Robotic Waterjet Integration
Ontario builder creates state-of-the-art waterjet systems for stone, composites, and difficult-to-cut metals
July 28, 2011
Multiaxis waterjet cutting opens new market for manufacturers
You know what to expect when you pull into the driveway of I-Cubed Industry Innovators, Stoney Creek, Ont., because of the small Fanuc robot that holds up the company’s sign.
From the first step through the front doors to the back door of the shop, you pass through a mixed bag of advanced, often one-of-a-kind, robotic waterjet systems. Even the routine, everyday work of this shop is unique, and that’s just the way owner David Bunker likes it.
“What we do is definitely not status quo manufacturing,” said Bunker.
A waterjet industry veteran, Bunker is now focusing his efforts on developing application-specific robotic waterjet cutting systems for a number of different industries, including automotive, power generation, and architectural. Typical cells created here include an ABB, Kuka, or Motoman robot integrated with pure or abrasive waterjet components from manufacturers KMT, H20 Jet, and Flow.
The company specializes in the design, assembly, and offline programming of these robotic cutting systems. An intensifier pump creates the high-pressure cutting force, which is delivered to a cutting head mounted at the end of the robot’s arm. Several robots can be run using a single intensifier.
For example, at I-Cubed a 90,000-PSI intensifier pump from KMT Waterjet Systems produces the pressure for all of the company’s waterjet cutting applications.
“We create practical and functional systems for the manufacturing problems posed by our customers,” explained Bunker.
The company’s goal is to integrate abrasive and pure water applications using articulated robotics. Robot tooling, fixturing, catcher tanks, abrasive management systems, noise attenuation, safety equipment, and all necessary components are designed, built, and assembled by Bunker and his staff.
Plastics, composites, stone, glass, and metals several inches thick can all be cut, making the waterjet cutting process one of the most versatile in the industry.
“Accurate, repeatable parts are easily programmed offline and then cut,” said Bunker. “And, because of the introduction of the robot to the process, labor is reduced.”
The robot’s multiaxis articulation also enables the cutting of parts in 3-D.
“Three-dimensional cutting opens up a whole new world for manufacturers. Both designers and parts-makers are no longer limited to flat stock,” said Bunker. “There is great potential in the 3-D market, and now it’s about exploiting it.”
The combined experience of the I-Cubed workforce is more than a century in the robotics and CNC cutting industries involving both waterjet and machining technologies. In the three years since it opened, the company has installed both flat-stock and 3-D abrasive and pure waterjet cutting cells around the world.
Understanding Jet Dynamics
“The waterjet’s stream is surprisingly stable as a cutting tool, but the ‘tool’ does bend as it moves along its path,” said Bunker. “In multiaxis robotic cutting, movement can get quite complicated. This makes programming a very important part of the process.”
Recently four I-Cubed employees traveled to nearby Cambridge, Ont., to receive training in the Mastercam programming system from local distributor In-House Solutions.
Stream lag and taper are two common problems that have long been associated with waterjet cutting. Proper programming techniques, cutting speed, pressure, and orientation of the cutting head to the part all are used to combat these difficulties.
At I-Cubed another advanced waterjet cutting theory is also employed.
Lead cutting, tilting the cutting head so that the stream preceeds the head, increases cut speed. For example, in thick granite cutting, 20 IPM is achievable, which is almost double normal cutting speed, according to Bunker.
“Waterjet cutting is also a cold-cutting process,” said Bunker. “This makes it ideal for cutting certain materials that cannot have heat introduced during the manufacturing of a part. It is also very easy to control dust in the cutting process, which is beneficial to those companies that have environmental concerns.”
Creating a Market
In addition to the complex cell-based waterjet systems, I-Cubed also creates unique accessories.
The company has added hydraulics to the waterjet table to make it tilt, enabling the easier loading of stone. Long pieces of stones, such as those for countertops, can break during the loading process if the traditional suction cup-based material handling design fails. This can be avoided by tilting the table itself and setting the stone in on its edge.
“We have the tools, we have the robots, the software, and machines,” said Bunker. “The challenges are ours too. Customers that are willing to expand their horizons and think about new manufacturing processes understand that this technology is leading-edge.”
Future Growth
Last month the company also began the process of moving to a new, larger location. Remaining in Stoney Creek, the new facility has 28,000 sq. ft. of manufacturing floor space. It also leaves room for all-important expansion and growth.
“The plan is to capitalize on the markets that we are in and continue to grow the business the right way,” said Bunker. “That includes hiring the right people.”
With the global manufacturing market rebounding, more companies are looking to be innovators. This will likely mean more installations, new markets, and more complicated builds.
“Our philosophy is that you create the product and then you create the market,” said Bunker. “Every day is a new challenge.”
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