he versatile fiber laser has been adopted by a diverse market base for myriad applications. Power, speed and machine features top most fabricators’ wish lists, but the number of different models on the market can pose a challenge for companies looking to invest in the technology. To help narrow the field, manufacturers should ask questions that will help identify the fiber laser with the capability to take shop floor production to the next level in a digitized environment.

Connected automation technologies—the backbone of Industry 4.0—continue to be deployed on shop floors. Considering a laser cutting system with features that support autonomous operation, such as AMADA AMERICA INC.’s REGIUS, gives manufacturers the ability to maintain operations with minimal operator involvement.

The REGIUS made its global debut at Fabtech 2019 in Chicago. AMADA’s linear driven machine uses vision and monitoring systems to support continuous operation. These systems also allow for ease of operation, better shop floor management capabilities, maximum productivity and reduced downtime.

The 3-axis linear drive system on the REGIUS softens the ramp up and ramp down traverse speeds to achieve high-speed, high-precision part processing. The linear drives communicate with a control processing unit that transfers information to the new Fanuc 3i-Ex control. The communication between the control processor and the drive system generating 5g of acceleration and traverse speeds of 13,300 in. per minute equates to a 15 percent reduction in common nest times over the previous linear-driven machine, the AMADA FOL-AJ.

The REGIUS’s autonomous machine features help reduce startup time. The fiber laser comes standard with automatic nozzle change and centering as well as nozzle condition monitoring due to the new iNozzle Checker feature. The camera system allows nozzles to be regularly inspected for position centering, shape and diameter. This feature minimizes the timely process of an operator selecting, installing and centering a nozzle. Reducing this process increases productivity by minutes or even hours a day, depending on the number of materials being processed.

Another feature designed to support autonomous operation is the automatic collision recovery system. In the event of a collision, the laser head damage prevention mechanism will retract the Z-axis, and use the iNozzle checker to inspect, replace and center the nozzle. The system automatically registers the NC coordinates where the collision occurs. When processing is resumed, the registered coordinates will be avoided and the next part will be processed. This system also allows the cutting head to have a tilt angle during a part tip-up to prevent any damage to the cutting head itself.

While the focus of the REGIUS has been autonomous functionality, when operator involvement is needed, other key features come into play. The iCamera feature allows for a real-time view of the material that is placed on the cutting pallet. This may be a remnant or an unused portion of the last nest processed. In the event that a hot job or part is needed, the operator can place the part geometry onto the remnant using the 3i-Ex touchscreen control and the iCamera system, press start, and process the part immediately. This prevents any additional trips back to the programming department, steps that can result in additional downtime. Often, pre-programmed micro-joints may not hold the tabbed part in place or internal geometry may not have been flagged for a micro-joint, creating a potential head-on collision. REGIUS allows the operator to select the desired geometry on the touchscreen control and adjust the tab size on the fly.

The V-Remote function gives an operator or shop floor manager access to the machine’s operational status to make changes to the machine’s schedule remotely. The ability to remotely access the control can be performed on any tablet. Operators who are performing secondary functions on the shop floor, or a manager who needs to take a quick walk through, can view the machine’s operational status via the 32-in. monitor that is integrated into the front panel of the REGIUS’s Class-1 enclosure. In addition, the V-Remote feature uses a camera installed inside the machine that can be checked in real time on smartphones or PCs. The camera records machine operations, and in the event of an alarm, an operator can review the video and the alarm condition. This allows an operator to make changes to tabbing or programming techniques to avoid alarms in the future.

The REGIUS is powered by AMADA’s ENSIS fiber engine technology. This patented technology allows for automatic adjustment of the beam quality to maintain low operation cost and high speeds in thin material. ENSIS technology also provides excellent edge quality and speeds on thick plate, previously only achievable by CO₂ lasers. The mode is changed automatically to optimize the cut quality throughout the entire range of the materials being processed. The REGIUS can be purchased in a 6 kW, 9 kW or 12 kW. The Auto Collimation Unit (ACU), is another unique feature of the REGIUS when it comes to cut quality and speed. This system allows for instant changes in beam diameter and depth of field for fast pierce times as well as superior edge quality.

AMADA developed the REGIUS laser system to integrate different technologies that support autonomous operation. The technology equips job shops that need to improve efficiency and productivity in today’s manufacturing environment, and prepares companies for Industry 5.0, which will leverage advances in automation, IoT and big data.