INTELLIGENT AUTOMATIC NESTING

INTELLIGENT AUTOMATIC NESTING
INTELLIGENT AUTOMATIC NESTING
The keys to unlocking profits with lasers, plasma, gas, waterjet and combo machines can
be found in P.E.P.’s automation. As with any lock, the user must have the right key to
gain access. P.E.P.’s 30 plus years of writing CAD/CAM software with seamless database
technology, amazing intelligence and intuitive menus allow sales, engineering and
programming departments to do 5 times the amount of work they would otherwise be
able to do with any other CAD/CAM product.
The proof. The parts in the picture below are three inches thick and nested at .375”
spacing. The nest is so tight it looks like a laser nest. The company that cut this nest with 8
oxy torches used their existing equipment and personnel, and saved $4,000.00 / plate by
using P.E.P.’s automated nesting and CPT technology to cut the nest. Please take a close
look at the picture to see if you can spot how P.E.P. has dissipated the heat.
HIGHLIGHTS OF P.E.P.’S AUTOMATED MANUFACTURING SOFTWARE
ILLUSION #1 - Which nest (A or B) has 11% better yield?
Can you pick the nest with the best yield from nest A and B? If your software generated the wrong nest
and your programmer did not catch it then your company lost 20% in material (11 parts), and possibly
30% in machine productivity. Can anyone pick the best material yield by merely looking at the nest, the
answer is NO, you need to count the parts. Automatically nesting the parts multiple ways and saving
the best result is what great software does automatically.
ILLUSION #2 - How important is part rotation to material yield?
Interlocking the parts as shown below right yields 7 more parts per sheet (24.13% better material yield).
Furthermore, by sequencing the nest and strategically assigning the lead-ins 200 head raises were
eliminated. Could your programmer have manually created the same nest, rotating and interlocking the
parts. It’s very unlikely. Automatic nesting results like the results in the lower left are typical of most
automatic nesting engines, and consequently jobs like this go to the shop every day when the
programmer does not have the TIME to re-nest the parts manually.
Brand-X automatic results
P.E.P. Technology's fully automatic mode
ILLUSION #1 - ANSWER is B (20% better yield)
QUESTIONS: Can you pick the nest with the best yield from nest A and B?
ANSWER:
B has 11 more parts than A, that is a 20% increase in material yield.
COMMENT: Can a skilled programmer pick the best material yield by merely looking at the nest, NO.
ILLUSION #2 - Nesting at 12 degrees interlocks the parts in the horizontal and vertical.
QUESTIONS: Does a programmer have the time to renest, checking every angle to get the best rotation?
ANSWER:
NO. Failing to find the interlocking angle for BOTH the horizontal and the vertical
interlock will cost the company up to 24.13% in material.
COMMENT: It’s not enough to check every angle, the automatic nesting engine must check 360
degrees of rotation comparing a part interlocked with itself at all rotations.
Brand-X automatic results
P.E.P. Technology's fully automatic mode
DO AUTOMATIC NESTING PRODUCTS PRODUCE ACCEPTABLE RESULTS?
YES…P.E.P. creates great AUTOMATIC results! Most automatic nesting product requires a skilled
programmer with UNLIMITED TIME to re-nest the automatic results a 2nd and 3rd time, and then
manually interact with the automatic results essentially editing 90% of the nests your shop cuts.
HOW MUCH IS IT COSTING YOUR COMPANY TO RE-NEST AND EDIT THE AUTOMATIC RESULTS
An automatic nesting product like P.E.P. that can nest automatically as effectively as a skilled
programmer given UNLIMITED TIME to edit a nest will typically save $120,000.00 per laser per year in
material and machine productivity. The savings increase when the skilled programmer accepts the
automatic results and does not renest the parts. That’s the documented number P.E.P. customers have
reported back after switching to P.E.P. and analyzing the savings.
WHERE DO THE SAVING COME FROM
The bar graph below breaks down the ROI comparing the skilled programmer to PEP’s automation.
This document discusses Material Yield and Machine Productivity comparison in the grid. The P.E.P.
speed and automation typically allows 1 programmer to do the work of 5 SKILLED PROGRAMMERS.
WHY ONE AUTOMATIC NESTING PRODUCT CAN BE SUPERIOR TO OTHERS
#1 MATERIAL YIELD
The interlocked COLUMNS of parts in the picture below were nested by P.E.P. automatically!
COLUMN NESTING is a concept and a technique that P.E.P. has been perfecting since 1986, this concept
is proven to produce better material yield and better machine productivity, and it is fully automatic.
To deviate from the column nesting concept “even once” within any area of the nest makes it impossible
to control HEAT. When heat is not controlled on every plate, then ALL of the parts on all of the plates
must be cut at a greater distance (spacing)….or….cut with the tech table speed and power reduced.
The P.E.P. automatic nesting engine AUTOMATICALLY creates perfect nests on the 1st try. There is no
editing and or re-nesting required, as such, sales, engineering and programming all get the same results.
#2 HEAT CONTROL
Controlling heat allows parts to be spaced closer to improve material yield.
Heat control also improves cut quality and allows the machine to cut faster.
When heat is not dissipated into the uncut material the parts must be nested
further apart to get acceptable quality, and the cutting speed must be
reduced.
P.E.P’s automatic nesting engine AUTOMATICALLY nests parts in columns
100% of the time as seen on the right, thereby setting up the secondary
sequencing process and the assigning of lead-in’s to dissipate heat.
