KEMPER Clean and efficient plasma, laser and oxy-fuel cutting solutions Brochure

Clean and efficient plasma, laser and oxy-fuel cutting solutions www.kemper.eu ENAbout KEMPER GmbHKEMPER is an internationally active company based in Germany. We’re a family-owned company and have been investing in developing technology since 1977. Our fields of business include occupational safety, extraction and filter technology, as well as warehousing and automation engineering.Customer satisfaction is very important to us. We always strive to meet your needs. We have several hundred employees worldwide handling projects for our clients and consistently keeping abreast with the very latest engineering developments.We have production locations in Lünen, Shanghai and Prague as well as at our main base. KEMPER has eight offices and numerous dealers allover the world. Our head office in Germany, howeverremains the heart and soul of the company. We intend to continue developing and manufacturing our products there.YOUR PARTNER FOR CLEANAND EFFICIENT SOLUTIONSGerd Kemper Björn KemperGerd Kemper has managed the company since it was founded and is nowadays responsible for the Development, Production and Purchasing divisions. He always aims to develop and manufacture top quality products.Björn Kemper joined the company 12 years ago and now runs the Marketing and Sales divisions. He is primarily interested in innovative sales concepts transparently reflecting good ideas and mature technology.KEMPER GmbHVon-Siemens-Straße 20 48691 VredenTel.: +49 (0) 2564 / 68-0Fax: +49 (0) 2564 / 68-120mail@kemper.euCONTACTwww.kemper.euTABLE OF CONTENTSOverview: pageExtraction tables for cutting systems 4 KemTAB Basic 5 KemTAB Advance 6 KemTAB HiEnd 7 KemTAB Vibro 8 KemTAB Aqua 9 Overview & selection criteria 10 - 11 Material supporting equipment 12 - 13Preliminary separator – SparkTRAP 14 Fans – FanBOX 15About extraction and filter systems 16 PlasmaFIL | OxyFIL 17 PlasmaFIL Basic | OxyFIL Basic 18Dust disposal – DustEVAC 19FOR CUTTING SYSTEMSEXTRACTION TABLES Important things to knowCutting systems, of whatever kind, must primarily do one thing – cut in a qualitative and effective optimal manner. This predicates not only optimal plasma, laser or oxy-fuel systems but a cutting table perfectly tailored to the needs. That’s not all. The smoke that is generated in thermal cutting of metal must be extracted away to prevent any risk arising to the health of anyone in the vicinity. Dust, sparks and smoke represent a risk to machinery as well in the long term and may hamper its functioning. An Extraction system is thus absolutely essential.KEMPER Extraction tablesExtraction segmentsTo keep extraction needs as low as possible our tables are split into individual segments which can be separately extracted from.Fire safetyTo prevent fire due to sparks being sucked up, the tables are so designed that they pre-clean the extracted air. CleaningTable maintenance is important to ensuring smooth functioning of the system. Crane hooks are installed on every element of our extraction tables. This makes it easy to remove the material supports, gratings and dust/slag containers. Containers are designed to make emptying easy. Modular designKEMPER extraction tables consist of individual standard modules that can be connected together. This makes it possible to implement any size of table desired. This standardisation makes combining modules quick and easy.Surface extractionThe design of the extraction tables ensures that the dust generated is extracted evenly over the entire table surface area. This yields efficient and safe extraction of dust generated without sparks getting into the filter.4 KemTAB Basic KemTAB Basic cutting tables are the economical solution for cutting metal of up to 75 mm thickness. The standard package includes mechanical control of the extraction valves, material support frames and slag trays. Individual system modules are split into segments. The valves of each segment are administered by sliding controls. The extraction flap control makes it feasible for only the segment over which cutting is being done to be opened.The material support frames of the basic table consist of flat steel rods inserted at a slant.KemTAB BasicCUTTING TABLES KemTAB Basic PRINCIPLE OF OPERATION The downward pressure exerted in cutting metal generates ascending dust and sparks. Large particles and major sparks land in the slag tray. On KEMPER extraction tables the ascending fine dust is extracted by the integrated surface extraction system and deposited in the filter system connected to the table. Each module has its own internal integrated extraction channel. The internal extraction flaps are opened mechanically. BENEFITS• Longer cleaning intervals thanks to the large slag trays• Simple table cleaning• Improved cutting quality thanks to the design• Efficient and safe extraction of dust by the surface extraction systemSlag trayTechnical dataLoad capacity: 75 mm sheet steel Module widths: 1.100 mm, 1.600 mm, 2.100 mm, 2.600 mm, 3.100 mmTable