Erik Metternich - Bystronic

Mikrocentrum Thema middag:
Geld verdienen met kleine
series plaatwerk

Erik Metternich – Sales Manager Bystronic Benelux BV

Eindhoven – 22 mei 2012

Bystronic

• Founded in 1986

• Field of activity: Sheet
Metal Processing Systems

• Headquarters:
Niederönz (CH)

• Since 1994 part of the
Conzzeta Group

© Bystronic | 05 .2012

Core Activities

Laser Waterjet
Cutting Cutting Bending
• Process chain:
cutting - bending
• All from a single source
• For all flat materials and
all shapes

Handling & Software & Services &
Automation Control Support
• Automation of entire
material and data flow
• Increased productivity
• Cost efficiency


Research and Development

• Bystronic is master of
all key technologies
and components

• Every 10th employee is involved in the development
of products and services


Key Figures 2011
• Sales 500 million CHF
(408 Mio. €, 563 Mio. $)

• Employees 1492
– Europe 1018 (of which 510 in Switzerland)
– Americas 110
– Asia 364

• Apprentices 98


Worldwide just around the corner

4 manufacturing locations
26 sales and service companies

Bystronic in Niederönz (CH)
• Headquarters

• Development and
manufacturing of laser
and waterjet cutting
systems

• Applications and demon
center

• Bystronic Sales Ltd


Bystronic in Gotha (D)
• Development and
manufacturing of Xpert
and Hämmerle
pressbrakes

• Application and
demo center


Bystronic in Tianjin (China)

• Development and
manufacturing of
pressbrakes

• Development and
manufacturing of laser
cutting systems for local
markets


Bystronic in Braşov (Romania)

• Refurbishing Center for
laser cutting systems


Product Portfolio
Laser cutting and automation (I)

BySpeed Pro Byspeed ByVention

Bystar Bystar L

BySprint Fiber BySprint Pro/BySprint

Product Portfolio
Laser Cutting and Automation (II)

ByTrans / ByTrans Extended BySort

BycellCross BycellLine


Product Portfolio
Waterjet cutting

ByJet Smart ByJet Classic ByJet Classic L

ByJet Pro ByJet Pro L


Product Portfolio
Bending

Hämmerle 3P Xpert Robot applications

Xact Xcel


Latest Developments

BENDING

Fast Bend+
Effective efficiency

Effectiveness can be efficient
Comparison safety systems
• AKAS manual
Speed changing Fast speed
Standard safety system on point area
many machines

16-25mm
Working
speed area
AKAS manuell

0 [sec] 3 6 Material

App. 5,5 Seconds cycle time

Lower
tool



point area

AKAS III motorisch 9-12mm Working
speed area
AKAS manuell


App. 4.2 Seconds cycle time

• AKAS III motorized Lower
tool
Optional on many machines



point area

Fast Bend (manuell)
AKAS III motorisch 9-12mm Working
speed area
AKAS manuell


App. 4.2 Seconds cycle time

• Fast Bend Lower
tool
Standard safety system on
Xpert


point area

Fast Bend+

Fast Bend (manuell)
AKAS III motorisch

AKAS manuell <4mm Working speed area


approx. 3.4sec bending cycle time

• Fast Bend+ Lower
tool
Standard for 3P and optional
for Xpert

Fast Bend+

Automatic height adjustment

100 [%] 110 120
+ Higher safety
+ Faster job change
+ Also for lateral tool changes



• ROI
AKAS AKAS III Fast Bend Fast Bend+
Speed changing <25mm <12mm <12mm <4mm
Time saving per bend 0 1.2s 1.2s 2s
Set up time safety system 60s 40s 60s 20s
Bend per hour* 400 480 480 560
Bends in % 100 120 120 140
ROI after (in Months) 0 7 0 4

Capitalised value 0€ 14.000€ 15.000€ 30.000€
*Oberer Todpunkt = 100mm, 90°, Materialstärke T=2mm, V=16mm, Wartezeit im UT 0,5sec, Xpert 150t, 20 Werkzeugwechsel pro Schicht, eine Schicht
pro Tag, 5 Tage die Woche, 40% Leerlauf, Werkzeugwechsel von 175 auf 250mm Höhe


