WORLDWIDE SERVICE & SUPPORT NETWORK FOR LASER PROCESSING MACHINES

NORTH, CENTRAL AND SOUTH AMERICAwww.mazakoptonics.com

MAZAK OPTONICS CORPORATIONChicago140 East State ParkwaySchaumburg, IL 60173Tel: 847-252-4500Fax: 847-252-4599

MAZAK SULAMERICANA LTDA.AV. Juscelino Kubischek de Oliveira1350 Distrito IndustrialSanta Barbara D’ Oestes SP, BrasilCEP 13456-401Tel: 5519-463-7614Fax: 5519-455-3145

MAZAK OPTONICS CORPORATIONLos Angeles1333 West 190th StreetGardena, CA 90248Tel: 310-327-7172Fax: 310-538-4084

EUROPEwww.mazaklaser.be

YAMAZAKI MAZAK OPTONICS EUROPE NVWeiveldlaan 39, B-1930 ZaventemBelgiumTel: +32 (0) 2 712 55 00Fax: +32 (0) 2 725 33 20

YAMAZAKI MAZAK OPTONICS EUROPE NVFrench Branch10 Avenue Lionel Terray (BP 326)F 91958 Courtaboeuf Cedex-FranceTel: 33 (0) 1601 43100Fax: 33 (0) 1601 43892

YAMAZAKI MAZAK OPTONICS EUROPE NVU.K. BranchBadgeworth DriveWorcester, WR49NF - United KingdomTel: 44 (0) 1905 455780Fax: 44 (0) 1905 456360

YAMAZAKI MAZAK OPTONICS EUROPE NVGerman BranchEsslinger Strasse 4-6D-73037 Göppingen, GermanyTel: 49 (0) 7161 504 710Fax: 49 (0) 7161 504 7111

YAMAZAKI MAZAK OPTONICS EUROPE NVItalian BranchVia Olona 183l 21013 Gallarate VA-ItalyTel: 39 0331 796143Fax: 39 0331 794469

ASIA AND OCEANIA YAMAZAKI MAZAK SINGAPORE PTE, LTD(Asian Headquarters & Manufacturing Plant)21 Joo Koon Circle, JurongSingapore 629053Tel: 6862-1131Fax: 6861-9284

YAMAZAKI MAZAK KOREA CO, LTD59 Cheonggye-Ri, Dongtan-Myeon,Hwaseong-Si, Keonggi-Do, KoreaZip: 445-811Tel: +(82) 31-376-6052Fax: +(82) 2-372-6052

YAMAZAKI MAZAK TECHNOLOGY (Shanghai) CO., LTDThe ground floor of No. 186, Hedan RoadWaigaoqiao Free Trade ZoneShanghai P.R. of ChinaTel: 021-5866-8318Fax: 021-5866-6909

YAMAZAKI MAZAK SINGAPORE PTE, LTDIndia OperationsElpro Compound Chinchwad GaonPune-411031, IndiaTel: 020-27451417Fax: 020-27451398

YAMAZAKI MAZAK TAIWAN CORP.E2.203 No. 11 Wn-Chuan 1 RoadHsin-Chuang CityTaipei-Hsien, TaiwanTel: 022-299-5200Fax: 022-299-5204

MAZAK (THAILAND) CO., LTD719 KPN Tower, 11th Floor Zone B1, Rama 9 RoadBangkapi, Huaykwang, Bangkok 10320 TahilandTel: +(66) 2717-1071Fax: +(66) 2717-1072

JAPANwww.mazak.com

YAMAZAKI MAZAK CORPORATION(World Headquarters & Oguchi Plant)1 Norifune, Oguchi-cho, Niwa-gunAichi-pref, JapanTel: 0587-95-1131Fax: 0587-95-3611

YAMAZAKI MAZAK OPTONICS CORPORATION(World Headquarters for Laser machines)333 Yamazaki Naka-HachiyaHachiya-cho, Minokamo CityGifu-pref, JapanTel: 0574-28-2123Fax: 0574-28-1967

Specifications subject to change without notice. This product is subject to all applicable export control laws and regulations. The accuracy data and other data presented in thiscatalog were obtained under specific conditions. They may not be duplicated under different conditions (room temperature, workpiece materials, cutting conditions, etc.) Safetyequipment removed for illustration purposes.