height: 700 mmSegment intervals: 515 mmPiping connection: at the front 5KemTAB Advance in the production lineUnloading of material support and slag trayCUTTING TABLES KemTAB AdvanceKemTAB Advance KemTAB Advance tables offer rugged and flexible solutions for cutting systems. They are optimal for use in cutting metal of up to 150 mm thickness.The features include pneumatic control of the extraction valves; material support framework and slag trays. Individual system modules are split into segments. The flaps in each segment are actuated by control slides. PRINCIPLE OF OPERATION The principle of operation corresponds to that of KemTab Basic. The internal extraction valves in the KemTAB Advance, however, are pneumatically activated. BENEFITS• Longer cleaning intervals thanks to the large slag trays• Easy table cleaning• Improved cutting quality thanks to the support frame design• Efficient and safe dust extraction by the surface extraction system• Can be used for sheet metal of up to 150 mm thickness• Pneumatic activation of the extraction valves Technical dataLoad capacity: 200 mm sheet steel Module widths: 1.100 mm, 1.600 mm, 2.100 mm, 2.600 mm, 3.100 mmTable height: 700 mmSegment intervals: 515 mmPiping connection: at the front or under the table6 KemTAB HiEnd KemTAB HiEnd extraction tables are used under extremely demanding conditions. It can even cope with tasks with a cutting performance in excess of 600 amperes and a sheet thickness of over 250 mm. Features The KemTAB HiEnd offers rugged design and consistent separation of the material support frame from the load-bearing parts of the table. This makes for less strain on the latter and the cutting table can hence be used with high cutting power and at high temperatures. Temperature resistance is further increased as valve activation and the associated pneumatic system are attached externally. The reinforced specially shaped slag trays with downward facing extraction apertures make it possible tohandle high slag volumes and heavy sparking. CleaningLike all other KemTAB extraction tables the KemTAB HiEnd is easy to clean. The slag and swarf generated by cutting fall through the supporting frame and collect in the big slag tray. They can then easily be disposed of once the support frame has been removed. This ensures efficient low-maintenance table operation.Material-supporting framesKEMPER offers a variety of extremely rugged support frames for the KemTAB HiEnd depending on use and cutting method.ExtractionTransverse extraction apertures integrated in the slag trays with equal pressure distribution make optimal extraction feasible. In this way complete capture of the cutting dust is ensured. The valve channels are laterally integrated in the table and only minimally influenced by the cutting beam. All pneumatic components are isolated from the airflow, which results in less wear.CUTTING TABLES KemTAB HiEndMaterial support and slag tray of the KemTAB HiEnd BENEFITS• Ideal for very high cutting performance• High temperature resistance• Rugged separate cutter support• Separation of airflow and mechanical parts• Low-resistance extraction channel• Easy to assemble• Little down timeTechnical dataLoad capacity: 300 mm sheet steel Module widths: 1.700 mm, 2.200 mm, 2.700 mm, 3.200 mmTable height: 850 mmSegment intervals: 515 mmPiping connection: at the front 7CUTTING TABLES WITH VIBRATING CONVEYORS KemTAB VibroKemTAB Vibro Efficient cutting systems need efficient cutting table systems. This way, down times, due to cleaning and maintenance can be cut to a minimum. This is especially important if the cutting process is automated. Features KEMPER’s KemTAB Vibro is a cutting table for use underdemanding conditions and in addition to this is equipped with an automated discharge system. This makes uninterrupted operation without cleaning breaks feasible. The KemTAB Vibro functions using the oscillating conveyor principle. The slag and swarf generated by cutting are constantly moved into a containerto the end of the table. The result is a much higher degree of utilisation of the cutting plant and hence much higher efficiency. Cleaning intervals are thus cut to an absolute minimum.Oscillating conveyor systemThe oscillating channels operate in the resonance range and thus save a lot of energy and are low in wear. One or more such channels are installed longitudinally on the table, the number depending on its length. The drives are installed externally on the table front in a rugged housing. Each channel has its own drive.Material supporting framesKEMPER offers a wide range of material support frames for the KemTAB Vibro. There are a variety of models to choose fromdepending on cutting process and requirements.ExtractionAir diffusers installed in the table segment-wise and runninglaterally with equal pressure distribution ensure optimal extraction. This guarantees that all cutting dust is dealt with. The valve channels are laterally integrated in the extraction tables. The pneumatic parts are separated from the air flow, which reduces