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Nesting

art8.pngThe main task in true shape nesting is placing flat objects on plate blanks. The objects can be individual parts or groups of nested parts – blocks.

The efficiency of nesting has the most significant influence on the use of metal.

The tight nesting saves metal, the loose – increaces the losses from scrap.
The system nests objects step-by-step and provides interface for nesting control.
Vintech RCAM-Pro nests automatically, interactively or manually.

The system optimises, finds the place and orientation of the object on the plate and nests it tightly to other already nested objects.meq_sh.jpgВъв всеки момент Винтех RCAM-Pro извършва on-line контрол против припокриване – за недопускане поставяне на обект върху вече разположени обекти. Vintech RCAM-Pro performes on-line control against overlapping all the time - to avoid placing an object on other already nested objects.

The automatic nesting is performed in the sequence specified in the nesting queue and with the quantities specified in the nesting job. The automatic nesting can be performed on single or multiple plates until the permitted plates or the parts in the job are expended.

Under the management of Vintech RCAM-Manager, Vinteh RCAM-Pro performs simultaneously automatic nesting on all plates for all jobs in the order.

It is possible to choose an object located on the plate or in the nesting queue, at any time. The selected object appears under the mouse cursor and can be dragged, pushed and rotated near the desired location on the plate. After dropping, Vintech RCAM-Pro nests it tightly to the already nested objects, performing on-line control against overlaping at the same time.

The user can switch off the on-line control against overlapping and nest the object on the desired location on the plate using the mouse cursor.

True shape nesting technology

 

The true shape nesting technology determines the quality of the manufactured parts, the productivity and the degree of wear of CNC machines for thermal and jet cutting.
Combining optimal nesting methods and processing technology is a task with the highest complexity in true shape nesting.

Each cutting type - laser, plasma, oxy-fuel, water-jet or mechanical, has its own peculiarities and requirements.
The cutting technology is determined by the ongoing physical and chemical processes inside the cut, the type and thickness of the material and the type of the processed contour.
Vintech RCAM-Pro supports the specific tecnology knowledge as tabular rules in datasets, stored in the SQL database of the system, called Technology Knowledge Base (TKB).
The system uses TKB to determine what processing technology to implement on the nesting layouts in the project.The user can always change a technological parameter assigned by the system.

 

 

 

 

Cutting path is the path of the jet, which moves along a separate contour from a part in a manner determined by the processing technology. Vintech RCAM-Pro differs which contours are outer, inner, holes, slits, which paths are marked (or engraved), and also which points are for centring. Vintech RCAM-Pro creates paths automatically or interactively.

Route of rapid moves is the order of processing separate paths in a part and in a nesting layout.

Vintech RCAM-Pro provides advanced capabilities for creating and managing processing technology:

  • Vintech RCAM-Pro provides advanced capabilities for creating and managing processing technology:
    Vintech RCAM-Pro has no restrictions on the sequence of creating technology and nesting.
    The user decides in what state to nest the objects – parts and blocks. They can be:
    • without paths and route,
    • with partially or fully completed paths and no route,
    • with paths and partial routes,
    • with completed paths and route.
  • Special technologies
    Vintech RCAM-Pro implements high efficiency methods for processing programming, such as:
    • bevel cutting (optional),
    •  combined thermal cutting and drill-boring processing (optional),
    • variable number and distance between parallel cutting torches (Advanced Multy Torch)
    • processing by frames of plates longer than the work stroke of the machine,
    • cutting holes without defects at the extinguish point,
    • cutting with bridges, with common cuts,
    • chain cutting with circumventing, and others.
       
  • Optimisations and automatic control when creating paths and routes
    • Optimisation of cutting paths
      In every moment, Vintech RCAM-Pro performs on-line control and avoids placing paths and path elements on already nested objects or other paths.
       
    • Optimisation of the route of rapid moves
      Vintech RCAM-Pro automatically or interactively creates a rapid moves route. The system allows working with partial routes.
      When automatically creating a route, it minimises the length of the route, taking into account constraints such as the part by part and insertion.

      -Insertion is nesting a part in the hole of another part. The levels of insertion in the system are unlimited. Vintech RCAM-Pro automatically programms the processing of the inserted contour before the one enclosing it.

      -Part by part is a limitation of the processing of all contours of a single part, before moving on to the processing of the next part. The control for part by part and insertion can be turned off.
       