Manufacturers are struggling to keep up with their customer’s ever changingdemands. Yet to keep ahead of their customers, manufacturers must get evencloser to production and delivery requirements. Therefore, the need for increasedproduction efficiency will continue to rise.

To achieve these challenges, machines must run with extremely high green-lightutilization rates, while increasing the number of value-added processes performedin one operation. And they must do so for longer periods with less labor.

This is the underlying philosophy of HyperGear laser cutting machines.

The HyperGear incorporates innovative technology that provides:• Reliable laser power at the torch• Fast cycle times• Automated set-up functions• Value-added process integration• Integration with automated information and material flow processes

These innovative technologies allow HyperGear to exceed customer expectations while gaining greater profitability and cash flow.

Unleash the innovation, technology and productivity ofMazak

INSIDE

• The machine’s foundation is a heavy steel fabrication developed on the Takumiprinciple (meaning craftsmanship in Japanese). Its box-construction utilizes aseries of stiffeners and tie rods designed to dampen internal and external vibrations that can cause inaccuracy and wear.

• Non-contact linear motor drives on all five axes of motion work at rapid traverserates of up to 4,724 ipm. All Mazak linear motors are uniquely air-cooled. Thereis NO need for special chillers and their associated maintenance.

• Unique CNC controlled U-Axis provides constant beam length to the torchresulting in consistent cutting in all areas of the cutting table.

Takumi Frame

STANDARD MACHINE SPECIFICATION

Laser Output 2.5 kW 4.0 kW

Max. Workpiece Size 1525 x 3050 mm (60.04" x 120.08")

Cutting Capacity

Mild Steel 22 mm (0.87") 25 mm (0.98")

Stainless Steel 10 mm (0.39") 15 mm (0.59")

Aluminum 8 mm (0.31") 12 mm (0.47")

Work Table Height 900 mm (35.43")

Max. Load Capacity 810 kg (1786 lbs) 930 kg (2050 lbs)

Axis Strokes

X Axis 3070 mm (120.87")

Y Axis 1545 mm (60.83")

Z Axis 100 mm (3.94")

Axis Driving System 5 axis linear motor drive

Positioning Accuracy 0.01/500 mm (0.0004/19.7") X, Y Axis

0.01/100 mm 0.0004/3.94") Z Axis

Repeatability 0.005 mm (0.0002") X, Y, Z Axis

Specifications subject to change without notice.

THESE FEATURES PROVIDE RELIABLE LASER POWER

X2

X1

UY

Z

Linear Motors

Automatic Torch/Tool Changer isunique in the industry, allowingfour different torches or tools tobe resident in the magazine.

OPTIONAL EQUIPMENT: 20-StationAutomatic Torch/Tool Changer

The Automatic Nozzle Changer is a ten-nozzle magazine used to matchthe torch with the correct nozzlefor optimum cutting on every job.

Nozzle Inspection with a CCDcamera prevents cutting failure bydetecting any problems with anozzle and deciding if the nozzleis to be used or not.

For cutting programs prepared bythe Mazak CADCAM system, thepiercing gun performs all piercingoperations in the worksheet. Itthen reloads the normal torchhead for cutting the remainder ofthe sheet.

Perform secondary threading operations right on HyperGearwith our tapping tool, eliminatingunnecessary handling and manual tapping.

Makes finding the “blue flame”calibration a fast, programmableand automatic process. Is alsoused to determine focal lensquality by comparing the currentreadout with previous positions.When out of specification, thedefective torch and lens areexchanged.

4-Station AutomaticTorch/Tool Changer

10-Station Automatic Nozzle Changer

AutomaticNozzleInspection

Piercing GunTapping Tool

EXCLUSIVE AUTOMATED FEATURES THAT SLASH SET-UP TIME AND PROVIDE VALUE-ADDED PROCESS INTEGRATION

The grinder head and wire brushperiodically removes spatter thatadheres to the nozzle by NC program commands. As a result,cutting failure due to nozzleproblems is eliminated and productive, unmanned operationis realized.

