General specification CCS robotcutting line

CCS robot cutting lineSpecifications CCS 600, 900, 1250© 2014, Kranendonk Production Systems BV. No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose without the express written permission of KRANENDONK. KRANENDONK reserves the right to make changes to any and all parts of the documentation, at any time, without obligation to notify any person or entity of such changes.© 2014, Kranendonk Production Systems BV1 The CCS cutting conceptThe CCS is a standardized system for the cutting of steel profiles. A CCS can handle all common profile types and can be supplied with plasma and OFC cutting equipment. Programming is automated with the ARAC software. Because of the easy programming there is no limitation on the cuts which can be made. KRANENDONK has a standard library for the most common cuts. Due to the open software, cuts can be programmed without the help of KRANENDONK.Main benefits• • • • • • • • • Rigid main frame holding all components Takes little floor space Quick installation Automated programming with ARAC software Cutting paths adapted to product deviations (DFP module in ARAC) Large robot means no sliders, thus less maintenance In-flow measuring (no ‘gripper’), means less maintenance Continuous non-repetitive production flow Plasma hole-cutting, so can replace a drilling/sawing lineCCS Robot Cutting Line specifications Page 2 of 10© 2014, Kranendonk Production Systems BV2 Basic configurationsThe system is available in three dimensions and with two different cutting processes, being OFC and Plasma. For operator safety, a sound proof cabin with fume extraction unit is supplied with the plasma option.2.1 Dimensions• CCS 600 – maximum profile 600 * 300 mm • CCS 900 - maximum profile 900 * 300 mm • CCS 1250 - maximum profile 1250 * 500 mmThree CCS models2.2 Processes• Oxy-fuel cutting • Plasma cutting • Combined OXY fuel and plasma cutting, with tool changerCCS without cabinCCS with sound proof cabinCCS Robot Cutting Line specifications Page 3 of 10© 2014, Kranendonk Production Systems BV2.3 ControlsA continuous, non-repetitive, production flow can only be realized when there is no times spend on programming of the system. Our software eliminates the need for programming. The central controller of a CCS is the ARAC software. The operator can manually insert the preferred dimensions, after which the system will measures the beam and adapts the cutting shape to reach a perfectly fitting part. The preferred dimensions can also be derived from a CAD system. If needed, adjustments can be made on the shopfloor. The operator is provided with: • Two large touch-screens with camera system • Operator interface with clear graphics, no language barriers • Remote controlCCS Robot Cutting Line specifications Page 4 of 10© 2014, Kranendonk Production Systems BV3 General functionalityThe general functionalities of the system are explained below. Continuous flow Profiles are cut in any order, without set-up time between different profiles. All production functions such as cutting, transport and positioning are automatic, and completely integrated. In-flow profile positioning Profiles are accurately positioned with in-flow rollers. This eliminates the need for a length-measuring trolley (‘gripper’), which is often high on maintenance. Fitting constructions The cutting path is adapted to deviations in the raw profiles. Also, deviations in connecting profiles can be taken into account. Perfect fits are the result. Robust design The CCS concept is based on the integration of components in a rigid main frame. The main frame increases durability and shortens the installation time. Cutting holes with plasma A CCS station can replace a sawing/drilling line, because holes can be cut with plasma as well. The robot’s movements compensate for the plasma bevel. No programming Operation is easy: with a CAD connection or direct input on the shopfloor, no time is lost with complex programming tasks. Safety and environment Safety provisions according European regulations, optionally with fencing. With plasma cutting, a sound proof cabin with fume extraction is supplied for operator safety.CCS 1250 with sound proof cabinCCS Robot Cutting Line specifications Page 5 of 10© 2014, Kranendonk Production Systems BV4 Production flowThe production process involves the following steps: 1. Transfer of one raw profile from the infeed buffer onto the rollerbed. 2. Positioning of the profile under the robot for the first cut. 3. Clamping and making the first end cut. 4. Transport and intermediate cuts. 5. Transport and making the final end cut. 6. Output of the finished profile onto the output buffer. 