wear.Discharge of slag and small parts in containers BENEFITS• Permanent discharge system• Best possible degree of utilisation• Efficient dust handling• Separation of airflow and mechanical parts• Extraction channel with optimised resistance• Minimal down times• Minimal maintenance costsTechnical dataLoad capacity: 200 mm sheet steel Module widths: 1.600 mm, 2.100 mm, 2.600 mm, 3.100 mmTable height: 850 mmSegment intervals: 515 mmPiping connection: at the front8 KemTAB Aqua KEMPER water cutting tables in the KemTAB Aqua series are suitable for plasma and oxy-fuel cutting systems of metal panels above and below water. This has many benefits. In addition to reducing the noise level to a great extent as well as absorbing most of the cutting dust when cutting under water the material being worked on suffers very little distortion. Last but not least, this ensures high cutting quality. A water cutting table with variable water levels is essential for cutting both above and below water.Integrated air chambers KemTAB Aqua water cutting tables with level control have air chambers used to adjust the water level. Pumping in or extracting air to/from the integrated air chambers adjusts the water level At low water levels, cutting can be done above water. KEMPER naturally offers the right means of capturing the dust on the material surface that results. The slag generated by cutting is captured in slag trays located below the material support frame. When the water level is lowered and the support frame removed, these trays can easily be removed and cleaned.Table control systems The tables have their own control systems. These can either be operated manually or linked with the cutting plant control system. Automatic and easy operation is thus ensured.WATER CUTTING TABLEKemTAB Aqua Side view of a KemTAB water cutting tableKemTAB water cutting tables in production line BENEFITS• Very little distortion of the cut material • High cutting quality • Hardly any burring on the lower cut edges • Absorption of the cutting dust in the water • Very little noise pollution• Project-specific sizing 9OVERVIEWEXTRACTION TABLES KemTAB table models:Technical Data Basic Advance HiEnd Vibro AquaSheet metal thickness capacity in mm75 200 300 200 300Maximum width in mm 5.200 optional 4.400 4.200 optionalMaximum length in mm 20.600 optional optional 12.360 optionalTable height in mm 700 700 850 850 850Weight / m² approx. 180 kgapprox. 250 kgapprox.400 kgapprox. 300 kgapprox. 700 kg(incl. water)Segmentation in mm 515 515 515 515 -Slag trays ? ? ? - ?Material supporting frameseasyFRAME Basic ? - - - -easyFRAME Advance - ? - ? -Control systemsMechanical ? ? - - -Mechanical-pneumatic ? ? ? ? -Inductive-pneumatic - ? ? ? -Electronic-pneumatic - ? ? ? -Discharge / cleaningManual ? ? ? - ?Oscillating conveyor - - - ? -Chain conveyor - - - - ?Piping connectionAt the front ? ? ? ? -Under the table - ? - - -10 SELECTION CRITERIA EXTRACTION TABLES BasicMetal thickness in mm 350300250200150100500KemTabOXY-FUEL-CUTTINGAquaVibroHiEndAdvanceBasicCutting power in Amperes 7006005004003002001000PLASMA-CUTTINGKemTabAquaVibroHiEndAdvanceThis overview makes clear which table is optimally suitable for which process. 11MATERIAL SUPPORTING FRAMES easyFRAME BENEFITS• Self-supporting support frame with no welded parts• The material support frames can be completely disposed of• Slag doesn’t accumulate in corners and pockets• Less reflection of the cutting beam• Support frames can be made by the client to specifications provided• Simple installation of a new frame without any need for welding• Disposal of old frames and installation of new is quick, easy and time saving• Optimal solution for use when loading with a magnetic craneeasyFrame for KemTAB Advance and Vibro Jagged edged support rods, 120 x 5 mm, version 116easyFrame for KemTAB Advance and Vibro Straight support rods, 120 x 5 mm, version 11917043,6°120170120easyFrame for KemTAB Basic Straight support rods, 120 x 3 mm, version 603easyFrame for KemTAB BasicJagged edged support rods, 120 x 3 mm, version 60717012017043,6°120easyFRAMEFeaturesThe KEMPER easyFRAME cutting plant support frames consist of interlocking rods, supporting rods and deflector plates. The result is a self supporting construction without any outer frame which can therefore do without welded parts.It is quickly and easily assembled. This design yields a smaller contact surface for the cutting beam. This leads to less reflection and therefore less wear and better cutting quality.12 OVERVIEWMATERIAL SUPPORTING FRAMES Version 004Support frame of sheet metal, 120 x 10 mm, with support rods 120 x 5 mm, Inserted aslant at 100 mm intervalsVersion 000Support frame of sheet metal, 120 x 10 mm, with support rods100 x 5 mm, inserted aslant at 100 mm intervals51901201701005Version 028Support frame of sheet metal, 120 x 5 mm, with support rods, inserted slightly aslant at intervals of 130 mm for use with forkliftsVersion 054Support frame of sheet metal, 120 x 10 mm, with support rods 100 x 5 mm, jagged edged, inserted aslant at