10KW PHOENIX 4020 光纤激光切割机 + MOVIT 料塔自动化系统

作为配备英国首台MOVit塔式自动化系统(TAS)的Phoenix激光切割系统,该系统的生产效率使该企业在这台新机床上将110小时的激光切割和100小时的等离子切割浓缩为70小时。这使得该企业能够在大型合同上削减20%的成本

J.A. Harvey由现任董事Paul Harvey和Dave Harvey的父亲于1974年创立,最初专注于农业领域的工作。现在的工厂面积有5万平方英尺,雇员50多人。董事Paul Harvey表示:“我们的核心业务是装配—在分包合同的基础上提供完全装配的组件,我们尽量在内部完成。”

该企业拥有非常广泛的客户群,生产各种材质和厚度的产品,即从薄板到厚板,涵盖低碳和高强度钢、铝以及不锈钢。该企业仍在农业领域做大量工作,即为三家英国领先的农作物喷洒公司提供产品,并为建筑机械、储罐和钢结构生产组件。 2013年,该公司购买了第一台4.5 kW的二手二氧化碳激光切割机。由于它每周运行120小时,需要一名操作者一直上夜班,公司决定购买一台10 kW LVD Phoenix激光切割机。

得益于该机器的切割能力,一些以前在等离子切割机上切割然后钻孔的工作现在在激光切割机上一个工序就搞定了。

Paul Harvey说:“假设您想在一个25毫米厚的板上开一个直径90毫米的孔,使连杆销或衬套的公差达到0.15毫米。等离子只能切割到一毫米的公差,钻孔需要10分钟,但如果我们使用激光,它不需要钻孔时间,并且可以满足我们需要的公差。这样就加快了生产速度也保证了精度。”

他们最初只是打算买一台激光切割机。“当您是一个分包商时,是不太会考虑自动化的,但我们已经运行了5年的单机版的激光切割机,所以我知道上下料有多费时间。”关键的一点是,任何自动化都必须具有很高的灵活性—要能够在同一台机床上进行手动上下料的小批量生产和完全自动化的大批量生产。‍Paul说:“可能我们的这一项工作是将一个边角料快速加工出六个轮廓件,但下一个工作可能是切割50张10毫米厚的材料。”

当Paul看到一张MOVitTAS的照片时,他意识到这可能就是自己要找的答案。“LVD可以提供量身定制的解决方案,完全符合我们的需求。” 这个系统现在安装在J.A.Harvey,包括两个储存塔,共有33个储存位,每个储存位最多可容纳3吨材料。它们沿着工厂墙壁放置,中间有一个上料站。Phoenix激光切割机有两个常规的穿梭工作台和一个直接下料站,可在机床的一侧卸载零件。高架横梁连接储存塔、常规穿梭工作台和下料站。‍

“我们有三个工作台。当有两个工作台在机床里工作时,我们可以把工件卸到另一个工作台上,然后可以把工作台拿出来,用手或铲车取下零件,或进行其他操作。”这大大增加适应紧急和小规模工作的灵活性,同时有效利用了那些大量的边角料。

此外,TAS还可以储存各种准备加工的材料,允许在夜间无人值守的情况下进行加工。拼图的最后一块是CADMAN-JOB工作流程管理软件。Paul说:“除了管理激光切割机的工作流程外,这个软件也可以告诉我们工作效率如何,我们已经安排了多少小时的切割工作量,以及还有多少空余时间可用。”

总而言之,他说:“从节省时间的角度来说,我们进行这项投资的最大原因之一是您可以从运行一台自动化光纤激光切割机中获得的成本效益。这意味着您可以在不增加客户成本的情况下增加产品的利润。‍”

J.A. Harvey Bassingham Limited. 

We use the name Harvey Fabrication more often. We're a family-owned business, solely. It’s me and my brother Dave, I tend to run the production side and Dave runs the financial side. We're 60, 65 people strong, limited company. It is purely a family-owned business. It was started in 1974 by my father.

The business started out of the fact that he had livestock and they couldn't afford to buy the equipment they needed so they started making it. So we work for construction, in structural steel work. Right the way up to execution class four. We plasma, we drill. Obviously now we'll start doing a lot more laser. 

So that's where we are today. We serve the whole of the UK and Ireland. 

We're already running a laser, a CO2, four and a half kilowatt, and we work bottlenecking. Our business has grown around bottlenecks. So we cure a bottleneck, get a bit of capacity, sell it and create another bottleneck. It's like any business, if you stay with old technology, you're going to fall by the wayside because things move forward in this day and age at such a fast pace. 

So financially we've got to keep up with that, so we've got to make that investment to be at the forefront of that technology, so we're continually growing, as a company and as people too. 

If we were just a laser cutter, doing 2D laser and press work and that was our mainstay business, there are many solutions out there that would all do the job. Being the sort of company that we are, we needed something that had way more flexibility than that. Because this week we need to run on full automation because we have a big job coming.

Next week we might have 55 little jobs that don't suit automation. So we needed a machine that could be run as a standard machine. We also needed a machine that could be run on full automation. We'd already been to Belgium and seen what you guys had to offer in terms of the compact towers and all that.

And, you know, a great piece of kit. Didn't really fit for us how we envisaged we wanted it to fit. Many discussions with Neil, you know, trawling through the internet, trying to find different solutions. Me and Neil, we spoke hours on end, you know, in all fairness. We'd been sitting in this office at eight o'clock at night some nights scratching our heads and he just sent me a picture one Friday night, probably six or seven o'clock.

He said, yeah, look at this. I went, that's it. You could clearly see that was the solution. And to be fair, I think probably two weeks after that, you guys had the order. 

One of the things we're always up against is production costs, how we reduce production costs. How do we do the same job better but faster. The very first job we ran through the LVD was one that we took a punt on. We couldn't have won the job on our old laser. We were probably around 15% out on the finished price. 

But we looked at it and did a few quick sums and I'd like, well, finger in the air, let's have a go. Let's run it through the new laser. It ran through. The margin's still the same as the old laser but the cost to the customer has been reduced by, I’d say, probably 15%. And that's important, you know, talking on the phone with them yesterday, you know, they're keen to come and see this new equipment because I think we can save them money in other areas as well. 

Capacity is the biggest key. We ended up going for the 10 kilowatt. For its capacity, it costs more an hour to run with the nitrogen but the speed gains are worth having. Already, you know, it’s mind-blowing.