Project Description

The MG series – The all-rounder among cutting systems

The flag-ship among the MicroStep® cutting systems. It is built for continuous use in the industry and meets the highest demands on precision, performance and user-friendliness. The MG series can be configured with a variety of technologies: 2D cutting, bevel cutting, tube & section (I-beam, U- and L sections) processing, dished ends, drilling, tapping, countersinking and technologies for marking and scanning

Invariable precision and reproducibility of cutting parts

The cutting process in the production line is generally the first order of priority. Irregularities on components and precision losses can inevitably be transferred to the next processing step. Through the use of high quality components MicroStep®-cutting systems offer a high dimensional accuracy and precision of cut contours and components. Depending on the technology used, a high rate of reproduction without error can be accomplished without exception.

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Increased agility and dynamic

Standard AC drives from Panasonic provide high performance and best driving dynamics – even in harsh environmental conditions

Precisely calibrated tools_MicroStepSA

Fast and precise bevel cutting up to 50 °

The newly developed, endlessly rotating micro-step R5 Rotator offers brand new dimensions with fully automatic bevelling capabilities:

– Fully automatic and high precision bevel cuts up to 50 ° (plasma & oxyfuel)
-Bevel cutting of flat sheet metal, pipes and profiles and dished ends
-Cutting of Chamfers and Weld-preps on already cut components
-Intuitive and simple programming of bevels with the MicroStep® CAM software

3D Tube and profile cutting of up to 1,000 mm Ø

The 3D Tube and profile cutting is a great option to the MicroStep® system concept. Depending on the need for cutting for tube and profile processing MicroStep® CNC machines can be equipped with different pipe cutters “RSV ” . Once the MicroStep machine is fitted with the pipe cutter the following sized could be cut according to what size “RSV” is chosen. Pipes or profiles can be cut from diameters of 30 mm to 1,000 mm.

More running smoothness and precision

As a robust machine design is an important factor for excellent cutting results , the portal guides were elongated by 35% in the longitudinal direction (X – axis) This creates a larger contact area at the bridge portal creating an even smoother cutting result.

Durable, low-maintenance planetary gear

Flawless components are used in order to sustainably use the full dynamic power and tnew drive system with AC motors. This allows for an increased working life with the planetary gears.

Stiffened portal design

As of now, the new MG series comes standard with a revised , more rigid portal construction. By developing the design, the rigidity of the portal was increased by 3 fold – that means less vibration resulting in an absolutely clear and precise cutting product.

Fully automatic drilling up to 60 mm Ø and threads up to M30

Automatic drilling up to 40 mm Ø and thread cutting of up to M33

The automatic drilling of MicroStep of up to 40mm dia. And taping and drilling up to M33, creates a tremendous “added value” for your production. With these additional technologies you are therefore able with high presicion drill, tap and countersink before the profile is cut. For a smooth and fast tool change, the MicroStep system can also be equipped with a 6, 8 or 16 type tool changer.

DIshed_End_MIcrstep

Dished Ends

The sturdy construction of the MG series with heavier gantry allows for the cutting of individual dished ends of up to 6,000 mm in diameter. Depending on the cutting head (2D or 3D) and the correspondingly dimensioned Z-axis stroke the dome radius and the knuckle end can be cut without any issues. Of course with the MicroStep® CAM all cutting tasks can be instinctively programmed.

High reliability even in three-shift productions

Micro Step systems are designed for a long service life even under hard environmental conditions. This is supported by well-planned servicing of the machine. High reliability of the machines is a top priority for Microstep as it ensures stable production processes.

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Best engineering components

A convincing cutting quality can only be achieved through the use of high-quality components. Microstep uses linear guides on all axes, double-sided high-precision drives, annealed solid steel portals and invariably well-known suppliers. These include FESTO, IGUS, THK, BOSCH REXROTH, LAPP and more.

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iMSNC® Intelligent Control

In addition to the externally positioned control console with ergonomic 17 “touch screen display, the system has additional consoles on the gantry. This allows for the operator to easily interrupt a cutting program, do the installation process manually, import a new sheet metal panel or quickly perform a manual cut.

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Intuitive and easy to use

So that you can concentrate on your products, our innovative software offers solutions, intuitively implementing drawings and cutting plans into finished components.

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Remote Diagnostics

Allowing you quick and easy access via an Internet connection.

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Training & Professional Support

We know that our cutting machines are the first in the production chain. Therefore, in order to guarantee the highest possible system availability, we offer a reliable support network.

MicroStep’s modular design concept is optimally adapted to your production needs

The MG series can be configured with virtually any technology, thus forming the robust all-rounder from the MicroStep® home .

2D Cutting

The excellent cutting quality and dimensional accuracy of our 2D cutting systems reduces the post-processing of finished parts to a minimum.

Oxyfuel ensures efficient and angular cuts into thick materials. On a system with a plasma source, oxyfuel is the perfect addition to cutting costs in a thicker material region.

