HEAD Waterjet Automation Solution for Carbon Fiber Cutting

Client Name: A Global Technology Group

Waterjet Models: HEAD2515BA / HEAD42037Z with AB5-axis cutting heads equipped with drill mechanisms, integrated with robotic arms

Client Background

The client is a globally renowned technology group, utilizing carbon fiber in structural components within their 3C (computer, communication, consumer electronics) business. With increasing order volumes and product complexity, they sought a new processing technology to reduce costs and improve efficiency.

Client Requirements

1. Shaped Cutting: Equipment capable of cutting carbon fiber sheets into complex shapes based on drawings, meeting diverse product needs.

2. Layered Cutting: Ability to cut multiple layers of carbon fiber sheets simultaneously to enhance efficiency and reduce processing time.

3. Automated Loading and Unloading: Implementation of robotic arms for automation, minimizing manual intervention and reducing labor costs.

Solution Design

The HEAD Technology team proposed the following tailored solution based on the client's requirements:

1. AB5-Axis Precision Cutting

• Achieves slope compensation for smooth, burr-free edges, ensuring precise shaped cutting for complex designs.

2. Layered Cutting Technology

• Through extensive testing, determined the optimal maximum number of layers for carbon fiber cutting and designed custom fixtures to support layered cutting, significantly boosting efficiency.

3. Drill Mechanism Integration

• Added a drill mechanism to the cutting platform to pre-drill entry holes, preventing delamination during waterjet cutting and ensuring superior quality.

4. Automated Loading and Unloading

• Integrated robotic arms for automatic loading and unloading, reducing labor involvement and increasing production efficiency.

5. Custom Cutting Platform

• Designed a 2.5m x 1.5m cutting platform to match the client’s material specifications, ensuring optimal equipment utilization.

1. the size of the material to be cut is 1000*1000mm fiberboards; 

2. a plurality of fiberboards are stacked inside the tooling fixture which receives and clamps materials

3. The cutting platform is 2515 monoblock, which adopts AB 5-axis system and bit 

4. There are two fixed Cutting Frames on each 2515 monoblock, and tooling fixture for fixing materials are placed on the corresponding frames 

5. Two 2515 cutting machines are placed back to back, and one Placing Frame with two working stations for loading and unloading is placed on one side. 

6. A GP180 robotic arm is placed between the two cutting machines, which is responsible for moving 、loading and unloading the tooling fixture for the two cutting machines

7. After the robotic arm moving and placing the tooling fixture on the Cutting Frame, the cutting machine starts to process the material. After the processing is completed, the robotic arm integrally carries the tooling fixture with materials to the Placing Frame, and repeats the steps above after removing the material.

Equipment Advantages

• Efficient Layered Cutting
  Enables simultaneous cutting of multiple layers, drastically improving production efficiency and reducing processing time.

• Precision Cutting and Layer Integrity
  AB5-axis configuration ensures accurate cutting with no delamination or edge lifting.

• Automation
  Robotic arms for loading and unloading reduce labor costs and enhance automation levels.

The GP180-120 is a long-arm version of the GP180, providing fast and accurate performance to boost productivity for high-payload handling applications. Featuring a wide work envelope, this robot uses a streamlined upper arm for easy access to parts in confined spaces. While the wide wrist motion range reduces interference with fixtures, the reduced interference design enables close proximity placement of robots. A heavy mechanical balancer is not required any more, and latest high performance Sigma7 servo drive technology is leading to fast axis speeds and powerful acceleration. A wrist with high moment and inertia ratings enables the GP180-120 robot to efficiently handle larger and heavier payloads for superior performance. In combination with a robot track, this robot is a perfect solution to feed large panels between different machines or workcells.

Waterjet Carbon Fiber Cutting Machine