Abrasive Jet & Water Jet Cutting Machines
Perfect Technology manufactures both an Abrasive Jet and Pure Water Jet Cutting Machine. The Waterjet system is an ideal machine for the cutting of various materials and is extremely versatile compared to alternative machinery such as lasers and plasmas. Waterjet cutting is performed with pure water for the cutting of - foam, package products, gaskets, gibson board, carpet, food, rubber, and many other soft materials. The addition of abrasive (garnet ) to the water stream provides the ability to cut - steel, stainless, copper, aluminum, granite, marble, laminated glass. In general soft materials are cut at a lower pressure range of 40,000 50,000 psi with hard materials requiring the higher 50,000 60,000 psi. The Waterjet cutting process does not generate heat; elliminating the warping of materials like copper and aluminum.
STANDARD SIZED SYSTEMS
4 x 8 , 5 x 10 , 6 x 12 , 7 x 12
4 x 4 , 5 x 5
2 x 4 Cantilever Designed Gantry
CUSTOM SIZED & FEATURED SYSTEMS
PTC has the flexibility to custom fabricate any table size. All engineering and fabrication is performed by in-house staff. Our sales team would be pleased to discuss your application in detail and propose a machine design to meet your needs. Material test cutting by PTC is available and recommended. Test results provide a customer an opportunity to evaluate - edge quality and actual cut speed. PTC engineering also offers specialized features such as gantry mounted drill heads and ink printer, clamp down systems, noise abatement enclosures, conveyors, dual shuttle systems, and material lifting systems.
PURE WATER CUTTING
Based on the media to be cut, PTC can offer cutting systems with cut speeds that will exceed 4000 inches per minute. This speed is triple other water jet manufacturers capability due to the PTC state of the art Linear Drive motion system. Pure water systems are designed with the gantry across the tables short direction, this reduces gantry weight and is ideal for loading / unloading in combination with a conveyor system or shuttle system for increased productivity. Soft materials are typically cut using a sapphire orifice ranging in size from 0.005 0.007 at extremely high speeds with multiple cutting heads to maximize productivity.
Pure Water 7 x 14 System, Dual Shuttles , 3 Cutting Heads
Hard materials require the addition of garnet mixed within the water stream. The abrasive delivery system consists of three components - a bulk garnet hopper, a metering device to regulate garnet mixture, and a mixing chamber within the cutting head. Abrasive cut speed range from 1-500 inch per minute based on material hardness, thickness, and cut quality. The use of diamond orifice is common to increase cutting accuracy and provide longer replacement intervals. Based on available horsepower the typical orifice size for abrasive cutting will range from 0.010 0.018. As one increases orifice size the cut speed will increase by ten to twenty percent.
All PTC Waterjet systems are fabricated from stainless steel construction and 100% TIG welded, each frame includes a five year structural warranty. The high pressure water coupled with abrasive is a harsh environment. Waterjet tables fabricated from mild steel and painted begin to rust process in a short period of time and if not periodically repainted becomes structurally unsafe. PTC gantry system is fabricated from extruded aluminum. Even electrical access panels have stainless steel machine screws.
All PTC abrasive machines have cut bed=s fabricated from galvanized steel slat material mounted above the water collection tank. Slats are mounted on 1.187@ centers and held into place by stainless steel comb cut support members. Design is such that slat material is easily renewable. For pure water cutting of small parts, corru-plastic material can be easily placed on top of the steel slats and the cutting head elevated as necessary.
The abrasive systems require 32-34 inches of water to dissipate the water / abrasive stream energy. Less than 30 inches of water with time could cause structural damage (potential hole) to the bottom of the tank. High pressure water does not have the same energy without the abrasive additive, therefore a stainless steel collection trough is provided with pure water systems.
LINEAR DRIVE MOTION SYSTEM
All PTC Waterjet systems are equipped with a state of the art Linear Drive motion system for powering the gantry and cutting head movement. This system consists of a computer controlled linear induction motor, magnetic coupled by rail mounted inert magnet sets. This drive package transmits power without the use of any mechanical components and operates without racks/pinions, drive belts/sprockets or ball screws. Elimination of these components improves mechanical reliability and reduces maintenance.
THE LINEAR ADVANTAGE
Rack / Pinion Issues a common issue is premature pinion wear. Should abrasive overspray be introduced within the lubricant it accelerates pinion wear. Once the pinion is partially worn, accuracy and backlash are less than desirable. Some companies attempt to compensate for pinion wear by software adjustment.
Ball Screw Issues have a limited table length and require backlash nuts to partially compensate for backlash concerns. Backlash nuts require periodic replacement. Limited speed capability. Lubrication is required.
Belt / Sprocket issues - the belt systems will operate at higher speeds but lack the positioning accuracy of the Linear.
The operational software is designed exclusively for the PTC Waterjet. All operational software is written and updated by PTC in-house programmers. The software package is designed to read G code cut files created from the post processing software. The G code file is an inclusive cut file designated cut speeds, lead-ins, type of hole pierce, abrasive metering.
The operator has excellent control to include:
A hand held control unit is standard with each system. This allows the operator to manually make adjustments in the X, Y, Z axis in a slow or fast pace. A time saving feature is the 45 degree button to simultaneously move in the X and Y axis.
DIGITIZING CAMERA / SOFTWARE
Every PTC waterjet is equipped with its own digitizing software and camera system to trace a flat irregular pattern directly on the machines cut bed. The software outputs a DFX file ready for post processing to a G code cut file. Setup and file creation is quick and accurate enabling the user to handle odd shaped patterns that otherwise would be time consuming and difficult to formulate by measuring and drawing in AutoCad.
POST PROCESSING SOFTWARE
The waterjet technology tables are specific for each type of material, it provides reduction in speed at corners, special piercings and multihead capability.
Automatic and manual nesting with great flexibility and maximun performance. The perfect combination of automatic and semi-automatic nesting along with powerful manual nesting functions like: copying, moving, rotating, adjoining, etc. Lantek Experts automatic nesting optimises to the maximum the arrangement of parts on the sheet. Lantek Expert generates nestings on remnants. Just like for sheets, margins can be defined for remnants.
Configure and manage the type and value of lead-in/lead outs for different types of contours.
Common line cutting can be achieved on several parts or just limit to pairs of parts. With microjoints and pre-cuts.
It detects errors in the design and machining.
Lantek Expert Cut has automatic lead-ins, manual and automatic cutting, machining copy, customised machine configuration and postprocessor for all types of machine.
INTENSIFIER PUMP TECHNOLOGY
KMT Waterjet Systems ( formally the Ingersoll Rand pump division ) engineers and manufactures the finest High Pressure Pumps in the world market. KMT sells more pumps worldwide than any other high pressure manufacturer. Their product reliability, performance, and service support is superior to all providers. Competing pumps in the industry are not designed to the same rigid engineering specifications, resulting in frequent maintenance intervals, loss of production time and high spare part expense. Some pumps are not intensifier pumps but direct drive units whose initial capital cost maybe lower but they require multiple times the maintenance effort for the life of the pump. KMT manufactures a full line of intensifier pumps:
Model S-30 30 hp
Model E-50 50 hp
Model SL-V series 30 , 50 , 60, 75, 100, 150, 200 hp
For intensifier pump specifications visit:
© COPYRIGHT 2006 ALL RIGHTS RESERVED PERFECT TECHNOLOGY