7. These steps are repeated for next profiles in a nest. This process is repeated for all profiles in the infeed buffer. The infeed buffer can be loaded during production, without disturbing the flow.4.1 Handling and logisticsThe CCS system has an in-flow positioning system. This means that there is no limitation to the maximum length of the profiles, as it eliminates the need for a separate positioning device (‘gripper’). Also, maintenance costs are reduced. The accuracy that is reached with the in-flow positioning rollers is within 1 mm on every 10 meters of profile length. Infeed and outfeed buffers can be supplied with the system. The buffers are automatically operated, creating a continuous production flow. Other processes, such as shot blasting, edge milling and marking/printing are options which can be integrated in the system. The production software makes sure that the machine can run continuously. Our software also controls additional machines in the production flow, such as a shot blasting station or text-marking station.CCS Robot Cutting Line specifications Page 6 of 10© 2014, Kranendonk Production Systems BV5 ComponentsThe CCS cutting system consists of the following subsystems: Main frame • ABB industrial robot (IRB 2600 with CCS 600 and CCS 900, IRB 4600 with CCS 1250) • IRC5 robot control system • In-flow measuring rollers Control components (integrated in main frame) • 17” touch screen with graphical interface • 17” screen for camera view • Remote control for real time adjustments • ICS3000 industrial computer Other components • Standard with 12 meter infeed conveyor, 12 meter outfeed conveyor • ESAB EPP450 plasma power source, gas switch box and high power plasma cutting torch (PT-36) • Camera system • Scrap container (capacity of 1000 kg)CCS Robot Cutting Line specifications Page 7 of 10© 2014, Kranendonk Production Systems BV6 DimensionsOverall dimensions CCS basic configuration Roller bed in feed Roller bed out feed Overall length (approx) Overall width (approx) Height above floor, roller beds Height above floor, chain conveyors 12,000 mm 12,000 mm 20,500 mm 4,000 mm 900 mm 960 mmGeneral profile specification Length before cutting Length after cutting into standard buffer Profile height when laying on roller bed Profile width Profile weight, roller bedmin. 2,000 mm 600 mm 12 mm 80 mmmax. Equal to rollerbed length Equal to rollerbed length 500 mm 1250 mm Approx. 500 kg/mThe above specifications are based upon the standard design for robot profile cutting lines. On request, special solutions can be engineered to suit specified customer demands exceeding the given limits.Profile types HE, IPE, INP beams* UNP Flat strips L-beams Bulb (HP) profiles Rectangular tubes (RHS, SHS-HSS) (turning with optional turning device (r max.: 25) T-bars* * Small adjustments to the buffer may be neededminimumCCS 600 H 600 x 300 U 600 x 300CCS 900 H 900 x 300 U 900 x 300 900 x 50 L 900 x 300 HP 430 x 17 300 x 300 T 500 x 300CCS 1250 H 1250 x 500 U 914 x 100 1250 x 50 L 1250 x 500 HP 430 x 17 500 x 500 T 1250 x 500H 10080 x 08 L 80 x 40 HP 80 x 5 80 x 80 T 80 x 80600x50 L 600 x 300 HP 430x17 300 x 300 T 500 x 300CCS Robot Cutting Line specifications Page 8 of 10© 2014, Kranendonk Production Systems BVOptions6.1 Customization and consultancyKRANENDONK develops custom automation solutions for manufacturing companies. We do this by combining hardware, software and sensors. In this way, we can automate non-repetitive production processes with robotics. As a result, we can fit the CCS cutting cell in the existing production flow, or build a complete factory layout from the ground up. We have a large experience in shipbuilding, offshore and structural steel industries.6.2 ServicesImplementing robot technology is a major step. Therefore we offer services to assist with this transition.6.2.1 Training and installationFull installation of equipment Work preparation training • Operator training • Start-up assistance• •6.2.2 Customer supportYearly inspections (service contract) Local support by ABB and ESAB • Remote Assistance from our two support offices (Holland and Japan)• •Remote Assistance We can monitor your system through an internet connection. In this way we can quickly solve issues, often through the telephone. Various service packages are available in combination with inspections.CCS Robot Cutting Line specifications Page 9 of 10© 2014, Kranendonk Production Systems BV8ImpressionsCCS Robot Cutting Line specifications Page 10 of 10。