The strip or tilting burner is designed for mounting on standard burners and allows for strips of 30 – 400 mm to be cut with a thickness of 3 – 60 mm.

Bevel Cutting

The perfect setting of a cutting tool is precise bevel cutting. The patented MicroStep® ACTG measures calibration inaccuracies and discrepancies in the burner geometry and corrects them.

Using an oxyfuel 3 – burner, units can be bevel cut for joint preparation up to an angle of 45 ° Vertical cuts are also made. With the oxyfuel 3 – burner unit the two outer burners are tilted manually.

Using an oxyfuel 3 – burner, units can be bevel cut for joint preparation up to an angle of 45 ° Vertical cuts are also made. All angle settings on the 3 – burner unit are fully automatic with the iMSNC® software.

The Micro Step R5 Rotator is a five -axis bevel unit, which has been specially designed for 3D processing of flat material , pipes, profiles and dished ends . The rotator is mounted on a rigid design of a Z -axis support on the gantry of flame cutting equipment. Through a spiral bevel ring gear a highly precise and silent movement is created.

This cutting head is designed specifically for the extensive processing of 4 – developed profiles – Angle Profiles. Due to the high dynamics of the cutting head, it allows for “around the corner” cutting. A bevel cut in X – direction of sheets is also possible with this support and the height adjustment is automatic.

Pipe and Profile Processing

The optimal solution for the efficient and clean cutting of pipes up to 300 mm Ø

The optimal solution for the efficient and clean cutting of pipes up to 500 mm Ø

The optimal solution for the efficient and clean cutting of pipes up to 700 mm Ø

The optimal solution for the efficient and clean cutting of pipes up to 1000 mm Ø

The Micro Step tube cutters can be extended for the inclusion of pipe bends. The optional inclusion is stretched in the tube cutter and serves as an adapter. To use this device an appropriate CAM software (ElbowCut) must be in place

Cutting of Dished Ends

This special table allows loading up of dished ends from 500 mm up to 1,500 mm Ø and to be worked with plasma or oxyfuel. Through the pivoting of the head, the brim of the dished end is free. There is also the possibility of using the standard R5 Rotator on the underside of the dished end ( brim edge ) for cutting of the chamfer. The table can tilt the to a 45 ° angle and rotate endlessly . The clamping of the dished end is carried out by an inner chuck . Also, the extraction of the dished end is carried out on the inside through an opening in the centre of the chuck.

Drilling, Tapping, Countersinking

Precision drilled and cut parts with just one machine – compliment your cutting plans with the fully automatic drilling system of MicroStep® developed precisely to ensure all steps. These include tool changes and optional measurement and calibration of the tool. Drilling up to 22 mm Ø, threads up to M16.

Precision drilled and cut parts with just one machine – compliment your cutting plans with the fully automatic drilling system of MicroStep® developed precisely to ensure all steps. These include tool changes and optional measurement and calibration of the tool. Drilling up to 30 mm Ø, threads up to M20.

Precision drilled and cut parts with just one machine – compliment your cutting plans with the fully automatic drilling system of MicroStep® developed precisely to ensure all steps. These include tool changes and optional measurement and calibration of the tool. Drilling up to 40 mm Ø, threads up to M24.

Precision drilled and cut parts with just one machine – compliment your cutting plans with the fully automatic drilling system of MicroStep® developed precisely to ensure all steps. These include tool changes and optional measurement and calibration of the tool. Drilling up to 40 mm Ø, threads up to M33.

The fully automatic controlled 6 – tool magazine is co-moving, and is located directly on the side of the machine gantry. This allows very fast tool changes with minimal distances.

High capacity and optimum protection for your tool. The fully automatic sealable 8 -station tool magazine is located at the end of the cutting table. After a quick tool change, the magazine closes again automatically and protects the tool from dirt and damage.

Marking and Labelling

The inkjet marking unit with a nozzle suitable for single-line marking and labelling tasks. The size of the printed dots is about 3 mm.

By using a non-contact unit for ink jet marking, placed plates of up to 20,000 mm / min can be labelled. Alphanumeric characters, graphics and bar codes can be applied in a high resolution. Due to the technology used, innovation can be applied to various materials without damaging the surface. The low ink consumption and virtually wear -free technology, compared to other marking, will help to reduce your operating costs.

The needle marker uses a high- performance needle and penetrates the material to be marked up to 2.0 mm. Driven by Micro Step iMSNC® machine control it works the cutting job into the nested cutting plan automatically. We do not recommend the use of oily or rusty materials. The feed is based on the use of a high needle markers of up to 2,000.

Scanning, Reading

A laser measurement ensures that at least two sides of the applied metal sheet can be determined exactly. The iMSNC® machine controller processes this information and adjusts the current cutting plan to the possible misalignment of the plate. Thus, even a wrongly placed sheet or coil is cut properly. If necessary, the entire outer contour of the plate can be scanned.

