New products for a competitive edge
The world market leader, elumatec AG, is presenting new solutions for profile machining at BAU 2015 with which companies in the metal construction and industrial sectors can propel their businesses to new heights profitably. On a floor space of 365 m2 in Hall C1 at Stand 502, visitors can obtain comprehensive information about how the innovations can help them get a step ahead of the competition.
The new products stand out especially through ergonomics, efficiency and flexibility – in other words, the key factors for increasing productivity and profitability. “Our products are adapted to customer’s needs – not the other way around. This applies to existing solutions which we configure with tailored precision or expand modularly. It also applies in particular for our new products, as well as optimised versions of existing equipment, which we adapt in close cooperation with our customers to suit their needs,” says elumatec chief officer for sales and marketing, Ralf Haspel. A prime example of this is the SBZ 628 profile machining centre that elumatec is presenting as a world premiere.
The new SBZ 628 profile machining centre.
Entry level products with cutting edge technology
The newcomer in the SBZ family takes the cutting-edge technology of the SBZ 630/631 that is already successfully established on the market and combines it with an impressive versatility for the machining and length cutting of aluminium profiles for windows, doors and curtain walls. “This model is aimed at companies that want to reach the next level of productivity using automation, but don’t need a high-end machine to do so,” Mr. Haspel notes. The SBZ 628 is notable for its versatility and user-friendly operation. This allows a wide variety of different requirements to be fulfilled with a minimum of effort using up to eight routing units that can operate freely on the profile cross-section in coordination with patented innovations, such as travelling clamps and pivoting grippers.
Thanks to the rotating milling spindles and the infinitely variable pivoting saw, the centre can accomplish even complex machining tasks in any number of angle combinations. In spite of its compact layout, it has a large loading magazine to ensure an interruption-free production flow. The system is controlled using the intuitive eluCad software from elusoft. The advantages are a high level of process reliability as well as increased output. Visitors can view the SBZ 628 on a video wall at the exhibit stand or experience it live at the elumatec headquarters in Mühlacker.
Compact and user friendly with formula 1 performance
The four-axis SBZ 137 was launched last year for PVC machining and will be making its debut for aluminium at BAU 2015. “In designing this machine, we placed considerable emphasis on making it as compact as possible, while still providing a large machining area, so that companies can integrate the machine into their production processes with no difficulties,” says Mr. Haspel. The SBZ 137’s workpiece table with a 30 degree tilt sets a new standard when it comes to ergonomics. The operator can load profile bars with no back strain, and has a very clear view of the machine in all machining positions. The ring module reaches a top speed of 150 m/min, which greatly reduces machining times.
The on-board tool magazine and the software-controlled clamps that can be adjusted by and large without tools support short working cycles and fast conversions. Consequently, the machine is especially suitable for companies that, in addition to high volume jobs, must also regularly process one-off pieces. The SBZ 137 was awarded the innovation prize at “Equipbaie et Métalexpo 2014” in Paris, and with its groundbreaking and patented machine concept, it represents the future generation of 3 and 4-axis machines in the elumatec family.
The SBZ 137 profile machining centre, featuring patented solutions.
Maximum capacity with the smallest possible footprint
The concept machine, first introduced at BAU 2015, already demonstrates some of the key elements of the coming solution generation. It continues the trend to maximum machining capacity in the least space possible that was begun with the SBZ 137. By reducing the installation footprint and increasing the machining range, users are given improved flexibility because they can process profiles with larger cross-sections. A new controller delivers better handling while the safety hood offers work safety and reduced noise emissions. The energy consumption has also been reduced: Thanks to a new drive technology, the motor draws only the amount of current it needs (regardless of its power rating) for the load it is handling at the moment. This saves operating costs and increases the service life of the motor.
