LaserCoil Technologies LLC has released information on how its patented conveyor design significantly contributes to the speed of the company’s coil-fed laser cutting systems. The LaserCoil process relies on a series of dynamic profile conveyor lanes that independently and dynamically reposition to maintain a clear path below the moving laser head while also automatically shedding scrap during the cutting process. This multi-lane high speed conveying system is designed to adjust quickly and not limit the overall system's laser cutting speed, even in the direction of material flow. The dynamic conveyor lanes can clearly be seen in operation in the video below....

​With the LaserCoil approach, scrap falls to the bottom of the machine where it is conveyed to a scrap bin or shed to a scrap system. This delivers a high precision quality edge, ready-to-stack part at the end of the line without impacting production time.   

The Impact of Scrap Handling
Coil-fed laser blanking systems that do not remove scrap automatically during the laser blanking process require users to redesign blank shapes that utilize the entire coil strip, eliminating any scrap. This approach can potentially help speed production rates, but impacts the ability to design blanks that are optimized for the forming process. Alternatively, with systems that don’t automatically shed scrap, if the blanks are not designed to use the entire coil strip, then an auxiliary scrap removal solution has to be incorporated into the line. This greatly slows down the production rate and adds tooling costs to the solution.

With the LaserCoil design, users have the flexibility to configure blanks and use the system in a way that best meets their needs.  For example, Service Centers might select to optimize material usage whereas OEMs can program the system to meet the highest production rates. This ability is enabled through the fact that scrap is gravity-shed automatically and, therefore, does not impact the system speed.
 
Additional Flexibility 
LaserCoil  systems come with lasers up to 8kw in strength, available as single or multi-head systems, in a multitude of configurations, where each head can cut independently of the other, and which also allows an increase in flexibility as well as a decrease processing time for improved productivity.  Additionally, the LaserCoil systems offer multi-mode capability where users can choose either Feed Index Mode (stop/start) or Continuous Mode for optimizing cutting parameters for each part configuration, increasing processing rates and enhancing quality. 
By laser cutting direct from coil stock, LaserCoil systems provide a fast and flexible approach to blanking that is well-suited for production environments running multiple blank profiles and mixed material types. The systems can handle coil stock up to 2.1 m wide in any length, and can process aluminum, mild steel, advanced high-strength steels, materials for surface sensitive panels as well as structural components.With 8kW systems, simple shapes in material thicknesses from 0.5 to 0.75mm can be cut with speeds approaching 2.2 meters/second, making laser blanking a viable and competitive manufacturing choice for volumes of over 100,000 per year, in some cases.

LaserCoil Technologies LLC has increased the cutting speed and power of it laser blanking systems with the introduction of 8kW fiber lasers featuring a proprietary Z-axis design integrated directly into the laser blanking system. This feature allows the laser head to more rapidly adjust to height variations in the material, maintaining consistent stand-off. As cutting speeds increase with the higher power laser, it is imperative the performance of the Z-axis increases accordingly to realize the system’s full potential. 


In the past when reaching higher cutting speeds, especially in the range of 1000-2200 mm/second, the system’s ability to adjust to variations in material height with less than perfectly flat material lagged behind the laser’s potential cutting speed, essentially keeping the system from reaching its full throughput potential. This was, in part, due to this Z-axis adjustment being tied into a separate controller, functioning through a separate HMI. But the new integrated Z-axis offers the ability to maintain the higher speeds with a wider range of less than perfectly flat material. 


“We’re proud of our continuing enhancements of the LaserCoil blanking systems and really excited to unleash the power of these machines,” said Jay Finn, general manager and chief technical officer. “With the speed capability of an 8kW laser, any fabricator should be seriously looking at laser blanking as an alternative to mechanical blanking operations, if they haven’t been already.”


The systems can be sold with a single laser 8kW head or with multiple heads, which allow a shared balancing of the cutting workload to decrease processing time and improve productivity. Additionally, the LaserCoil systems offer multi-mode capability where users can choose either Feed Index Mode (stop/start) or Continuous Mode for optimizing cutting parameters for each part configuration, increasing processing rates and enhancing quality.