The CCD scanning system is ideally suited to determine already cut or drilled forms on a metal sheet. The scanned contours are taken from the iMSNC® machine control directly in the cutting plan.

The barcode scanning unit automatically reads the material lying on the cutting table, as long as they are provided with a bar code. In connection with the MicroStep® production management “MPM” it forms the base for automated plasma cutting. Retrieving material information (material thickness, quality, format, batch, etc.), as well as automatic nesting of outstanding cutting.

Scanning, Reading

Micro Step cutting machines can be equipped with automatic lubrication devices. All important points are thus automatically lubricated and assist the operator in the maintenance of the cutting system. By pressing a button the lubrication is performed and upon completion the user is informed.

The interface communicates with the existing runways and reports a locked facility or a clear work area on the flame cutting table. The flame cutting table is digitally divided into different zones. The system detects whether a crane is in the table area and thus locks the machine or recognizes that the machine is in the section to be travelled by the crane and therefore blocks the crane. The operator is notified of the situation on the control panel. This module can only functionally operate if it has been arranged for with the crane rail manufacturers.

MicroStep infoMessage® immediately informs you via SMS when your cutting machine stops during the processing of a cutting plan – no matter where you are. This allows you a fast and targeted intervention and the cutting plan can be recorded again. This saves on expensive machine downtime and increases the efficiency of your cutting system.

Safety

The MicroStep® light barrier secures the area around your system before the entry of people during the cutting operation. The light barrier may either give off an alerting beep or the cutting process can be stopped. This is particularly recommended for systems with high cutting speeds in the X direction.

Options

Measurements

Length of the Cutting Area* – 1.500 up to 50.000 mm
Width of the Cutting Area* – 1.500 up to 8.000 mm
The entire Cutting Area is completely workable with all tools.

Tools

Amount of Tools – 6 (8 Oxyfuel)
Possible Cutting Processes Plasma, Oxyfuel
Max Material Thickness for Plasma – according to power source
Max Material Thickness for Oxyfuel – 250 mm

Precision

Positioning Speed – up to 50.000 mm/min.
Positioning Accuracy – according to DIN 28206 / ≤ 0,06 mm/m
X-, Y-Axis – dual driven guides via helical rack and pinion
Z-Axis – ball screw
Version of Gantry – steel gantry

Control Unit and Software

Control – iMSNC®
Main Control Panel – ergonomic 17” Touchscreen
Software Package – Windows 8.1™ 64-bit PRO
Additional Controls –  2 LCD panels on the gantry

Software

MicroStep® has its own software specifically designed for cutting

MicroStep® software solutions assist you so that you can concentrate on your production. Drawings and cutting plans are intuitively put into finished components. A part of the product range also includes automation solutions to organize your entire cutting process.

asperwin-basicAsperWin Basic

The Micro Step 2D CAM software AsperWin allows easy and intuitive creation of cutting plans for your facility.

asperwin-basicAsperWin Nesting

“AsperWin Nest” fully automatizes your cutting plans, thus achieving the optimum utilization of material. The items can be sorted and easily managed according to criteria such as material, material thickness and order numbers.

mpmproduction-managementMicroStep mCAM

mCAM is a CAM software that has been developed for an advanced and automated 3D production with machines of different technologies (plasma, oxyfuel, water jet and laser) of MicroStep.

mpmproduction-managementMPM® Production Management

A powerful production management software for coordination, management and monitoring of your cutting process. From the management of cutting jobs, their automatic nesting, to cutting plans and up to detailed reports and costings.

The iMSNC® machine control handles even the most complex cutting tasks

The iMSNC control from Micro Step is one of the most advanced control systems for CNC cutting machines. It was developed to simplify and to reliably and effectively implement interface cutting plans for a modern user interface.

 MicroStep iMSNC® Control Unit

Handles even the most important performances at a glance:

– 17 “Touch-screen

– Efficient management of tool data

– Very short programming times

– Fast data transfer

– Flexible and fast

– Simplified representation

– Advanced cutting simulation for greater process reliability

– Intuitive input help with animated elements

The intelligent solution for cross-technology interface

The system consists of a single control panel with a TFT touch screen monitor and a control panel with a LCD display on the portal bridge. In order to achieve maximum efficiency and flexibility for our machines, the ergonomic control panel offers the option to run current cutting processes parallel with inter leading new cutting programs and to generate more NC codes. Since the iMSNC control system and all CAM software solutions are designed by us, the software with its versatile modules can be customized individually to your production requirements. Being tuned into the technology parameters database, a consistently high cutting quality even with different conditions is enabled. In order to optimize the production process the iMSNC control comes standard with a number of efficient evaluation tools. The necessary overview of current cutting jobs, cutting time, cost calculations or machine utilization is thus made easier.