Following the principle of small steps, MicroStep continuously improves its series and systems and thus permanently provides customers with state-of-the-art solutions with which they can manufacture economically, flexibly and with high quality. MicroStep has already integrated many options in the basic equipment that enable process-reliable work for the entire life of the machine. In addition, a number of extras provide an additional improvement in the production possibilities to create different geometries even faster, even more precisely and even more flexibly.
Thousands of MicroStep cutting solutions with different tasks and equipment perform their service reliably every day all over the world. The spectrum ranges from all-rounders that combine a multitude of processing options to true specialists – all under the premise of serving the requirements of different industries and producing reliably day after day for many years – whether with plasma, laser, oxyfuel or waterjet. Series such as the MG, the DRM or the CombiCut are “true multi-functional wonders and pioneers in the cutting industry”, says the manufacturer confidently. Combined with MicroStep’s close training support and innovative automation solutions, this guarantees the highest production quality.
The topic of research and development takes on a special role at MicroStep. “In addition to the rapid integration of relevant innovations from our suppliers, we continuously implement the results of our own research in our products – always with the aim of optimizing the entire technology-based production process,” promises Dr.-Ing. Alexander Varga, Head of Development and co-founder of the MicroStep Group. A large number of systems developed in-house support process-safe, reliable and precise production at every plant – including the patented ACTG automatic calibration unit.
In addition, MicroStep has developed other special solutions that help customers to complete their cutting tasks even more efficiently, even faster, even more precisely and to get the maximum out of their cutting system. “We have many special extras in our portfolio, often implemented as special solutions for a customer. These offer immense advantages for many applications. The topic is an ongoing process for us, with new ideas and projects being added all the time. That’s why it’s always worth taking a look at our latest developments and having a consultation with our experts,” emphasizes Uli Kisslinger, Head of Internal Sales at MicroStep Europe.
A number of customers around the globe are already benefiting from the extras presented here from the more recent development.
More precise and faster hole cutting
Cutting holes in flat material is one of the frequently required cutting applications with plasma technology. Straight bolt holes must be cylindrical. The physical angle deviation of the plasma arc makes this difficult and often requires reworking or the additional use of a drilling unit. For this reason, MicroStep has developed the “PowerHole” technology, which largely compensates for the angular deviations and minimizes them accordingly by means of appropriate parameter settings, combined with tilting of the plasma torch during the hole cutting process. PowerHole not only significantly increases the cylindricity of holes, but also the speed during the cutting process.
Acceleration of the cutting speed
The MicroStep “Smart Z Movement” function makes it possible to significantly speed up cutting processes without sacrificing cutting quality. The solution ensures that the traversing height of the plasma torch is optimized and generates additional time savings through simultaneous, laser-like motion sequences.
Subsequent chamfering and saving of material
With the “Additional Beveling Process” (ABP) from MicroStep, subsequent weld seam preparations can be realized on already cut components. This is ensured by the ABP laser scanner, the ABP technology and the plasma, laser, autogenous or water jet rotator. This saves operating costs, material and often the use of an additional workstation and opens up new possibilities.
Acceleration of the cutting process for cutting tasks with 2D and 3D contours
In combination with the MicroStep Plasmarotator, an endless rotating chamfering unit, and the “Corner Loop” technology, the production time as well as the consumption of wear parts are significantly reduced. Corner Loop enables automatic and uninterrupted switching from 2D to 3D cutting and back.
Less rework and significantly higher cutting quality in 3D tank bottom processing
MicroStep has developed the mScan technology to significantly increase the cutting quality when processing container bottoms. In combination with the “Pantograph” plasma rotator and a laser scanner, well-known customers such as Slawinski or GEA Production Kitzingen generate high-quality results in this way and save themselves a great deal of reworking. The system determines the 3D geometry of the container base, compares the real contour to the ideal contour, automatically compensates for production-related deviations and sets the cutting paths precisely.
Capacitive height control for oxyfuel torches: Accurate results and increased service life
MicroSteps height regulation ensures the optimum distance between cutting torch and material during the piercing and cutting process. The sensor ring responsible for the distance measurement can optionally be retracted after the measurement has been completed, thus considerably reducing its contamination during oxyfuel cutting.
Slag prevention and quality improvement
Another useful extra is the installation of a spray device on the plasma torch. This applies a release agent (anti-spatter spray) to the flat material before the piercing process. The result: Reduction of slag adhesion to the workpiece as well as an improvement of the cutting quality during hole cutting.
Automatic central lubrication: Save time and extend service life
By using an automatic lubrication system for linear guides and racks, users save time and can increase the service life of their equipment.