FINE FOCUS
Plasma Cutting
with Robots
Pioneers in Plasma Cutting since 1959
made in Germany
Versatile • Efficient • Safe
FINE FOCUS
Plasma Cutting of Three Dimensional Structures
Industrial robots are excellently suited for
economic large-scale production, for effective
low-volume production and even for piece
production.
Kjellberg plasma cutting systems can be adapted
to all robots and robot controls in the market.
Robot-assisted plasma cutting offers all features
that are required for the use in industry and craft:
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Cutting to length, contour cuts and cutting of
openings on pipes
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Cost-efficient cutting
Simple programming and operation
High cutting speeds
High cut quality, nearly no rework required
High flexibility
It is possible to cut all electrically conductive
materials and diverse types of work-pieces:
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Structural components for vehicles
Pipes and containers
Hollow profiles, open and closed profiles as
well as bulb flat profiles
Dished bottoms
Plasma cutting with robots offers a number of
possible applications:
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Cutting a window into a passenger car sidewall
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Cutting on pre-selected paths or of workpieces with greater tolerances on paths with
automatic torch height control
Vertical cutting (straight cuts and holes)
Complex three-dimensional contours
Precise and variable bevel cutting
With some systems also marking
Underwater plasma cutting
Plasma cutting on hot work-pieces
At present, Contour Cut is the latest way of highquality plasma cutting.
It is the further development of the HiFocus
technology for cutting fine inner and outer
contours in mild steel and convinces with:
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Cutting of bevels of up to 50°, mostly for weld
preparation purposes
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High cut quality and contour accuracy
Low angular deviations and smooth cut
surfaces
Excellent repeatability and dimension
accuracy
High productivity at low costs
FINE FOCUS
High Flexibility of the Production
Today, robot-assisted cutting technique is mainly used for the processing of three-dimensional workpieces. The most important users are the automotive industry and its suppliers as well as enterprises in
container and pipe production, steel construction and shipbuilding. In these sectors, the plasma cutting
technique has already many times proven its advantages with regard to flexibility and cost benefits
compared to other technologies.
Examples from the Automotive Industry
End-cutting of hydro-formed axle components
for a passenger car
Cutting of a passenger car B-pillar from high-strength
material
Contour cut on a section of a vehicle exhaust system
from CrNi-materials (method: Underwater plasma
cutting for trim-free inner pipe surfaces and clean
cut surfaces)
Kerf on a galvanised passenger car body, the corrosion
protection layer next to the groove is preserved
on the work-piece surface
End-cutting of a safety profile for a passenger car body
Gap bridging: hole cutting with high cut quality
on spot-welded sheets
FINE FOCUS
Plasma Cutting in Container and Pipeline Construction
For cutting on curved surfaces, the robot requires a good sensor system with respect to the data exchange
with the plasma cutting system in order to achieve a constant torch height. So the conditions are fulfilled for
achieving excellent bevel cuts especially in this industrial field and, thus, reducing weld preparation costs.
Precise cutting of a pipe socket and the opening
on the pipe
Holes in dished bottoms also with bevel cuts for weld
preparation
Pipe end cutting of an external swivelling axis
Plasma cutting of a core hole with circumferential
counter bore
Cutting Tasks in the Shipbuilding Industry
One of the typical plasma cutting tasks in shipbuilding in connection with robots is the cutting of profiles.
End cutting and hole cutting with and without bevels in diverse flat profiles, angle profiles and above all
bulb flat profiles can be done easily and quickly. Also strongly varying material thicknesses on one workpiece are manageable without any problems.
Notches on diverse profiles
Bulb flat profiles are characteristic for the
shipbuilding industry
FINE FOCUS
Plasma Torches for Special Applications
For plasma cutting with robots, Kjellberg Finsterwalde has developed a wide variety of torches.
Depending on the task, several models are on offer:
l As straight version or with 60° or 90° angled cutting heads – they make it possible to cut even highly
structured work-pieces optimally
l With quick-change head
With Kjellberg plasma torches, bevel cuts up to 50° are possible. In connection with special torches, bevel
cuts up to 60° are possible.
