MEGACUT 5A - 5 AXIS GANTRY MACHINING CENTRE

The MEGACUT 5 Axis workstation is formed from an open high level gantry which carries the system of overhead X and Y axes movements, which supports the vertical Z axis column that in turn carries the rotating and tilting processing head. 

The MEGACUT system robust modular construction ensures the accuracy and repeatability required for the laser operations desired and is capable of accommodating a wide range of fixtures and parts.

The MEGACUT series are proven solutions for 3 axis or 3 dimensional flexible low and high volume laser production.

MULTI AXIS GANTRY SYSTEM DESIGNS

Parallel to the development of the relatively simple 2 - 3 axis laser systems progression into the processing of three dimensional shapes has rapidly taken place.  Development of mirror and optical path technology together with machine movement and control advances have made it apparent that considerable advantages can be gained in a large range of applications within a three dimensional envelope.

Developing these systems machine manufacturers divided themselves into two camps, those who continued with moving the workpiece in at least one axis and those who utilized the development of the moving optic principle.  Essentially, both principles can provide a full 5-axis capability contained in three linear movements (X,Y, Z) with two rotational axes (A & C).

Each machine concept relies upon the rotational and tilting axes being contained within the processing head assembly which is mounted upon the Z Axis column.

In much smaller numbers, some manufacturers convert the fixed optic design (two or three axes based) to five axes by the introduction of a rotary and tilting supplementary table secured to the workstation table.  However as previously stated, even with its high resolution capability this type of configuration is limited in size and confined to applications such as hole drilling in radial components or restricted profiling in such a component. These types of system are generally to be found in such areas as aerospace engine part manufacture, automotive stamping and research centers.

Very early developments centered upon adapting existing robot technology with an optical chain of mirrors.  The concept of using an articulated arm presents several problems in the form of severe restriction in working volumes due to the presence of the articulated arm carrying the processing head, an extensive series of fixed mirrors (perhaps up to nine, rigidly fixed in pairs at each of the arm joints), which are needed to transmit the output beam from source.  Further limitations were the inability to transmit powers in excess of 1 Kw and the need for continuous realignment.  Systems of this type are now produced in very small numbers and limited to use with the Nd:YAG laser with fiber optic delivery.

With recognition of the robotic limitations, manufacturers turned their attention to finding an alternative method that would allow the free multi axis manipulation of the CO2 laser beam in the larger three dimensional envelopes required by industry. 

In providing a solution, suppliers adopted the Carthusian method of construction and even now, this remains the predominant type of system offered.  The design concept of the system allows for the components to be positioned or mounted upon a stationary work table or specific component fixture which is positioned within the working envelope of the system.

The workstation is composed of an open gantry which carries the system of overhead X and Y axes movements, both of which support the vertical Z axis column that in turn carries the rotating and tilting processing head. 

The laser unit is positioned adjacent to the gantry assembly and similar to the moving optic principle the laser beam output is directed from the laser through a series of mirror fitted to the movement of the various axes to the process head.

The development of the less prominent machine design, sometimes called the 5 axis (4+1) system is founded upon the workpiece table moving in one axis (X Axis), whilst the remaining linear movements Y and Z axes are contained in a fixed bridge assembly whereby the Y axis movement is incorporated into carriage assemblies carried by the bridge.  In turn the Z axis design arrangements and movement are as described in the moving optic system  Essentially the machine is an extension of the 2 - 3 axis hybrid design concept enlarged in its capability by the incorporation of the rotary and tilt processing head.

NV L. Balliu MTC introduced its first Carthusian gantry design, in the form of the Megacut High Level 5 axis system in 1991 and from that time has extended its multi axis system range to include the Megacut Low Level Large Area design and the LCF Cantilever systems.

The introduction of the Megacut Low Level Large Area system by NV L. Balliu MTC was a significant step forward in laser system design. For example by providing a 3 dimensional large processing area that can be extended to suit a specific need such as could be found in commercial vehicle and ship building manufacturing NV L. Balliu MTC was the first company to take the industrial laser into these areas.  Combining the ability to accurately handle large and heavy blanks and efficiently process with higher laser powers in a 3 dimensional envelope NV L. Balliu MTC is uniquely placed in this field.

The open work station design of the LCF Cantilever system has increased the ability of NV L. Balliu MTC to provide a flexible 3 - 4 - 5 axis work handling requirement within a compact area. The open access on three sides of the LCF gantry allows for the easy placement and removal of many forms of material work tables or fixtures. This flexibility offers the opportunity to not only design and manufacture purpose built work retention devices but also process small and large production batch quantities with minimum changeover time.

There are now many proven examples of each type working in industry. The ability to provide a multi axis configuration tailored specifically to suit a given three dimensional production requirement either as a stand alone installation or as part of a turnkey line has ensured that NV L. Balliu MTC is an automatic first choice in this area of laser processing.