    • Control against formation of islands of uncut paths
      Vintech RCAM-Pro allows building bridges between nested parts for wich a cutting technology has not been assigned (parts without paths and route). By automatically creating cutting technology, the system does not allow the formation of islands of uncut paths.
       
    • Control of the sequence when cutting with common cuts
      Vintech RCAM-Pro creates sequence of common cuts ensuring the proper processing of the contours of joint details. In nesting layouts with common cuts, the system automatically sets cutting of the inserted contours and holes before the enclosing contour of the common cut.
       
    • Control of the sequence in chain cutting
      When chain cutting, the system automatically sets the cutting of the inserted contours and holes before the enclosing contour with chain cutting.

Results

The main result of the true shape nesting with Vintech RCAM-Pro is the nesting layout. Using the nesting layouts the system generates NC programs, reports and valuation documents.

The nesting layout accurately and completely visualises the order of processing: plates, parts, rapid moves, paths with directions, points of lighting and extinguishing, other path elements. Each type is displayed with a separate color and fill.

The nesting layout is created through combination of automatic and interactive methods for nesting and processing technology.

Vintech RCAM-Pro provides various capabilities for flexible management of the strategy for nesting layout creation.
The automatic strategies are:

  • The system nests objects consistently filling all available plates, without creating paths and route. This mode is used for preliminary nesting, nesting with common cuts or bridges.

  • The system nests objects, until filling the current plate, then creates paths and route. The cycle continues until all parts in the nesting job are expended or the limit of the plates in the project is reached.

  • The system nests objects and creates paths for the current plate. After filling the plate it creates the route. The cycle continues until all parts in the nesting job are expended or the limit of the plates in the project is reached. This mode is used when there are rectangular parts in the nesting job

  • The paths and route of each object on the job are created in advance. Parts with paths and route are nested on the current plate until it is filled or until the parts in the job are expended. Then a route between the objects on the current plate is created.
    The cycle continues until all parts in the nesting job are expended or the limit of the plates in the project is reached.
    This mode is used to generate NC programs with subprograms with translation and rotation of every part or by users who have worked with CAM systems, that have only this mode of creating nesting layouts.

NC programs are generated using open and configurable postprocessors, from nesting layouts with paths and route on the nested objects.

The NC programs can be in ISO / EIA or ESSI command systems, in their "dialects" or other command system for a specific CNC machine.
The structure and format of the NC program is determined by the capabilities of the machine, the CNC controller and the cutting equipment.

The true shape nesting imposes specific requirements to NC programs, such as:

  • NC programs with block search

    A nesting layout can contain hundreds of parts. For various reasons, the process of cutting may be interrupted. Specific and especially important for the CNC machines for thermal cutting is the functionality to continue the processing as close to the place of interuption as possible. The universal CNC controllers restart the processing with a simple block (line) number selection and appropriate operator actions.

    Some specialised CNC controllers for thermal cutting have built-in capabilities for automatic run trough the program or restart the processing from the beginning of any part or block.

    Others use NC programs with sub-programs, parameters or other methods to restart the processing from the cutting point of any part or contour. Vintech RCAM-Pro easily adjusts to generate NC programs with a structure according to the requirements of the specific CNC controller.

  • NC programs with automatic control of the cutting conditions

    The machines for thermal cutting have highly advanced capabilities for recognising the specifics of the cutting conditions and programming their management.

    Vintech RCAM-Pro analyses the cutting paths and allows generation of NC programs with optimal cutting parameters according to the grade and thickness of the material, the length and shape of the processed contour.

    Vintech RCAM-Pro can easily adjust to generate NC programs, that customise sets of parameters for water-jet, oxy-fuel, laser or plasma sources.

  • NC programs with technological tables
    In some modern laser cutting machines, the functions for analysing the length and shape of the cutting paths are performed by the CNC controller. The parameters of the cutting conditions for each path type are supported in machine technological tables and the NC program reportst the grade and thickness of the plate blank to the CNC controller.

    In other laser cutting machines the technology tables can be loaded in the CNC controller by the NC program.

    Vintech RCAM-Pro supports redefinable technological tables in its database and can easily adjust to generate NC programs with technological tables.

Reports and documents, including technological, organisational and commercial, are generated based on open, accessible for editing document templates. The language of the documents matches the localization language of the system.
The documents can be created for each layout or for all layouts in a project.
The documents can be saved in PDF, DXF or HTML file format.