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COIL FED PUNCH-LASER COMBO SYSTEM DALCOS ELXN: ULTRA HIGH SPEED PRODUCTION

Dalcos was the first in the world to combine the efficiency of EXN punching system and the flexibility of LXN in-line laser cutting system, and double the output thanks to the special configuration with independent modules.

DALCOS ELXN combo line processes strips from 200 up to 1000mm wide: its setup includes a 6 ton decoiler, straightener, Dalcos EXN electric coil-fed punching machine and LXN 1000 laser cutting system.

Material optimization, Productivity and Flexibility. All in one product

Lean Production and Material optimization

Great advantage of coil-fed production is material optimization up to 100% by using materials of the same width as the end product, eliminating the skeleton (as well as the need to separate the pieces).

Fast: Higher thru-put than all the other Dalcos or traditional systems

By separating the punching and the laser cutting areas, ELXN output is twice the output of the main traditional sheet-fed combined punching and cutting systems. In fact the laser and the punch operate simultaneously on two different portions of the strip: thanks to the patented Dalcos ACX vision system, the LXN identifies the exact position of the holes previously punched by EXN machine and the laser cutting is guided by these holes.

EXN punching machine uses up to 48 standard thick turret tools and has an electrically operated 20-ton hammer activating indexable, embossing and cluster tools to increase furtherly productivity.

Powerful with absolute flexibility

LXN laser cutting area adds complete flexibility to the process allowing the laser cutting of special shapes, notching, and nesting of complex parts. With EXN machine it is also possible to create embossing and threads on the sheet



Operation

strong>Efficient, lean manufacturing line

In line with the Lean Production principle, Dalcos ELXN keeps setup times to a minimum while efficiency, productivity and flexibility are kept to a maximum.

The system boasts real-time operation and an extremely compact footprint considering its very high thru-put and flexibility. The line consists of the modules described below.


Decoiler

The decoiler is the raw material storage system with a capacity of 6, 8 or 10 tons. Line speed is optimized when processing coils since machine loading and unloading times no longer exist. This is one of the elements that makes ELXN combo so productive.

Dalcos RD straightener

The straightener receives the material from the decoiler and eliminates the curvature or coil set caused by being wound on a reel. The straightener can be incorporated in the ERGO roller feeder for some lines.

EXN punching machine

The straightened material enters EXN servo electric punching machine, which carries out a part of the processing, such as punching, forming and multiple perforations, because it is faster than the laser cutter. At the end of the machine there is a shear to cut off product shorter than 4 meter long. If the product is longer, the pre-punched material enters a loop control unit and is subsequently cut off by LXN laser-cutting machine.

LXN feeding table

The pre-punched pieces are placed on a roller table, which centers them and conveys them to the independent LXN system. This separation of the EXN and LXN machines means they can operate simultaneously, thereby halving the processing time compared to just punching or just laser cutting. This is the second cutting-edge element allowing DALCOS combined machine to achieve the highest production rates.

LXN independent laser cutter

LXN receives the cut workpiece and with the special Dalcos ACX camera detects the position of the previously made holes or forms. It now starts to make notches, openings and special shapes that would be more difficult to obtain by punching.

Unloading system

The finished piece is finally delivered to the unloading system. ELXN combo machine can be equipped with Dalcos® Dumonde, Smartbatch unloading systems or with robotic unloading systems.

  1. Programming

DALCOS ELXN system uses the ALMACAM CNC program: it is identical to the programming system of any combined machine, where the operator selects when punching and when nibbling. At this point the program automatically divides up the work between EXN and LXN units in a way that is clear to the operator.

Processing with EXN and LXN separately

A small customization of the layout gives the possibility to have two systems - EXN and LXN - working together as a combined machine or completely independent. In this case EXN operates as a simple coil punching machine, while LXN can be sheet-fed even with completely different products

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