Multi-dimensional energy supply for a flame cutting machine

Durable drive, control, and data cable guidance to extremely mobile units in harsh conditions

Every SATO thermal cutting machine is custom-built to meet the specific requirements of each customer. As cutting applications continue to evolve, machine components must meet increasingly demanding standards for reliability, flexibility, and performance. This is especially true for the energy supply systems that ensure uninterrupted operation in harsh industrial environments. To support the continuous multi-axis movement of the plasma bevel units, igus® triflex® R multi-axis cable carriers safely guide power, control, and data cables, enabling unrestricted motion in all directions.

Profile

What was needed: Series E4.42 and series 3400 linear e-chains®, triflex R multi-axis cable carriers, chainflex® cables, drylin® W linear guides
Requirements: energy supply system must operate under harsh operating conditions such as heat, flying sparks and extreme dirt accumulation. System needs to be used in compact designs with complicated motion requirements
Industry: Machine tool manufacturing
Success for the customer: igus energy supply systems optimally serve the various requirements within the plant: E4.42 series handle high speeds and accelerations in linear movement, triflex R handles multi-axis movement; drylin® W linear guides provide maintenance-free linear motion for moving machine components; close cooperation in planning phase for a highly specialized customer solution

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Problem

The company SATO Schneidsysteme Anton Hubert e. K. in Mönchengladbach has been a successful manufacturer of CNC-controlled cutting machines in gantry and cantilever design for over 25 years. One of their product lines, the "Satronik" series covers oxy-fuel, plasma, laser and the water-jet range.

The company's flame cutting machines cut sheets ranging from a few millimeters up to two meters. In order to ensure that these machines function perfectly with a long service life despite operating conditions, including heat, flying sparks and extreme dirt accumulation, the individual components must also be extremely robust.

This requirement also applies to the innovative 3D plasma bevel unit, which has proven itself in customer applications. With this system component, SATO Cutting Systems sets new standards in dynamics, precision and energy efficiency. The programmable 3D plasma bevel cutting unit is used for machining in the weld seam preparation of structural and stainless steels. "We designed it to be exceptionally compact," explains director Reiner Schiffer. "As a unique selling point, the new design ensures an extremely small footprint on the machine as well as high dynamics in the actual cutting process."

The system's efficiency is particularly evident in multi-plate processing, where multiple parts can be cut in a single operation without interruption. Material utilization is also improved through reduced waste. Thanks to its lightweight design, the unit can be integrated into compact machine configurations. The 3D plasma bevel cutting units feature automatic height control and unlimited rotational movement, allowing continuous bevel cutting without mechanical rotation limits. Available in both single- and multi-torch configurations, they can produce bevel and trim cuts up to 45°. With traverse speeds of up to 6,000 or 12,000 mm/min, the units are compatible with a wide range of plasma bevel-cutting systems.

The challenge was to ensure reliable energy and data transmission while maintaining system performance and uptime under these harsh operating conditions.

Solution

The energy supply of a cutting system with two 3D plasma bevel units is ensured by energy supply systems from igus. On the x-axis with a travel length of 42 m that traverses the entire burner system, An E4.42 series e-chain that is openable from both sides, proves its efficiency. It is suitable for high speeds and accelerations as well as for long travels and high additional loads. The main feed for the complete flame-cutting system runs through this cable carrier.

Installed in three separate guides, three 3400 series e-chains are used for the transverse movements on the bridge to supply a 3D bevel unit. This means that six energy supply systems in six guide troughs provide the supply lines to the two burners. They are easy to assemble and have a long service life.

The two bevel units each have an energy supply system in a bracket version. It guides the complete system overhead to the burner in each case and ensures that all vertical movements are carried out safely over a long period of time.

On the compact 3D plasma bevel units, triflex® R multi-axis cable carriers, which are now available in its third generation, prove their worth in all directions. triflex R has been specially developed for demanding 6-axis robot applications. Two types of triflex R were used in this application. Series TRC with an enclosed design, and series TRE which has an easy design for the simple pressing in of the cables. While all chainflex drive, control and data cables, including the cooling system, are safely guided in the series TRC cable carrier, signal cables and special cables responsible for the initial ignition of the combustion engine or for emergency monitoring run through the series cable carrier.

Focus on cooperation

The length and the assignment of the individual energy supply lines are subject to change. "That's because we don't build standard machines. During assembly, we often have to lengthen or shorten the chains. If we optionally add laser pointers at a later date, for example, they must be connected with a separate cable. If the appropriate chains are already occupied, we simply open them and insert the additional cable. Subsequent changes do not cause us any problems at all," clarifies the director Reiner Schiffer. "In the run-up to the design of the machines, it is therefore important to work closely together. We don't need off-the-shelf energy supply systems, but special chain widths and chain lengths that meet our high requirements and prove themselves in tough everyday operation."

Technical Sales Consultant Ansgar Endries from igus SE & Co KG adds: "We not only offer a wide range of products, but can also provide many special solutions from stock. And should there ever be any problems, we carry out appropriate tests under real conditions in our own test laboratory. That's currently around 10,000 tests of all kinds per year." In addition to the energy supply systems, various plastic bearings and drylin® W linear guides are also used in the flame-cutting machines. Tests are currently being carried out on the linear guides in particular, which are adapted to the special dirt accumulation during flame cutting in order to further reduce machine downtimes.

"We have been working with the energy chain supplier for many years," concludes Wolfgang Saehsen, Vice President at SATO Schneidmaschinen. "The advice is right, it's the only way we can ensure the required quality, after all, our burner machines are put to the test in day-to-day operations. With the complexity of our machines, we need contact persons on site who are quickly available in person when required. And we have had the best experience with the energy chains. The machine operating times are right; complaints are a thing of the past!"

We have been working with the energy chain supplier for many years. We have had the best experience with the energy chains. The machine operating times match; complaints are a thing of the past!