Nozzle Spatter RemovalSystem

Counter Sink Tool automatescleanup and saves the extra downstream labor.

Counter Sink Tool

Auto-calibration of the torch and nozzle setup specified for each material and thickness ensures optimum cutting.

Automatic Focal PointPosition Calibration

AutomaticLensCalibration

OPTION OPTION OPTION

The result is enhancedproductivity at lowercosts.

STANDARD FEATURES:• 4-Station automatic torch/tool changer

• 10-Station automatic nozzle changer

• Automatic nozzle inspection

• NC programmable nozzle spatter removalsystem

• Cutting torch for 7.5" lens (lens notincluded)

• Automatic focal point position calibration

• Automatic lens calibration

• Constant beam length delivery system

• Torch presetting equipment

• Clean air supply system (compressor not included)

• Chiller unit

• 2-Pallet changer

OPTIONAL EQUIPMENT:• FMS

• FMS with OptoPath

• Load/Unload cell

• Piercing gun

• Tapping tool

• Countersink tool

• Cutting torch for 3.5", 5" and 8.5" lens

• 20-Station torch/tool changer

• e-Tower

• Smart System CAD/CAM system

• Compressor

• Mazak clean air booth

• Dust collection system

• Ball transfers

For optimum cutting, match thefocal lens to every job and have3.5," 5.0," 7.5," and/or 8.5" cutting torches stored in theautomatic torch/tool changer.

Cutting Torch

Nozzle with spatter

• The Mazatrol PREview CNC is the first of its kind, developed specifically for high-speed laser cutting.

• Conventional CNCs simply react to commands as it readsthem, meaning that higher speeds generally equate to loweraccuracy. For laser processing, this approach also causesproblems of accuracy of holes and round corners, too muchconcentration of heat in square corners, and burning of coated or galvanized steel, to name a few.

• Mazak has invented a software technology in PREview basedon a new, read-ahead philosophy. This concept has been successfully integrated into the CNC that automatically calcu-lates cutting speed and acceleration for every programmedcontour, predicting the optimum speed and power to reachthe next cutting shape. This next-generation control makesit possible to achieve ultra high speed with ultra-precisioncutting and greatly reduce heat build-up.

Intelligent control system for all-axes linear motors.

Command Screen:This is the main operating screen.Upper left shows the machine positions,upper right shows cutting conditioninformation, lower left shows real-timegraphics display, lower right shows theNC program.

CNC SYSTEM SPECIFICATIONSCPU 64 bit

Control Method Preview control (full-closed loop)

Controlled Axes Simultaneous 5-axis control

Minimum Program Unit 0.001 mm (0.0001")

Programming Method Marking code program system and EIA/ISO

Input Method MDI key input, pointing device

Keyboard and mouse (optional)

Memory Device Hard disk 20 GBProgram memory capacity 10 GB

Network Port LAN port

Display 15" color LCD (TFT)

Graphic Screen:Full screen graphics display shows real-time cutting movements. 2D and3D graphic display.

Tool Changer Inventory Screen:Shows the inventory of the tool changer.Information includes available nozzlesand torches, as well as focus settings.

Program File Screen:Shows the interface for loading andsaving programs. Files are stored infolders and directories format. Cuttingconditions and nest files do not sharethe same memory allocation.

Program Edit Screen:Shows the program edit interface. The editor shares all the features of a standard text editor (ie: Search, Replace,Copy, Paste, etc.).

Mazak Smart System Mazak Smart System is a PC-based CAD/CAM system that streamlines sheet metal processing,dramatically reducing the time from order to production. The user can either import a CADfile or quickly create one using the software features. The Smart System automatically generates the part program off-line using the CAD file, and it is designed for ease of use byoperators of varied skill levels.