By laser cutting direct from coil stock, LaserCoil systems provide a fast and flexible approach to blanking that is well-suited for production environments running multiple blank profiles and mixed material types. The systems can handle coil stock up to 2.1 m wide in any length, and can process aluminum, mild steel, advanced high-strength steels, materials for surface sensitive panels as well as structural components. With 8kW systems, simple shapes in material thicknesses from 0.5 to 0.75mm can be cut with speeds approaching 2.2 meters/second, making laser blanking a viable and competitive manufacturing choice for volumes of less than 100,000 per year.
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When LaserCoil upgraded its systems from a 4kw to 6kW laser, it produced a 10 -25 percent increase in speed enabling the systems to cut 0.5 to 0.75mm thick materials at 1.5 meters/second. Since then, the company has developed multiple-head systems capable of improving throughput by 85 percent, its own LaserCoil CAM software, a multi-mode option and integrated robotic stacking, as well as this recent 8kw capability. Currently, there are four LaserCoil cutting systems installed and running production.

LaserCoil Technologies LLC has announced the addition of Continuous Mode (On the Fly Cutting) capability to its coil-fed laser blanking systems enabling users to choose either Feed Index Mode (Stop/Start) or Continuous Mode in order to optimize cutting parameters for each part configuration, increasing processing rates and enhancing quality.  To illustrate the process, LaserCoil has posted a 2:15 minute video on the home page of its website.

“The introduction of our multiple head systems featuring 6kW lasers had already enabled LaserCoil systems to reach high processing speeds,” said LaserCoil Technologies Chief Technology Officer Jay Finn. “But the ability to change between Index Mode and Continuous Mode allows the customer to select the mode that offers the best production run from a rate and reliability standpoint.”

“Most parts will run faster in continuous mode, which offers a smooth and steady mode of operation. For production run that are 10,000 blanks and over this would be the mode of choice for customers,” Finn elaborated. “In some instances, the length of a single cut path can take longer than the existing cutting window allows at the faster production rate. Rather than split the cuts between the heads, index mode allows the user to choose a mode where the cut can be completed prior to indexing the material.”

LaserCoil Technologies’ coil-fed laser cutting systems feature gantry-mounted laser heads stationed in multiple cutting cells that travel along the moving strip, and balancing the workload. The laser cutting heads, using linear-induction motors, enable cutting of tightly nested, complex curvilinear shapes while the system’s dynamic profile conveyor features adjustable lanes that support the coil strip while automatically repositioning as needed to clear a path for the laser cut. This feature also facilitates gravity-shedding of scrap and offal, delivering completely finished blanks without any scrap to any type of stacking system.

Importantly, from a capital investment standpoint is that LaserCoil systems are flexible and can integrate with any coil line automation, as well as be retrofit into aging blanking press lines.

By laser cutting direct from coil stock, LaserCoil systems provide a fast and flexible approach to blanking that is well-suited for production environments running multiple blank profiles and mixed material types. The systems can process a wide variety of coil material in aluminum, mild steel, the new high-strength steels, and other materials for surface sensitive panels as well as structural components in thicknesses from 0.5 to 3.5mm and up to 2.1 m wide coil at any length.

For more information on this approach to laser cutting watch the video to see a LaserCoil system running in continuous mode.

​LaserCoil Technologies LLC announced that it has added end-of-line robotic stacking capability to its coil-fed laser blanking. Available in either single or dual stations, the stackers are side-by-side. The stackers can be programmed to handle rectangular, trapezoid, patterned, contoured or irregular shapes in both aluminum and steel.

The addition of automated stacking capability to the LaserCoil offering can lead to improved blank quality by preventing marring of the surface finish and contaminants that can be introduced via manual operations. Additionally, LaserCoil’s use of automated vision technology allows for high accuracy stacking without tamping or touching the edges of the blanks.
 
