The machine and apparatus engineering specialist Lohse has decided to modernise its sheet metal cutting. Since the beginning of 2023, the company has been using an erlcut e545 to cut steel and stainless steel. The new machine offers the user more processing options, while the cutting quality has been improved and rework has been reduced.
Lohse Apparate- und Maschinenbau, once founded as a construction and engineering metalworking shop, now has around 115 employees and more than 10,000 m² of factory space where it manufactures high-quality steel and stainless steel products that are used in a wide range of industries. Based in Heidenheim an der Brenz, the company's range of services extends from simple steel cutting to complete machines and apparatus for wet processing of organic waste and high-quality fittings for the paper industry.
Therefore, it is obvious that Lohse's own cutting department is indispensable. ‘We always have sheet metal, mostly stainless steel, up to 35 mm in stock, thicker sheet thicknesses are required less frequently and we often buy them in,’ says Grünwald, Head of Work Preparation. Nevertheless, it is also important for him to be able to cut thicker sheets efficiently. ‘In some projects, we only have a lead time of 6 to 8 weeks. If you then have to order the required parts, time is tight. That's why it's good to be able to cut what you need and when you need it,’ explains Grünwald.
‘The previous cutting system had been in operation for around 16 years,’ explains Grünwald. It is hardly surprising that it could no longer fully meet today's requirements. ‘The system was past its prime and it was becoming increasingly difficult to obtain spare parts. The power sources used, a Hifocus 160 for sheets up to 20 mm and a Finefocus 800 for thicker steels, were no longer state of the art,' says Jochen Grünwald, Head of Work Preparation at Lohse, explaining the decision to invest in a new machine.
Lohse hoped that the modernisation of the cutting system would enable it to cut more precisely in order to reduce rework. Other advantages include faster processing of thicker sheets and the ability to produce better contours and holes of a higher quality. At the same time, an economical solution was required in which as many system components as possible could continue to be used.
All conditions taken into account
ERL Automation has developed a concept that perfectly fulfils Lohse's requirements. On the one hand, the portal system, including the entire cutting technology, was completely replaced. At the same time, the existing programming system can continue to be used, as the erlcut has a corresponding converter. ‘It was also crucial that the existing peripherals such as the cutting table and extraction system could continue to be used and integrated into the new layout by ERL,’ confirms Grünwald.
Large format system for plasma and oxyfuel cutting
ERL has provided an erlcut e545 cutting system with a track width of 4.5 metres. Lohse often requires very large-dimensioned cut parts for apparatus construction, which is why the system is designed for sheet formats of up to 3 x 12 m in order to produce even the largest possible components from a single piece.
Unlike its predecessor, the erlcut is only equipped with one plasma power source, a HiFocus 440i neo for precise cuts up to 50 mm. It is characterised not only by high cutting speeds and precise cutting quality, but also by comparatively low process costs. The plasma power source also features the automatic ‘Flow Control’ gas console, which mixes the plasma gases to the optimum level for each cutting task. A separate database ensures the exact regulation of the required gases, saving the user time and reducing errors. An oxy-fuel cutting torch with external ignition and height control is available for thicker sheets up to 200 mm.
The new technology has also significantly improved angularity and the formation of slag on the cutting contour. This results in a time and cost advantage during reworking, as less allowance and deburring work is required.
What is a technological leap for Lohse is an anniversary for ERL, as the erlcut from Lohse is the 40th erlcut to be handed over to the market. In 2015, ERL Automation took the bold step of manufacturing a portal cutting system itself for the first time. Since then, the range of services has been continuously expanded: In addition to various marking tools, an optional drilling system and a plasma bevelling unit have been developed. There is also a whole range of options available with which users can optimise their system to suit their requirements, such as a soundproof enclosure for less noise during plasma cutting or the erlcut-cam camera system for easy set-up of distant metal sheets.
Smooth transition
After the cutting system was put into operation at Lohse in the spring, production got off to a smooth start. ‘There is a huge difference between the control system of the previous system and the erlcut, because of the difference in age alone,’ says Grünwald, but nevertheless the changeover went smoothly.
The control system e*volution is a network-compatible touchscreen control system with a 21-inch monitor, which ensures fatigue-free working and guarantees good legibility in different lighting conditions thanks to its anti-reflective glass surface. A display that can be swivelled in height and to the side allows the operator to work in an ergonomic position at all times.
The integrated process database, which is based on ERL's many years of experience, also makes the machine easy to use. All parameters for both the plasma and oxyfuel processes are stored ready for use. This means that even inexperienced operators can start parts production in just a few steps and achieve the full performance of the machine after a short training period. Lohse can edit and expand the database as required. An overview with graphics and article numbers for all torch wear parts makes it easier for the user to change wear parts and place repeat orders.
The erlcut is programmed using Lohse's existing programming software. Despite a change of product, there is no additional effort involved, as a converter integrated into the erlcut's control system makes it easy to convert the programmes so that they can be read by the erlcut and simply reused without having to recreate the cutting programmes.
‘It's a very simple system, and even if you're not yet familiar with the system, you quickly find your way around because the user interface is simply self-explanatory,’ confirms Wolfgang Schrabeck, cutting manager and machine operator at Lohse. ‘The system went into operation even faster than planned. Initially, a one-week trial run was planned, but we were already able to cut production parts during the training,’ continues Schrabeck. The system is now running at 100% capacity in a single shift.
The two companies had been in contact for some time. ERL had been looking after the existing cutting system for many years and the positive experiences had been one of the reasons for intensifying the collaboration with ERL. ‘With large companies, we have often found that you can only reach a hotline when you need to call for service and the response times are correspondingly long. With ERL, we like the fact that we have a personal contact person and that we get help quickly,’ reports Schrabeck.




