Laser cutting has significantly improved the manufacturing process of steel components
in production plants.
They are extremely precise and very economical.
Today we take a trip to Kimla, a Polish manufacturing company that has succeeded in conquering the
market with their own laser cutting machine.
Kimla decided to bring the international corporations, which have already established their position
in CO2 laser market, down to size.
They have taken advantage for the high demand for fibre laser cutting machines.
The Polish company is a manufacturer of lasers using fibre technology which is much faster
and cheaper in operation compared with CO2 technology.
Almost all of the components of Kimla equipment are manufactured in the Częstochowa based
plant.
Lets take a look at the production process.
First the designer prepares the technical drawing taking into consideration all the
requirements that the equipment has to meet a given factory.
The design is circulated to respective production departments.
The main body is where the other components will be mounted.
Heavy walled steel profiles used for production are delivered directly from the iron works.
Profiles achieve their length, shape, service and structural openings by utilising a plasma
profiling machine.
Once cut the pieces are sent through the shot blaster ensuring the surfaces are clean and
smooth prior to moving on to the fabrication department.
Profiles are fixed onto the welding panel.
Welded, and once finished the joints are cleaned.
The machine frame is now subject to high precision machining utilising a multiple axis milling
machine enabling Kimla to produce extremely large machines.
The frame is positioned onto the machine bed so all critical mounting faces can be machined
in one.
This allows the frame to be machined to micromillimeter accuracy.
After machining is completed the frame is transported to the paint shop where it receives
an aesthetic and protective coating.
The subsequent work stations manufacture and provide the remaining components of the machine.
One machine may consist of several hundred components.
The laser covers are processed on one of Kimla's very own fibre lasers, prior to being sent
onto the bending department.
Once bent, panels are dipped to remove any grease or other contaminants so a perfect
powder finish can be achieved.
These powdered coatings offer maximum protection and durability.
Aluminium components are cut by the water jet.
Machines manufactured by Kimla are dynamic so it its critical weight is kept to a minimum.
So most of the components are made of various aluminium alloys.
The lasers velocity reaches 5m/ second with an acceleration of 6G.
All machined components are subject to detailed drawing and preparation.
The technicians ensure the tool path is optimised utilising state of the art machining centres.
Accuracy is critical so machining is undertaken in one operation using five axis machining
centres.
Where high precision is critical Kimla undertake extremely precise measurement checks.
This is particularly useful when development components are developed.
As mentioned before, lasers are completely produces in the Częstochowa based plant.
This includes Kimla's own linear motors used to position each axis.
The linear systems offer a high power density reducing space required for the overall machine.
Let's see how the entire device is assembled.
The body is transported from the paint shop to the assembly hall.
Appropriate parts are collected from the depot.
Inner casings and duct vents are mounted.
These allow smoke and dust to be evacuated from the machine area and discharged once
cleaned by the filter system.
The drive chain which is responsible for the powered movement is mounted.
Next is the installation of the linear motors.
Magnets are covered under the bellows which also provide cover for the measuring system.
At the same time the control cabinet is mounted, equipped with automation components and Kimla's
very own PLC produced in the electrics department.
The entire mounting is done step by step at the respective work stations on a systematic
automated assembly line similar to automotive companies.
Finally, the device casing is made and the control cabinet mounted.
The laser is equipped with software supplied by Kimla IT developers specifically designed
to optimise the fibre lasers.
Once completed the machine is configured and fine-tuned.
Parameters are tested and the whole machine is put through a strict test program.
After the operation is carefully tested to the producers satisfaction the device can
be delivered to the client.
In addition to lasers, Kimla also manufacture a range of other machines and equipment.
These include milling machines ranging from small used for engraving or the production
of dentures to large multiple axis devises capable of processing various materials such
as cardboard, timber, rubber, plastics, non-ferrous metals or textiles.
Here you can purchased tools and parts that become wear and tear during the life cycle
of the machine.
Lasers are often equipped with many additional options.
In factories in both Poland and abroad approximately several hundred lasers are in operation produced
by Kimla.