent and thorough when performed by robots. Productivity - Robots produce effectively because they can work inexhaustibly and consistently. Speed - Robots move from one weld to the next very quickly, making the entire process much faster. Less Waste - Robotic welding uses fewer consumables than its human counterparts. Material is saved and more product produced because of this exact welding. Reduced Costs - Investing in robotic welding saves money. One robotic welding cell has the potential to complete the work of four human welders.

19

Application Examples Locomotive Engineering

Offshore Rigs

Heavy Fabrication

Ship building

Steel Manufacturing

DRUPE AUTOMATION SIMPLIFIED

DRUPE ENGINEERING PVT.LTD. Plot No.B29/2 MIDC Taloja Dist Raigad - 410208 Navi Mumbai Tel: 0227411922 / 27401153 Fax: 022-27411933 Email: [email protected] / [email protected] Web:www.drupeeengg.com

Distributors/Partners