Part of the record Fabtech 2013 checks out the latest in welding equipment at McCormick Place in Chicago. Fabricating and finishing equipment were displayed in an adjacent exhibit hall—a total of 650,000 square feet of exhibits.
Extreme enhancements. Koike Aronson, Inc./Ransome, has made a series of upgrades to its Versagraph Extreme integrated thermal cutting machine. The new Versagraph Extreme features improved gearbox resolution, increased torque and very low backlash, and a larger and stiffer main beam for less z deflection and greater load carrying capabilities. The Extreme also features heavy-duty rails, a heavy-duty rack, and a module design that allows the operator to add a bevel or other equipment without making major changes.
The Versagraph Extreme is available in cutting widths ranging from 72 to 288 inches. Up to 10 oxy-fuel stations and up to 4 plasma stations, including dual full-contour plasma bevel stations, can be configured. Maximum rapid traverse speed is a very fast 1,400 IPM. www.koike.com
It cuts both ways. ESAB Cutting Systems will demonstrated its new Hydrocut LX waterjet shape cutting machine, a combined waterjet and plasma cutting system.
The Hydrocut CNC shape cutting machine uses the patented combination of thermal and non-thermal processes operating on the same gantry, allowing the machine to cut with the high accuracy of waterjet where needed, but employ the high speed and low cost of plasma whenever possible. By combining waterjet and plasma on the same machine, both tools can be used on the same parts. High precision contours can be cut with waterjet, while non-critical contours can be cut with plasma. This patented system allows users to obtain precise cuts when needed without sacrificing speed on every cut. Parts that are suited for the waterjet-plasma combination can be cut in a fraction of the time, resulting in dramatic cost reduction and productivity increase when compared to waterjet cutting alone.
ESAB also introduced a family of inverter-based welding machines that can be used for AC/DC GTAW (TIG) and SMAW (Stick) welding. The new Heliarc uses inverter technology, which delivers significantly increased energy efficiency and functionality in a package that is lighter and smaller than an old SCR technology machines and competitively priced versus other AC/DC inverters.
Easy-to-achieve, optimized arc settings enable the operator to weld aluminum using a pointed tungsten. The tungsten remains pointed improving arc starts, heat input and arc stability, thus assuring high quality welds. Heliarc’s pulse current allows for smaller heat affect zone, better control of the weld pool, and less plate deformation.
Emphasizing aluminum welding. Lincoln Electric had a number of products for truck body and trailer manufacturers, including this sample of a trailer sidewall. For example, its new Gem-Pak bulk packaging system is designed specifically for aluminum MIG wire. The packaging system uses glass gems rather than a payoff ring to control the release of wire. With reduced tangles, this engineered system helps increase production without an expensive external payoff device. The Gem-Pak bulk system is available in 275-pound and 300-pound boxes that include an integral pallet that is fork-lift ready. The box for is 100% recyclable.
Lincoln introduced the Power Wave® Advanced Module designed to increase flexibility for manufacturers by expanding their welding capabilities. The module has alternating current (AC) welding capability to run aluminum processes, including shielded metal arc, metal inert gas (MIG), pulsed MIG, tungsten-electrode inert gas (TIG) and Surface Tension Transfer (STT). With STT welding capability, the module can also help welding open root gaps with high frequency inverter technology. STT is a controlled MIG short circuit transfer process that uses current controls to adjust the heat independent of wire feed speed, resulting in superior arc welding performance, good penetration, low heat input control and reduced spatter and fumes. The Advanced Module reduces burn-through and increases wire feed speed and cleaning. Also, it incorporates a high frequency starting mode that can be controlled at the wire feeder or power source user interface.
The company also introduced its new Weld Sequencer program. Weld Sequencer shows a picture and explains where to add the welds step-by-step. The benefits of the Weld Sequencer include
• The welding power source parameters, such as voltage, wire feed speed and others, are automatically set for each discrete weld, helping to ensure that the operator performs an optimal weld on the part.
• Because each weld may be best performed using different weld parameters, it is sometimes difficult, time consuming or perplexing for the operator to manually make these changes at the machine or wire feeder. The Weld Sequencer makes the parameter changes automatically and tracks the operator’s action to confirm that each weld was performed.
• The Weld Sequencer tracks time, wire feed speed, voltage and other parameters while comparing against the predetermined optimal path. Then, the actual performance is scored, which helps to determine if the part was correctly assembled.