intervals of 100 mm for precision sheet metal support5190120190120Version 101Support frame of sheet metal, 120 x 10 mm, with support rods 100 x 1.5 mm inserted longitudinally at intervals of 50 mm,for handling thin coiled sheet metalVersion 131Support frame entirely of sheet metal, 120 x 10 mm for cutter tips170120120100To cater for all needs KEMPER offers a variety of material support frames for all extraction tables. The material support frames are tailored to the table module concerned and available in differing versions.The choice depends on the cutting process employed and the material to be cut.Additional material support frames 13PRELIMINARY SEPARATORSKEMPER SparkTRAPPreliminary separatorLarge dust quantities, such as those that arise in many cutting procedures, strain filter systems and cut filter service life. Sparks and glowing particles also constitute a filter fire risk. KEMPER‘s innovative SparkTRAP preliminary separator is the answer. This rotary separator enormously reduces the dust generated and cuts the filter fire risk.Filter stressBy separating out most of the dust, SparkTRAP cuts extraction system filter use considerably.This considerably increases filter system service life and dramatically reduces maintenance and compressed air costs.The SparkTRAP offers virtually complete protection against filter fires by reliably separating out sparks, glowing particles and even burning foreign bodies (e.g. cigarettes).Preliminary separationIn metal processing, filter systems often have to deal with large amounts of dust, glowing particles and flying sparks. The SparkTRAP preliminary separator developed by KEMPER is a great help here. It constitutes a fire prevention system and greatly increases the filter system service life.Spark detectionA spark detection system can be added to SparkTRAP.The extraction and filter system can then be automatically shut down if defined limits are exceeded. This improves safety and cuts the filter system fire risk enormously. PRINCIPLE OF OPERATION The upstream swirl nozzle rotates the air. In the acceleration path that follows, the rotation speed increases to up to 150 kph. The SparkTRAP swirl separator thus separates out large particles, sparks and glowing foreign bodies virtually entirely. The sparks and particles thus separated out are trapped in a dust collection tank separated from the filter system. This can be removed for disposal of the content even whilst the plant/unit is running. BENEFITS• Virtually complete separation of sparks and large particles• Reduction of the fire risk to an absolute minimum• Increased filter service life• Reduction of operating costs• Simple installation, including as modification• Easy removal of the collection tank during operation• Spark detection can be added to further reduce fire riskKEMPER SparkTRAP14 FAN UNITKEMPER FanBOX KEMPER FanBOXKEMPER fan units consist of efficient, noise suppressed industrial standard fans in a rugged steel housing with a soft start facility. They are available in versions of various capacities and can be connected up to our extraction tables. They are to be found together with SparkTRAP preliminary separators wherever permissible and where an economical means of extracting harmful substances is needed. OPTIONS• Automatic start-stop • Frequency converter • Control system with monitoring function • SparkTRAP preliminary separator FEATURES• Efficient fan • Soft start facility • Noise insulated • Rugged steel housing • Stackable • Crane rings 15About KEMPER Extraction and filter unitsThermal cutting of metal generates lots of very fine dust harmful to machinery, surroundings and users. It is hence essential thatoptimal extraction and therefore clean air in the workplace is ensured in all cutting processes.The amount of dust generated depends on the specific procedure employed and the material being cut. The risk to health involved in oxy-fuel, plasma and laser cutting is especially high as it is dependent on the size of the particles involved and extremely fine particles are generated when these procedures are used KEMPER can supply tailored filter systems for these procedures.They are tailored to handle the dust generated by these procedures and can be optimally adapted to the specific cutting unit by the incremental power-adjustment of each type.KEMPER only uses top quality filters in their extraction and filtering systems. Cutting in particular generates very fine particles with a diameter between 0.1 µm and 1.0 µm that are hence alveolar.It is these particles in particular that get into the alveoli (human lungs), diffuse from there into the blood and then settle in the body. The extraction begins in the cutting table of either a pre-existent cutting unit or a suitable system supplied by KEMPER. The dusty air is sent to the filtration system via piping. After preliminary sepa-ration of larger particles the remaining dust particles are separated out at the filter cartridges applying the surface filtration principle.EXTRACTION AND FILTER UNITSKEMPER System 8000 extraction