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Material flow concept for tube lasers
As part of a customer project, a comprehensive automated material flow solution was designed in…
LaserFLEX
Universal Laser Automation for Laser Cutting Machines
Automation
Designs & Variants
LaserFLEX Cross
Two automation units traverse one or more laser cutting machines on two levels. New sheet metal blanks are loaded by the loading unit with suction matrix. Cut sheets are removed from the shuttle table by the unloading unit with rake.
Stand Alone
The stand-alone version is the simplest way to get started with automated sheet changeover. The operator is alternately presented with a pallet of raw sheets and a pallet of finished parts via a shuttle station.
Multi Laser Automation
With LaserFLEX, several lasers can be operated via one automation line. Several stations or deposit places can also be integrated individually. In addition, sheet metal storage systems can be connected at both ends of the line.
LaserFLEX Line
With this solution, up to two lasers can be automated in one line. Optional solutions for automatic sorting can also be integrated into the automation line. Sheet storage towers can be placed on the outside. When a MIDI sheet storage system is placed parallel to the LaserFLEX line, a laser center with maximum storage volume is created in the smallest possible space.
Automation for Thin Sheet Metal Processing
This version of the loading unit is specially designed for handling thin sheets in the 0.25 to 8 mm range. The suction matrix is designed to prevent deformation of the sheets during pick-up. A special device for picking up sheets from the stack and double sheet detection ensure trouble-free operation.
Handling of Large Partial Sheets
The loading unit can be equipped with a single suction cup control so that individual sheet metal segments can be picked up again with the suction cup unit after the laser cut. This results in specific advantages for the process.
Automatic storage of remnant sheets
With this option, sheets that are not fully processed with a nesting plan can be stored back in a connected Remmert sheet storage system and made available for further processing at any time. This avoids a manual bypass for remnant sheet handling and increases flexibility when creating nesting plans.
Sorting of Large Metal Sheets
Due to their size and weight, large sheet metal parts pose a physical challenge for personnel during manual sorting. With this option, large and heavy sheet metal parts can be automatically picked up and palletized with the LaserFLEX.
Softtouch Finger
The removal unit can be equipped with soft touch fingers to protect sensitive surfaces. The belt drive ensures that the sheets are deposited gently and surface damage is avoided.
Picking Bridge for Sheet Metal
With LaserFLEX, sheet metal picking e.g. for steel trade purposes can be fully automated. All that is needed is the suction unit. The SMART control system automatically forms pyramids when sheets of different sizes need to be packed. It is also possible to place protective plates alternately with the sheet layers. The solution can be combined with all Remmert storage systems.
Integrations
Sheet Metal Storage
Only in combination with Remmert sheet metal storage systems does LaserFLEX Automation become a production booster for your laser cutting system(s). All types of sheets are automatically fed via the connected storage system. Buffering of cut sheets is also possible. This means that the laser cutting machines can in principle be operated around the clock independently of subsequent processing steps.
MIDI
The MIDI storage system can be set up parallel or at right angles to the LaserFLEX. The system is ideal for providing large storage capacities.
BASIC Tower
The sheet metal storage towers can be docked as single or double towers at either end of the automation line. A chain conveyor provides pallets for transferring the sheets.
CNC Cutting Machines
Remmert specializes in integration with various OEM systems. This gives you a great deal of freedom when selecting your preferred machine. It is also possible to change the machine type at a later date. Remmert systems have already been successfully combined with a large number of systems from different manufacturers, e.g. Amada, Astes4, BLM, Bystronic, Eagle, HG-Tech, LVD, Mazak, Messer Cutting, Pivatic, Trumpf and Prima Power.
Sorting Solutions
Various solutions are available for sorting the cut parts, offering different degrees of automation and ergonomic improvements depending on the requirements.
Deposition carriage
The cut sheets are deposited on station carriages, on which the sheets are transported outside the danger zone for sorting. Various models are available here.
Conveyor
The LoopFLEX conveyor belt is the solution for fast manual sorting of laser-cut sheet metal parts and scrap skeletons. The adjustable belt feed of the LoopFLEX enables up to 35% faster sorting.
Sorting robotics
In fully automatic sorting, sheet metal parts are picked up and palletized automatically by robotic solutions based on the nesting plan. The Remmert SortFLEX system and third-party systems can be integrated into the LaserFLEX automation.