Intelligent controllers increase speed and production reliability
Both the 5-axis centre, SBZ 151, a powerful multi-talent for the industrial machining of aluminium and steel profiles, as well as the DG 244 double mitre saw, which cuts large-volume and thick-walled aluminium profiles quickly and with precision, have been equipped by elumatec with the most advanced control technology. In the SBZ 151, this makes the machining of complex profiles even more reliable, user friendly, and cost effective. The low-wear direct drive increases the level of machine availability. A light barrier ensures protection and compliance with current safety standards. Users also benefit from rapid and exact positioning of the machining assembly and shorter travel paths for parts manufacturing. In the DG 244 double mitre saw, the new 12-inch touchscreen gives access to control of all relevant functions while providing improved ergonomics and a clearer overview. “Our innovative solutions offer cutting edge technology that is ‘made by elumatec’ and goes a step beyond current needs,” says Mr. Haspel. These attributes include functions such as intelligent control technology, which, thanks to greater networking between machines, has the potential to simplify or automate an ever growing number of process steps, particularly in conjunction with eluCad software from elumatec’s subsidiary, elusoft.
The DG 244 double mitre saw, featuring a new control system.
eluCad 4.0: Complex functions that are easy to use
Our subsidiary, elusoft, has released an updated version (4.0) of its eluCad profile machining software. One of the main improvements in the new version is that it makes operation simpler and more user friendly than ever before. In keeping with market requirements, the scope of eluCad’s options has been steadily broadened, and many of these now open in separate windows. Thanks to a revamped structure, eluCad 4.0 incorporates the software’s numerous functions into a single overall view. This enables the user to become comfortable with the software even more quickly. Job-related variables, i.e. placeholders for values that can be changed, such as the X-position of a lock case machining task, can now be given any name desired, and the number of variables per job is unlimited as well. The eluCad add-on is useful for CSV imports, for example. Excel tables for controlling ready-made master programmes can also be imported using this function. These master programmes only need to be programmed once and can then serve as a basis for many machining programs. This dramatically reduces the amount of effort required for programming. In curtain wall construction, for example, machining programmes can be created very quickly for similar parts that only differ from one another slightly.
There are also fewer windows in the settings dialogs. One aspect of user friendliness is that eluCad checks the input for plausibility. The software tells the user in plain text if tasks entered are illogical, or are deactivated by other features. All settings for any given target machine can be saved. This is important for all customers whose available machinery includes several profile machining centres.
3D import module: Rapid comparisons with the original file
Likewise optimised is the eluCad 3D import module, which automatically recognises machining tasks from 3D models, allowing programming in a matter of seconds. The low percentage of complex machined parts that prove to be unidentifiable can now be readily detected and rapidly re-worked. Once the relevant 3D model has been imported, the user can superimpose the original, for example from AutoCad, onto the eluCad model which includes the machining tasks. This enables the user to rapidly compare whether all machining tasks have been fully and clearly recognised. For example, if complex notching is not correctly identified, eluCad 4.0 enables the user to click on this machining task and rework it quickly. This also works for free forms, drilled holes, slotted holes, rectangular pockets, circular pockets, and lines.
eluCad 4.0 enables the user to superimpose imported 3D models over the model created in eluCad which contains the identified machining tasks marked in blue.
For the profile shown in the picture, all machining tasks were identified correctly.
Engraving text in aluminium profiles
Whether it be identification numbers, logos, company names or advertising slogans – sometimes businesses wish to engrave lettering on aluminium profiles during machining. This is now easier than ever because eluCad treats the lettering as a free form. The user writes the text, changes the font, font size or other parameters as needed and positions the lettering on the profile. eluCad then calculates and creates the required tool path for the engraving.
Engraving profiles – it’s even easier in eluCad 4.0.
About elumatec AG
elumatec AG is an international leader in the manufacturing of machines for processing aluminium, PVC and steel profiles. With its extensive product range, the company covers the entire spectrum of applications from small craftsman’s businesses to industrial profile processors. Custom-designed and modular machinery concepts provide flexible and individualised industry solutions for all groups of customers. The company, founded in 1928 with headquarters in the Swabian town of Mühlacker in Germany, has subsidiaries and representative offices in more than 50 countries and, with over 700 employees worldwide, most recently achieved consolidated sales of about 130 million euros.