Robotic water jet cutting is just what it sounds like, the integration of the water jet’s unique and flexible cutting characteristics with the productivity and precision capabilities of robotics. Pairing these two technologies creates a cutting, finishing, material handling, and/or cleaning solution that enables you to produce complex parts and/or processes across a wide platform of operations both accurately and efficiently.
Many materials can be cut simply using the high-pressure water. Water-only cutting works especially well when machining soft or flexible materials like rubber, plastic, foam, and textiles. When abrasive is introduced into the water stream, it exponentially expands the types of materials you can cut. This includes composite materials, aluminum, glass, stone, ferrous and non-ferrous metals, and specialty alloys like stainless steel, titanium, and Inconel.
A variety of 3 axis and 5 axis cutting heads can be mounted on the motion system’s gantry. The cutting table, often referred to as a catch tank, can range in size from 4’ x 4’ to 13’ x 24’ depending upon the size of the raw material and the characteristics of the finished parts. CNC software controls the motion of the cutting heads along with drives that deliver the accuracy and repeatability of the system.
Despite the advantages and efficiencies of these systems, the water jet head/gantry/table combination can be limiting in specific applications. Specifically, there are times where a water jet cutter would deliver a better total production result, but gantry and/or table could be a deal breaker. In these applications, freeing the cutting heads from the table and gantry by attaching them to robotic arms enables you to execute significantly more complex processing steps and cutting profiles. Two common applications of robotic water jet cutting applications are explored below.
Many parts are formed by methods other than cutting. Some examples include casting, molding, forging, and stamping. These parts share some common characteristics such as seams, sprues, excess material, flashing, etc. that need to be trimmed away to achieve a finished appearance. The trimming process often takes place in small, dedicated workspaces called trim cells.
Enter water jet trim cells. When a water jet cutting head is attached to a robotic arm, the need for routers and hand trimming operations is eliminated. Robotic water jet trim cell cutting involves securing a workpiece to a fixture that holds the part in place. The robotic arm then moves around the part freely, utilizing the water stream to execute the trimming cuts. The water jet robotic arm is not constrained by the 3 axis or 5 axis cutting that is done on a motion system table.
To see this in action, check out how Alliance Automation integrates Jet Edge intensifiers with their trim cell solutions to meet the needs of automotive manufacturers.
There are many benefits to using water jet systems for these applications. When using water systems, solvents and other harsh chemicals are not required as the power of water removes the material. When a water jet cutting head is adapted with a cleaning swivel and attached to a robotic arm, only the surfaces requiring cleaning are traced. The focused pressurized water stream replaces the need for manual cleaning and the use of corrosive chemicals. All of these processes take place in a purpose built chamber with various fixtures used for parts hold down.
For an example of this in action, check out how Progressive Surface uses Jet Edge water jets in these applications.
The robotic cutting and cleaning automation processes emphasize reducing or eliminating processing time. However, there are many additional potential benefits including eliminating secondary operations, automating repetitive tasks, improving process quality, reducing the risk of operator injury, increasing production throughput, and/or expanding unattended cutting capabilities.
Automation is pervasive on the material handling side of production systems. Pick and place systems, sorting, conveyors, etc. are very commonplace. Opportunities for increased efficiency exist in the integration of automated or semi-automated material handling systems into your water jet cutting. Three common types of material handling systems are detailed below.
In the most common application, robots pick a workpiece or part from a stockpile and place it on a work surface in position for cutting. The water jet cutting head then passes along the piece and cuts it to shape, creating the required profile and finish. At the end of the cutting cycle, the robotic arm moves the finished part to the next production stage, picks another part, and repeats the process. If the robotic arm/water jet cutting head combination has a steady supply of parts, it can run unattended, or with minimal labor, 24-hours a day.
To improve machine productivity and throughput additionally, they specified a dual cart solution to feed stock material to the cutting system on one side, and while the machine cut parts, the finished parts where removed at the other side. The carts were manually positioned. At the start of the cutting cycle they were locked in place and pneumatically raised to a cutting position. This ensured flatness of the material across the table. This system can be duplicated in any number of facilities.
Whether your automation goal is productivity, process improvement, throughput, safety, or all the above, Jet Edge can help you. We’ll work with your team to adapt our systems to your specific cutting, trimming, and surface preparation operations.
Contact us to talk with an application engineer about your product or application. We’ll perform an application analysis to get the discussion started. Visit our Case Study library to see more custom applications and how collaboration with the Jet Edge engineering team delivered a solution that optimized their water jet cutting operations.
Since 1984, Jet Edge has been designing and manufacturing Ultra-High-Pressure Water jet technology that doesn't back down. Our systems are used around the world in a broad range of industries from the world's leading airlines, to automotive, aerospace and industrial manufacturers, and machine job shops.
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