By laser cutting direct from coil stock, LaserCoil systems provide a fast and flexible approach to blanking that is well-suited for production environments running multiple blank profiles and mixed material types. The systems can process a wide variety of coil material in aluminum, mild steel, the new high-strength steels, and other materials for surface sensitive panels as well as structural components in thicknesses from 0.5 to 3.5mm (0.0197 to 0.1378-in) and up to 2.135 m (84-in.) wide coil at any length.
 
Additionally, laser systems can significantly reduce material scrap given their nesting capabilities. Not only can components be nested more closely, but lasers allow smaller parts to be co-produced from normally unusable hunks of metal — window cutouts, for example. In a conventional stamping operation, this material would be sent for recycling, or stacked and stored for future re-blanking, both of which are wasteful.
 
Importantly, from a capital investment standpoint, LaserCoil systems are flexible and can integrate with any coil processing line or be retro-fit into an existing mechanical press blanking line.

Article Post: 1/8/2018RAY CHALMERS
Contributing Editor

By 2025, use of advanced high-strength steel (AHSS) for automotive lightweighting is expected to double from current levels. Good news for steel suppliers. Not so good for automotive pressrooms. First off, stamping these materials typically requires increased forces, making shear blades or blanking dies wear faster. Often, processing high-strength steels requires moving the job to a larger-capacity press line to achieve the same cut. Not only do tools wear more quickly, the chance of micro-fractures occurring along the cut line also increases in line with material hardness. These micro-fractures can develop into splits during the forming process....
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LaserCoil Technologies LLC has entered into a strategic alliance with The Bradbury Group (Moundridge, KS), a world leader in roll forming and coil processing equipment. Through this agreement both companies will promote turnkey coil fed laser blanking solutions to Bradbury’s traditional customer base.
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“The strength of Bradbury’s sales team, the breadth of its product offering and the precision of its leveler technology makes this relationship an excellent way to expand LaserCoil’s blanking solution into new markets,” commented Jay Finn, LaserCoil Technologies general manager and chief technical officer.

​LaserCoil Technologies LLC has announced the addition of LaserCoil CAM to its coil-fed laser blanking systems, automating the importing of part profiles for optimized nesting and laser cutting to save significant time and money. LaserCoil CAM accommodates single and multiple cutting heads, as well as peripheral automation, such as the system’s dynamic conveyor lanes. In addition to optimizing the part recipes, LaserCoil CAM also controls and monitors the LaserCoil system during production.

“Creating nesting and cutting programs is a time-intensive process requiring a skilled technician,” said LaserCoil Chief Technology Officer Jay Finn. “LaserCoil CAM takes only minutes from the importing of CAD files to active cutting of a simple blank. To illustrate its efficiency, imagine if you could design and machine a blanking die for a complex part in less than 30 minutes.”

The program is designed for ease-of-use, enabling even less experienced system operators to quickly create an optimized program. LaserCoil CAM starts by creating a recipe with pre-built initial cutting parameters that are supplemented with the blank’s profile data imported via a CAD file.  The user can either ask the software to select the best coil from multiple coils in inventory, create the best nest for a specific coil width, or permit the program to specify the optimum coil width based upon part yield.

Taking into consideration the appropriate grain constraint for material flow as well as part profile, the software identifies the best nesting pattern. LaserCoil CAM then determines how the profiles will be cut by the laser. Next, the operator generates the cutting path, and adjustments can be made by simply clicking on the profile parameters and setting a new cutting routine.  A simulation is run to show the sequenced travel path of the laser cutting head.

“We’ve achieved real-world results that prove the value of this first LaserCoil CAM release,” noted Scott Sonnenberg, LaserCoil director of mechanical engineering/product development. “This software provides our customers a single interface to help reduce programming time and scrap rates, as well as improve their throughput and yield.”
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By laser cutting direct from coil stock, LaserCoil systems provides a fast and flexible approach to blanking that is well-suited for production environments that run multiple blank profiles and materials in runs of up to 100,000. The systems can process a wide variety of coil material in aluminum, mild steel, the new high-strength steels, and other materials for surface sensitive panels as well as structural components in thicknesses from 0.5 to 3.5mm and up to 2m wide coil at any length.