Fahrerloses Transportsystem
Mit dem Remmert AGV steht eine flexible Lösung zur Verfügung, um die geschnittenen Bleche dezentral, d.h. entfernt vom Laserzentrum, abzulegen. Das AGV kann verschiedene Ablageorte anfahren und dabei autonom navigieren. Nachfolgende Bearbeitungsschritte wie Entgraten oder Abkanten können so in einen automatisierten Materialfluss integriert werden.
CAD/CAM/Nesting Software
The LaserFLEX Automation control system interacts with CAD/CAM/nesting systems from numerous manufacturers. In addition to the OE suites of laser cutting machine manufacturers, universal systems such as Libellula, RADAN, SigmaNEST or WiCAM are also used.
LaserFLEX - Modules and Options
Gantry bridge
The loading and unloading unit of the LaserFLEX moves on two levels in the bridge. The supports and beams have joints for the rails so that the modules can be easily extended at a later date. In addition, the supports and beams of the scaffolding also provide a continuous cavity that allows cables to be laid safely and attractively.
Unloading unit
The unloading unit of the LaserFLEX is used to unload the processing machines. It is equipped with rakes adapted to the processing machine in order to be able to unload the various pitches of the shuttle table. The dynamic detection of the discharge height ensures that the sheets are deposited gently.
Loading unit
The LaserFLEX loading unit supplies the processing machines with single sheets. For this purpose, a single sheet is safely separated from a stack of sheets from a loading station under the LaserFLEX and transported to the processing machine. The vacuum suction cups can be connected in clusters for different sheet sizes. The suction frame has double sheet detection to ensure that the sheets have been separated correctly.
Top transfer conveyor
The transfer conveyor is the standardized transfer option for system pallets from the Remmert sheet metal storage systems. It provides the LaserFLEX with raw sheet metal pallets. A contour check ensures that there are no displaced sheets on the pallet when it is returned to the sheet metal storage system. The conveyor also has an overheight sensor to check the height of the loading space on the pallet.
Lower transfer conveyor
The lower transfer conveyor enables the buffering of cut metal sheets in the sheet metal storage system. It provides the LaserFLEX with finished part pallets and is equipped with a contour check to ensure that there are no displaced sheets on the pallet when it is returned to the sheet metal magazine. In addition, the conveyor has an overheight control to check the height of the loading space on the pallet, as well as a light grid that detects the maximum loading height of the load carrier and gives a message as soon as this is reached and a pallet change has to take place.
Change pallets
Change pallets are used on trolleys and storage locations on the LaserFLEX and can be removed by forklift and staged away from the system. They are used for sorting cut parts or for reloading the LaserFLEX with raw sheets.
Station - extraction table
The extraction table is used to unload a LaserFLEX with finished parts. The frame can accommodate an change pallet for this purpose. The height of the table makes it easy to unload the finished parts directly at the table without straining the operator's back.
Station – extraction cart
The station is used to retrieve cut metal sheets via a simple carriage. The station is equipped with a safety device that detects access but is not triggered by the carriage. In addition, a light barrier detects that the pallet needs to be changed or emptied.
Station - double extraction cart
The double cart station is used to remove laser-cut sheets from storage. When one carriage is under the LaserFLEX, the other carriage is in the station position outside the LaserFLEX safety area and can be unloaded. The advantage of shuttle operation is that one carriage can be unloaded and another loaded at the same time. In this way, downtimes are reduced to a minimum.
Station - hand cart
The station is used to remove finished parts from storage and is designed as a hand carriage. It is held in position under the LaserFLEX by a locking mechanism. When the lock is released, the hand cart can be moved freely by hand. A light barrier recognizes that the pallet needs to be changed or emptied.
Station - LoopFLEX
The station is used to remove cut sheets on a conveyor belt. The LoopFLEX can be operated in two different modes. Firstly, in "automatic cycling", in which a sheet is transported on the conveyor belt up to approx. 10 cm before the end of the belt. Secondly, in "manual cycling", in which the conveyor belt is fed forward by approx. 250 mm by interrupting a control light barrier.
Station – AGV hand over
The transfer station is used to transfer system pallets between the Remmert AGV and stationary storage systems or automation systems. For this purpose, the AGV can drive into the transfer station and lift the system pallet with the lifting gear.
References & Use Cases
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