HiFocus Plasma Torches up to 160 A
PerCut 160-2 LS
Robot plasma torch as straight version and with
acute-angled consumables
PerCut 160-2 60° LS
Robot plasma torch with cutting head angled by
60°, particularly suited for the processing of
structured parts
PerCut 160-2 90° LS
Robot plasma torch with cutting head angled by
90°, mainly for pipe end cutting
HiFocus Plasma Torch up to 440 A
PerCut 450M Robo
Robot plasma torch as straight version with
quick-change head
FineFocus Plasma Torch up to 300 A
PB-S80 W-2 Robo
Robot plasma torch mainly for cutting on even
surfaces, pipes and profiles, bevel cuts up to
45°
Overview of Plasma Cutting Systems Suited for Robots
Power Source
Cutting current at 100 % d. c.
Marking current
Recommended cutting range 1)
Max. cutting range
Max. piercing
Bevel cutting up to
Plasma torch
HiFocus 80i
10 - 80 A
0.5 - 15 mm
20 (25*) mm
15 mm
45°
PerCut 160-2 LS
Power Source
Cutting current at 100 % d. c.
Marking current
Recommended cutting range 1)
Max. cutting range
Max. piercing
Bevel cutting up to
Plasma torch
* With 2D consumables |
1
HiFocus 280i
10 - 280 A
5 - 50 A
0.5 - 50 mm
70 mm
40 mm
50°
PerCut 450M Robo
HiFocus 130
20 - 130 A
16 A
0.5 - 25 mm
25 (40*) mm
25 mm
45°
PerCut 160-2 LS
HiFocus 360i
10 - 360 A
5 - 50 A
0.5 - 60 mm
80 mm
50 mm
50°
PerCut 450M Robo
HiFocus 161i
10 - 160 A
5 - 25 A
0.5 - 25 mm
25 (50*) mm
25 (30*) mm
45°
PerCut 160-2 LS
HiFocus 440i
10 - 440 A
5 - 50 A
0.5 - 60 (80) mm
120 mm
50 mm
50°
PerCut 450M Robo
FineFocus 800
80 - 300 A
5 - 60 mm
80 mm
40 mm
45°
PB-S80 W-2 Robo
Listed material thicknesses depend on the kind of material
Example of a Connection Diagram
Connection diagram for HiFocus 360i with automatic
gas console: from an external CNC control, stored
cutting data can be activated, thus guaranteeing
optimum cut quality and highest reproducibility.
25.15 2.x4
Gase
gases
Air
2.x8
N2
25.11 2.x5
O2
25.15 2.x4
Air
2.x6
Ar
2.x9
N2/H2
2.x7
H2
Gasleitungen (5 Stück)
gas hoses (5 pcs.)
PBA- 360 Robo
6.xx (5/10/15 m)
6.00
3.31
3.32
3.4x
CNC
PBA-H
PGV 3
PGC
2.x3
3.5x
2.x2
8.xx
PZL 360
6.x0 (bis / up to 55m)
6.xx
1.61
Hi
360i
KWE 360
1.11
1.62
1.53
FINSTERWALDE
CE
1.63
FINSTERWALDE
CE S
Werkstückkabel
workpiece cable
1.64
Kjellberg plasma cutting units are CE-conform and correspond with the valid guidelines and instructions of the European Union. They are developed
and fabricated on basis of the standard EN 60974. The plasma cutting units are labelled with the S-sign and therefore applicable to environments with
increased hazard of electric shock. The fabrication takes place according to DIN EN ISO 9001. The factory-owned quality assurance comprises piece
and cutting performance tests, documented by test certificate.
Our products represent a high level of quality and reliability. We reserve the rights to change design and/or technical specification during the series fabrication.
Claims of any kind can not be derived from this brochure.
12-09-05
, FINE FOCUS ,
, YellowXLife , XL ,
HiFocus, PGC, PerCut and Contour Cut are trademarks of the
Kjellberg-Foundation/ Kjellberg Finsterwalde and may be
registered in Germany and/or other countries.
Kjellberg Finsterwalde Plasma und Maschinen GmbH
Germany
D - 03238 Finsterwalde
Leipziger Str. 82
Tel.: +49 3531 500-0
Fax: +49 3531 500-227
E-Mail: plasma@kjellberg.de
Internet: www.kjellberg.de
Copyright
2012
Kjellberg Finsterwalde Plasma und Maschinen GmbH
Alle Rechte vorbehalten.