Optical Bend Guiding System
For the fastest bending process worldwide

LED based
• Easier tool positioning

1 2

e.g. 2 tool positions over bending length


LED based

• Optically guidance through the bending process

– Easier tool positioning

– Clear back gauge position indication

– More effective station guiding

– Opened clamping information

– Error indication

– End of job indication


LED based
• Clear back gauge position indication

1 2

Indication of back gauge finger position


LED based
• More effective station guiding

1 2

Indication of next bending station


LED based
• Opened clamping information

Flashing stations or flashing over bending length


LED based
• Error indication

Light bars are indicating in direction of the control


LED based
• End of job information

Open flashing over complete bending length


Energy Saver
Bystronic Xpert

Bystronic Energy Saver

30% less energy consumption

Change of
product
and still
unique…
Up to 3% less energy consumption with START-STOP


Energy Saver versus conventional
Energy consumption
Consumption over time with Energy Saver (Xpert)
kWh %
Consumption over time conventional machine

100%

50%

Top dead centre Approach speed Bend Return Top dead centre Time

Energy consumption
Consumption over time with Energy Saver (Xpert)
kWh %
Consumption over time conventional machine

100%

Up to 30% energy saving

50%


Noise
Noise with Energy Saver
dB
Noise conventional machine

100 [Noise of a rock
concert]

70

40


Noise
Noise with Energy Saver
dB
Noise conventional machine

100 [Noise of a rock
concert]

Less noise – less stress

70

40


Less wasted heat

100

50

Energy Saver
Conventional
Heat %

0
Conventional Energy Saver

• Less heat – less climate costs*
*40% Standby time (some competitors assume 90%) 1 shift, 220 working days, 150t machine, 3kW power consumption
of a conventional machine in stand by, 24Cent/kWh


Let’s save energy.

LAMS
Quality up - Cost down

Bystronic Xpert
LAMS – Quality up Cost down


Bystronic Xpert
• Customer goal: First part, right part!

• Problem: Differences in …

Material 1 Material 2
Tensile strength / Quality

Same Sheet 1
material
Sheet 2
Sheet thickness /batch

Laminating direction

Spring back

Bystronic Xpert
Mode Compensation Special cycle

1 • Angle control • Non
LAMS ON
• Sheet thickness
• Geometry errors
2 • Angle control • Machine moves up by data
LAMS SB
with DB • Sheet thickness base SB value plus 2°
• Geometry errors • Sheet must be slightly guided
• Spring back
3 • Angle control • Machine moves 20° up.
LAMS SB
learn DB • Sheet thickness • Only used for data base learn
• Geometry error cycle for new materials
• Spring back

Bystronic Xpert
WITHOUT Data Base
start
No LAMS

90.0°
 15 S  5S
5.8 S
5.8 S

95.5°
10 S


BACK GROUND INFORMATION
Y
6mm P7 V40 ??steel??
DB


Bystronic Xpert
WITH Data Base
start
No LAMS
90.0°

 15 S  5S
6.1 S
6.1 S

90.6°
10 S


+0.0s
Y
6mm P7 V40 steel
DB


Bystronic Xpert
WITHOUT Data Base
WITH Spring Back Measurement start
LAMS - Mode 3

90.0°
16 S
 6.1 S
15 S  5S

90.1°
10 S


+9.9s

6mm P7 V40 ??steel??
DB


Bystronic Xpert
WITH Spring back value in Data Base
start
WITH Spring back measurement
LAMS - Mode 2
90.0°

 15 S  5S
6.1 S

90.1°
11.2 S 10 S


+5.1s

6mm P7 V40 steel
DB


Bystronic Xpert
start
LAMS - Mode 1

90.0°
 6.1 S
15 S  5S

7.5 S
90.1°
10 S


+1.4s

6mm P7 V40 steel
DB


Bystronic Xpert
start
Laminating direction 90° changed
LAMS - Mode 1
90.0°

 15 S  5S
6.1 S

7.6 S
89.8°
10 S


+1.5s

6mm P7 V40 steel
DB


Bystronic Xpert
start
Sheet was 0.5mm thicker!
LAMS - Mode 1

90.0°
 6.1 S
15 S  5S

7.4 S
90.1°
10 S

Sheet 1
Same
material Sheet 2
+1.3s

6mm P7 V40 steel
DB


Bystronic Xpert
Mode Compensation Special cycle

1 • Angle control • Non
LAMS ON
• Sheet thickness
• Geometry errors
2 • Angle control • Machine moves up by data
LAMS SB
with DB • Sheet thickness base SB value plus 2°
• Geometry errors • Sheet must be slightly guided
• Spring back
3 • Angle control • Machine moves 20° up.
LAMS SB
learn DB • Sheet thickness • Only used for data base learn
• Geometry error cycle for new materials
• Spring back

Bystronic Xpert
• All parts good parts, thumbs up!

• Automatic quality control

• No doubt, no stress


Bystronic Xpert
• Save cost on material

• Lower labour cost


Erik Metternich - Bystronic

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