Produce complex welding bevels quickly and easily with the cutting robot BIBER

The BIBER cutting robot creates completely new perspectives for the preparation of weld bevels on complex components. While there are simple thermal or mechanical processes for producing weld seam preparations for straight edges or for pipes, this is still very time-consuming for more complex components with several curves and angles. CNC cutting systems could take over this task to some extent with additional bevel aggregates, but they tie up valuable capacities and usually work too inaccurately. This system is economically profitable from a batch size of 1.

There is an excellent alternative to bevel aggregates, grinding and milling for the economical production of weld seam preparations on already cut-out components in large quantities, small series and single pieces: By using the BIBER bevel cutting system, expensive bevels that are complicated to produce can be realized quickly, easily and at low cost. All types of bevels can be applied to already shape-cut parts – in extreme cases, up to four different bevels on one edge. Single and double bevels can be created, as well as bevels with or without a ledge. Even isolated straight cuts are possible. The stable design of the cutting system guarantees maximum accuracy and dynamics. The BIBER cutting system is available with both oxyfuel and plasma tools. If required, both technologies can be combined on one system and quickly changed.

By using a special bevel cutting table, metal plates can be processed on the top as well as on the bottom side.

Equipped with the self-developed BIBER software , the most accurate bevel cutting results are possible without large setup and positioning efforts.

By using a laser scanner, even dimensional deviations from pre-processes are detected and corrected. This makes the system a cost-effective and efficient alternative to all conventional methods of producing bevels.

>> read more on our website: https://www.erl-cutting.com/produkte/roboterschneidanlagen

erlcut cutting systems set new standards in terms of flexibility and precision in sheet metal cutting. They impress with their robust and compact construction in a stable portal design combined with the latest control technology and integrated differential compensation for precise guidance in harsh working environments. Double-sided rack drives with brushless AC servo motors offer excellent dynamic characteristics with high contour accuracy for best cutting results.

The cutting systems from ERL Automation are available as pure plasma cutting systems or oxyfuel cutting systems. Of course, both cutting processes can also be combined on one system and, depending on the series, additional tool stations can be added, such as a pneumatic drilling system for drilling, countersinking and tapping or various marking and labelling tools.

erlcut cutting systems are developed, built and commissioned at the company's headquarters in Landau a. d. Isar before they are integrated into production at the end user – be it a contract cutting company, a manufacturer of cranes or a construction equipment supplier.

The profiBIBER is the most widely used BIBER system. In this design, the cutting robot is installed on an upstream console that can be moved on a linear unit. This allows the working area to be decisively extended. Two variants are possible: Either one large cutting area is available, or two smaller working areas, divided by a partition wall. Depending on requirements, the dividing wall is designed so that it can be lifted by crane or moved by a special rail system, creating sufficient space even for large components. The robot's working area is protected by light barriers. In the version with a dividing wall, the light barriers are active in the area in which the robot is currently cutting. The other area can be entered and loaded or unloaded at the same time. This system is ideally suited for small, medium and large components, depending on the table size, and can be combined with a noise-reducing operating centre.

To protect employees from unnecessary noise exposure, our erlcut cutting systems are available with a soundproof housing on request. In the silent version , the erlcut is completely surrounded by the soundproof booth. For an optimal isolation, the cabin has a wall thickness of 100 mm and is covered on the inside with galvanized, perforated, drawn special acoustic perforated sheet metal.

The sound pressure level to which the operating personnel are exposed outside the cabin is more than 30 db(A) lower than it would be without the housing of the cutting system. As a result, the permissible trigger level of 80 db(A), at which hearing protection measures would have to be taken in accordance with occupational health and safety regulations, is not exceeded, allowing the plant operators to work in comfort.

To meet different customer requirements, various options are available for loading and unloading the system. With the manual sliding door system, for example, the cutting table can be loaded in the booth by crane or forklift. For maximum productivity, an automatic changing table system can be used.

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With the erlcut-drill drilling unit, precise drilling and countersinking up to a diameter of 40 mm (depending on material and component) and threads from M6 to M20 can be realized. Depending on the tool, sheet thicknesses of up to 200 mm can be handled.

The tool magazine is designed to hold up to 12 tools and is located directly on the portal bridge of the system. It has its own drive to position the selected tool for pickup by the drilling spindle. In the parking position, it is protected from drilling chips as well as flying sparks.

To avoid errors in the process, the lengths of the drilling tools being used should always be accurately recorded. This function is automatically executed by the system. The tool measuring system measures the length of the tools before they are used.

To protect against flying drill chips, the drilling unit is located in a housing. To give the operator easy access to the drilling unit, the protective housing can be opened over a large area via four hinges. A pneumatic hold-down device fixes the sheet metal / workpieces during mechanical processing and reliably prevents any movement of the material to be processed.

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The new erlcut plasma beveling aggregate is designed for welding bevels on flat material. This allows simple components that have both, chamfers and vertical cut edges, to be cut out of the sheet metal in one step. Depending on the power source used, the plasma rotator enables bevels up to 40 mm long with angles between 0° and +/- 50°.

The rotator unit with intelligent initial height finding is attached to a fully automatic z-axis on the portal of the cutting system via a highly rigid construction and enables the cutting of a diverse range of parts. With a lifting height of 350 mm, the standard version of the bevel aggregate can pass over sheets up to 200 mm thick. As an option, the bevel aggregate is also available with a max. lifting height of 500 mm, which means that even up to 350 mm thick sheets can be traversed. A magnetic collision protection system is used to support the burner holder, which prevents major damage in the event of a collision, as the burner automatically springs back into the correct position within the holder. In addition, the bevel aggregate on erlcut portal cutting systems can be easily combined with other processes, such as embossing, plasma signing or oxyfuel cutting.

The new plasma bevel rotator enables users to cut out a wide range of components from sheet metal in a single step with simple bevels up to 40 mm long. This means that cutting with erlcut portal cutting systems can now be done even more efficiently. For applications where the use of a bevel aggregate reaches its limits, for example for complex components with very flat bevels, tight radii, bevels on all component sides or where an exact bridge measurement is required, ERL Automation GmbH has the robot cutting system BIBER in its portfolio, which has been especially developed for bevel cutting.

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Depending on the size of the component and the amount of beveling work to be done, different system layouts are available. The ecoBIBER is the entry-level model of our robot cutting systems and is designed for small to medium-sized components with low space requirements due to its compact size. In this version, the cutting robot is fixed to a pedestal on the factory floor. This allows the robot to work in the workspace that is within its reach. Loading and unloading of the cutting station is performed through the area in front of the cutting table, which is monitored by light barriers.

The BIBER cutting robot in the standard version has a reach of 2,000 mm. The BIBER.3000 was developed so that users with particularly large components can also benefit from the economical cutting system for automatic weld seam preparation. Thanks to a larger, reinforced suspension bracket in combination with a reinforced raceway, the BIBER.3000 has a significantly longer reach of up to 3,000 mm. For companies in the heavy engineering sector, it is also an interesting alternative to weld seam preparation by bevel aggregate & Co.

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The autoBIBER is the most complex version of the BIBER system. As with the profiBIBER, the cutting robot is installed on an upstream console which is moved on a linear unit. However, the autoBIBER is additionally provided with a changing table with integrated slag conveyor and a soundproof housing. While the robot is cutting in the sound booth, it is possible to restock on the second frame of the changing table. The advantage compared to conventional tables is that loading and unloading can always take place at the same position. When the robot has finished cutting, the table is changed automatically after the release button has been pressed. This design ensures optimal protection against noise, radiation, smoke and entry.