and filter systemExtraction and filter system with welding stations16 PlasmaFIL | OxyFILThis series of filter systems is specially developed for use with plas-ma and oxy-fuel cutting systems. The core – the filter element – consists of a specially coated filter medium. To this, the additional system components, that is, fan unit and SparkTRAP are added. The DustEVAC dust extraction system can also be added.Filter element service lifeService life can be disregarded when employing PlasmaFIL or OxyFIL. It is endless if annual servicing is carried out. This makes filter replacement superfluous. The resulting costs are low and calculable.Future proofOur systems are so designed that the changes in law concerning fine dust limits to be expected in the years to come are satisfied today. Operators can thus rely on our equipment being future proof.Dust dischargeInstead of changing dust collection containers, the system can be run using permanent dust discharge equipment. This permits virtually contamination-free dust disposal.EXTRACTION AND FILTER UNITSPlasmaFIL| OPTIONS• Endless filter service life• Permanent dust discharge• Spark detection system• Automated start-stop• Vacuum control via frequency converter BENEFITS• Filtering using the downflow principle• Modular design• Low power consumption• Minimal compressed air consumption• Touch screen controls• Contamination-free dust disposal• SparkTRAP preliminary separator PlasmaFIL connections 17PlasmaFIL BasicOxyFIL BasicThe filter systems in the Basic series are specially designed for use with plasma and oxy-fuel cutting. These comply with currentregulations and are an economic alternative for the efficient extraction and filtration of cutting dust. At the same time, these filter systems are characterized by their compact design and low requirements. Filter elementsHigh quality filter cartridges are used in PlasmaFil Basic and OxyFIL Basic filter systems. They efficiently filter the dust generated by surface filtration and have long service lives. The de-dusting is carried out by differential-pressure control using compressed air and without moving parts.InstallationThe Basic series filter systems are exceptionally compact and can be installed quickly with minimal space requirements. The systems are ready for use and can be connected to the cutting plant control system.OperationThe filtration control system is intuitive. System messages are clearly displayed. The dust collection containers are high capacity and easily removed for content disposal. All system components are easily accessible via maintenance apertures.EXTRACTION AND FILTER UNITSPlasmaFIL Basic | OxyFIL Basic OPTIONS• Contamination-free dust disposal• SparkTRAP preliminary separator• Permanent dust discharge• Spark detection system• Automated start-stop BENEFITS• High filtration efficiency• Compact design• Noise level below 65 dB(A)• Intelligent cleaning• Low power consumption• Space-saving• Control system with plain text display• Monitoring functions|18 DustEVACHigh-performance cutting systems usually generate a lot of dust. This is separated out in preliminary separators and filter systems and collected in containers. These have to be emptied frequently, often several times a shift. This involves interrupting operations, a lot of dirt in the vicinity of the filter system and major risks to health. In extreme cases systems may break down due to not being emptied in time.KEMPER’s DustEVAC is an excellent answer. It makes uninterrupted operation of the filter system feasible thanks to constant contamination-free dust discharge. The dust from one or more filter systems and preliminary separators linked to it / them is sent to a Big Bag of high capacity via extraction. It can then be disposed of without any contamination risk without interrupting filter system operation.KEMPER’s DustEVAC thus improves cutting efficiency, at the same time considerably reducing operating costs and improves occupational health and safety conditions for staff.A clean all-round solution.DUST DISPOSALDustEVAC PRINCIPLE OF OPERATION• Extracts dust from filter systems to a BigBag• Residual air is returned to the filter system• BigBags can be sealed and transported by forklift• Simple interim storage or final disposal• Control and monitoring is feasible via the filter system• Central discharge system for multiple filter systems or preliminary separators BENEFITS• Constant removal of dust from the filter system• Uninterrupted filter system operation• Contamination-free disposal• No moving parts in the extraction piping• High capacity up to 700 litres• BigBags can be moved by forklift• Easy disposal of BigBags• Uninterrupted system operation• Multiple filter system / preliminary separator connections• Major cost reduction• Improved occupational health and safety for staff 19www.kemper.euKEMPER GmbHVon-Siemens-Straße 20 48691 VredenTel.: +49 (0) 2564 / 68-0Fax: +49 (0) 2564 / 68-120mail@kemper.euArt.-Nr. 691 0176 · © 2012 by KEMPER GmbH · All rights reserved · Printed on environmentally friendly paper.