The 2D CAD software incorporates compatibility with IGES, DXF, and DWG formats. 2D unfolding, parametric function, and macro function are just some of the powerful utilitiesbuilt into the system. The 3D CAD system includes the following functions: 3D-unfolding to2D, 3D data import and 3D sheet metal part development.

The CAM software features powerful utilities providing part nesting for maximized materialutilization with minimum processing time. Smart order lead-in, combined with automaticfeature avoidance, enables the user to automatically minimize any Z lift movements whileobtaining the best cutting sequence. Nesting strategies for maximum sheet utilizationinclude rectangular, random and optimized. Cutting strategies such as lead-in data, corner looping and micro-tabbing can be saved in the resident Techniques Database. Auto-processing functions let the user select cutting, etching and piercing processes automatically.

Post processors capable of programming a variety of other laser, turret, punch press or plasma/oxy-fuel machines may also be added.

Networking and expansion is done easily as the system is PC-based. N/C programs can be downloaded directly from Smart System to the machine control. To be totally responsive to today’s market conditions, you can combine several Mazak laser machines with the Smart System to create an integrated manufacturing system.

FEATURES:• 2D IGES input / output• 2D DFX input / output• 2D CAD• 2D CAM• Nesting

e-checking function provides the currentstatus of items requiring periodic maintenance such as changing filters,changing oil, etc. It provides predictionsand notification when maintenance iscalled for.

e-monitor capability monitors machineoperating parameters and generates appropriate alarms. It provides focusedtroubleshooting advice to minimize downtime and service interventions.

e-manual features complete resident manuals for machine operation.Information about any item is easilyaccessed through a simple search function.

e-scheduler controls the process starttime, finish time, and delivery informationof each job in real time. It allows you toprioritize jobs in the queue and schedulethem to satisfy customer and productivitydemands.

Optional e-nesting function allows re-nesting urgent parts into existing production schedules for the quickest possible customer response.

e-technical help is a searchable library ofhelpful information. Cutting conditions,programming techniques, and much moreare always available right at the machine.

• Automatic Smart Order Lead-In• Program simulation• 3D SAT input• 3D sheet metal modeling

e-Tower UTILIZES INFORMATION TECHNOLOGYTO SUPPORT FACTORY OPERATIONSAND MAXIMIZE “GREEN LIGHT” TIME.

Mazak’s exclusive e-Tower is a networked PC,which gathers, stores, and distributes vitalinformation for factory staff and managementto act on in real time.

On the factory floor or in your remote “command center,” you maintain control overyour laser processing with e-Tower.

Intelligent Cutting FailurePreventionEliminates cutting failure due toheat build-up in material by atuomatically changing the workpiece cutting sequence for programs prepared by the MazakSmart System.

+ FMS + OptoPathTHE ULTIMATE LASER CUTTING SYSTEM

10-Shelf Material StockerA wide variety of worksheets – fromthick to thin – can be stored. Up to 3.3ton capacity on each shelf. Optionalstockers available for increased storage.

Scrap Conveyor (option)Scrap is automatically carried away by conveyor for disposal. Scrap bin isstandard.

Magnetic Floater – 2-WorksheetDetection and SeparationDetects and detaches stacked worksheetsthat are not completely separated to ensureonly one worksheet is loaded at a time.

Management ControllerProduction schedule management, on-line operation and control of thematerial stocker are coordinated usingdata from the Mazak Smart System.

OptoPath programming and operationall quickly prepared by the MazakSmart System. Vacuum pick-up padsare automatically programmed to thecontours of the nesting data.

Pick-up PadsWorksheet material and finished parts are automatically transferred by 7200pick-up pads. Pick-up pads are controlled by an NC program which uses astriker unit driven by linear motors to turn ON/OFF each pad. This dramati-cally increases throughput by reducing load/unload processes typically doneby an operator.

Finished Worksheet TableWorkpieces are automaticallytransferred to the finishedworkpiece table. Additionaltables available as option.

Fork Skeleton RemovalWorksheet skeletons are automaticallytransferred to the scrap bin by a full-sheet fork. No set-up is requiredregardless of skeleton configuration.This increases machine throughput by reducing load/unload processes typicallydone by an operator.