• The software includes the ability to monitor additional control issues, including badge scanning confirmation,
correct consumable confirmation and other functions. www.lincolnelectric.com
New bug. Bug-O Systems displayed its new K-Bug 3000, a digital, compact oscillating fillet welder. The K-Bug needs no track, instead running directly on the workpiece. The controller offers a choice of five weaving patterns and comes with a wireless remote control. Brad Mutscher and Jeff Nelson www.bugo.com
A clean shave. AlcoTec Wire Corporation displayed its 5XXX Series NT aluminum welding wire—a bulk welding wire that is virtually free of shavings. Shavings are usually collected in the liner, but can also accumulate on drive rolls and contact tips. Clogged liners often result in increased tip and liner replacement, downtime, and re-work. NT (new technology) is used to produce an aluminum welding wire that will not clog torch liners and offers improved feedability, says Thom Thompson. www.alcotec.com
Breathing easy. RoboVent Products Group displayed its Vortex collector, an air filtration system that creates a circular airflow pattern in a plant to clean ambient air. A complement to source-specific collection, the Vortex System uses 8-12 nozzles that can be adjusted to maximize the efficiency at which air is collected and filtered. RoboVent personnel engineer the system to meet the specific needs of the plant. The Vortex is especially effective when source capture of airborne contaminants isn’t possible due to large or unusual manufacturing operations or when overhead cranes limit the available ceiling space. No ductwork is required, a feature that lowers installation costs. www.robovent.com
Cordless punching. Hougen Manufacturing demonstrated a new cordless punch that can put a 19/32-inch hole in quarter-inch steel. The electro-hydraulic punch operates on a standard Makita 18-volt battery. www.hougen.com
Right angle. Tiger Angle, a new product from TigerStop, delivers automated material length positioning and compound mitering for complex cuts such as compound miters. TigerAngle is integrated by TigerStop and is equipped with the company’s automated length positioning system. This allows the TigerAngle to be used solely as a stop in a set point operation, or used as a push feed operation. Additionally, the miter saw has been retrofitted with TigerStop drives for automated miter adjustments. www.tigerstop.com
Under control. The Model Semi-Paxy CNC controlled plat positioning and punching system is shown here mounted on a Geka 110 ironworker. Compatible with all Geka automated machines, the controller shown here is mounted on a pedestal that swings out of the way as required. The positioning system has a positioning tolerance of +/- 0.0003 inches. Representing the company are Aitor Rodriguez and Don Letourneau.
Nonferrous? No problem. The new Scotchman SUP-500 NF saw specializes in cutting nonferrous materials. The upcut circular cold saw cuts up to six-inch materials at a 45-degree angle. Standard features include safety hood with safety switch so that the saw will not run with the hood up.
Punch it or burn it. Amada’s new ACIES punch/laser series of combination machines provide scratch-free processing of complex sheet metal parts. This innovative series also features automation and tool change options to suit virtually any production need. The ACIES series boasts extremely fast hit rates, stable processing, versatile forming and the unlimited shape cutting flexibility of a laser. Standard features include nozzle cleaner, and slug removal system. Tool changer provides a centralized tool location for up to 86 tools. www.amada.com
High-speed braking. The HG 8025 is the latest generation of high-speed press brakes from Amada America. A servo/hydraulic hybrid drive system provides speed and accuracy, as well as energy efficiency. Adding to the performance is software such as SheetWorks—a 2D and 3D modeling package that generates auto-batch processing based on 3D accociative drawing elevations and flat blank drawings that can be prepared automatically. www.amada.com
Fly like an Eagle. The Whitney fiber laser is touted by its manufacturer as the world’s fastest laser. The 6 kW fiber laser accelerates at six times the force of gravity. Whitney is part of MegaFab, Rockford IL. www.megafab.com
New ways. The Titan III features new linear ways in the Y-Axis, along with a new rack and pinion design. Wider end trucks allow for the electrical cabinets to mount within the truck for better protection against the harsh cutting and heat environments as well as providing a cleaner look to the machine. Wider end trucks with maximum guide roller spread further stabilizes the X-Axis motion. The new Titan III can be configured with high definition plasma torches, oxyfuel torches and even a fiber laser head. It can cut material up to 14’ wide with a machine motion accuracy of +/- .010”. www.messer-cs.com
Controlling the spray. Spray Systems Inc has developed proprietary software that works with an Allen Bradley controller to paint applications with the company’s spray booths, says Boris Orelliana. www.spraysystems.com
New fiber laser. Trumpf’s solid-state laser cutting machine, the TruLaser 3030 fiber, is a 2D laser that is able to cut up to 3/4 inch mild steel, 5/8 inch stainless steel and aluminum, and 1/4 inch copper and brass. With three kilowatts of power and a one micron wavelength, it cuts thin sheet metal, mild steel in all sheet thicknesses, non-ferrous or highly-reflective metals.
The enclosed frame ensures absolutely no laser light escapes, while its large certified safety windows allow the processing area to be clearly visible at all times.
The TruLaser 3030 fiber was shown with LiftMaster Compact and PartMaster. Capable of handing material while the machine is in production, the LiftMaster Compact achieves high-speed material handling in a minimal footprint. With the PartMaster, processed sheets are automatically transported to the sorting station, increasing sorting productivity by 30%. www.us.trumpf.com
Related story: Fabtech 2013 assembles “expo-nential”
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