#3 SEQUENCING OF THE NEST
P.E.P.’s sequencing logic will create a perfect cut sequence controlling heat. The software takes
everything into consideration to generate the cut sequence such as controlling heat, least number of
head raises, the shortest rapid path, and the smallest post processed code….all simultaneously!
ILLUSION #3 – The Material and Machine Illusion
PEP’s AUTOMATIC NESTING RESULTS
The PEP automatic nesting engine saved 8% in material across 4 plates, is there more to the ROI?
Check out this link…. PEP CPT Fully Automatic Sequencing Technology
BRAND-X AUTOMATIC NESTING RESULTS
 The white and or black coloring of parts as shown below makes viewing the material yield difficult.
 8% of the parts are missing, this is a minimum. To cut the brand-X nest the machine must cut slower.
 100% of the parts need to be cut with a head raise, where as PEP only required 11 head raises.
Check out this link…. Brand-X Fully Automatic Sequencing Technology with PEPs enhanced color mode
THE REST OF THE STORY
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The company using the BRAND-X automatic nesting engine and skilled programmers to create the
nest was knocking the head off multiple times a day, occasionally breaking the bellows.
The heat buildup in the parts necessitated that the parts be sequenced using a random path that
sent the machine rapiding around the plate to dissipate the heat. The extra rapid travel was time
consuming and potentially reckless as this company did not replace slates as often as the
manufacturer recommended. Removing slates resulted in more tipped parts and head crashes.
This company broke the laser bellows frequently BEFORE they bought PEP, consequently they had to
stock more than one bellows in the companies parts inventory.
Brand-X nest without the rapids displayed
Brand-X nest with rapids displayed using “Distributed heat dissipation”.
#3 SEQUENCING OF THE NEST - CONTINUED
The nest below left is an example of how the Brand X automatic nesting engine failed to setup the
sequencing. The lack of organization within the nest results in parts being sequenced incorrectly and
heat being trapped in the parts. Below right is the P.E.P. nest, the parts were nested in columns which
allowed the sequencing logic to automatically sequence the parts snaking up and down left to right.
Poor sequencing
The Brand X nest to the right is
another example of a nest that was
not nested and or sequenced
properly.
The RED arrows show locations
where the heat is trapped.
This is an example of what not to
do.
#4 LEAD-IN TYPE AND LOCATION
P.E.P. Technology lead-in logic will
automatically find the best location on
the part geometry to assign the lead-in,
strategically locating the correct lead-in
type to control heat, stay away from
press brake edges while at the same
time, eliminating head raises. Line
lead-ins are assigned to geometry
intersections; and line-arc lead-in are
assigned to lines and arcs.
#5 CAD FILES
P.E.P. supports the conversion of all the following 2D and 3D formats:
. PDF files
. CAD file formats DXF, DWG, IGES, etc.
. CAM formats such as Bysoft, Cinsoft, Lantec, MTC, Metamations, Sigmanest, Tops, etc.
. CAD formats such as Solidworks, Solidedge, Pro-E, Inventor, AutoCAD
. Structural Steel formats; KSS, NC1, Tekla, SDS2, etc.
It is not necessary to remove title blocks, dimensions, notations, cross hairs, alternate views ( top, side,
isometric, etc.), the P.E.P. software will analyze the CAD data and find the part, then fix all the geometry
errors automatically.
ERROR FREE CUTTER PATH IN 2 SECONDS
The P.E.P. software finds the part and creates a perfect cutter path by fixing ellipses, splines, gaps, duplicates,
blends, etc. automatically. When short lines are detected the software converts the lines to arcs and circles
automatically.
AUTOMATIC SCALING AND VERIFICATION OF DIMENSIONS
The part in the picture to the right was scaled, the part
geometry measured and compared to the dimensions, then
compared to the tolerances, dimensions in tolerance are
outlined in blue, and the part saved as a perfect cutter path
in 2 seconds along with the documentation showing every
task performed by the software.
The P.E.P. CAD converter will convert both single part and
multiple part files to a finished cutter path in one step in
seconds.
#6 COMMON CUTTING
P.E.P. Technology’s common cutting technology includes rotation to maximize common cutting, automatic
mirroring, safety cuts, etc.. The nest below was created fully automatically.
#7 MACHINE PRODUCTIVITY
All of the automation above used together allows your laser operators to increase the cutting feed rate back to
what the limits of the machine and material are. P.E.P. Technology customers gain a measured 15-20% more
throughput in laser and flame cutting operations.
The recent buzz about "tru-hole" plasma technology is old news to PEP customers. Because PEP customers can
accurately cut holes smaller than material thickness on plasma tables, they avoid secondary drilling operations.
The P.E.P. lead-ins and lead-outs allow parts to be plasma cut without gouging, or having to deliberately program
material left at the lead-in, with subsequent grinding and clean-up work.
#8 ERP INTERFACES
P.E.P. Technology has been a leader in bi-directional ERP and MRP integration using SQL, ODBC, and text files for
15 years. The P.E.P. WIP software has been working with cloud based products such as LaserQuote and Plex for
over two years. By bringing the work into P.E.P. to schedule, enormous savings in programming time and material
yield are achieved. PEP tracks and reports back what has been cut, what is scheduled to be cut, and what needs
to be scheduled. Fewer remnants, better reaction to "hot jobs" and accurate tracking of cut part quantities are
the result. Manufacturers, Job shops, Steel service centers, every business that runs thermal or WJ cutting or
punching can increase their profits and throughput with the automation in PEP. Visit www.peptechnology.com or
emails sales@peptechnology.com for more information
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