Laser Cutting System Hybrid Drive Technology for a Clean Cut

Related Vendors

Bystronic Laser AG

AMKmotion GmbH + Co. KG

FAULHABER Drive Systems

Wuxi InfiMotion Technology Co., Ltd.

Bystronic was searching for an economical drive solution for the ByCut Eco. The Swiss company found it at AMK motion. The specialist in electrical drive, control, and industrial automation technology provided the hybrid drive technology.

Bystronic focuses on automating the entire material and data flow of the cutting and bending process chain. The company employs over 3,600 people worldwide at more than 40 locations and generated around one billion euros (approx. 1.2 billion USD) in revenue in 2022. "The networking of our laser cutting systems and press brakes with innovative automation, software, and service solutions is key to the comprehensive digitalization of the sheet metal industry," says Stefan Züger, Global Media Relations & Product Communication Manager at Bystronic. "Our customers expect smart solutions and high-performance products from us."

The ByCut Eco laser cutting machine is one such system. For this entry-level machine, Bystronic was searching for a new drive system that meets the

The cutting head moves in the X, Y, and Z directions. "It needed to offer high dynamics, enable the required path and part accuracy during laser cutting, and be more economical than the system previously used," explains Adrian Krebs, who was responsible for the project together with Stefan Jacobi, Head of Systems Engineering at Bystronic. "I had a decentralized system in mind as the solution," says Jacobi. And since he had already had good experiences with AMK motion and their technology on a previous project, the Bystronic team turned to the drive specialists from Kirchheim unter Teck again with their inquiry and a rough plan.

Developed the Solution Together

Andreas Ochs, Team Leader for Drive Design and Commissioning at AMK motion, and his team took on the challenge. "We started with a basic design and approached it step by step," says Ochs. In close collaboration with Bystronic and the gearbox manufacturer, the suitable solution was developed in a process lasting around two months, with regular visits to Niederönz (Switzerland).

For movement on the Y-axis, an iDT5 synchronous servo motor with an integrated inverter is used. This combines the iX inverter with the DT servo motor, both directly wired together. "Like the individual components, the mechatronic functional unit is housed in a metal casing that protects the shock- and vibration-resistant inverter and servo motor from dust and moisture, according to IP65," explains Ochs. On the X-axis, the cutting head is mounted on a gantry system. "To move this synchronously and with the necessary dynamics, we use more powerful motors," says the team leader. "We installed two DT5 synchronous servo motors, each with a decentralized servo inverter iX5." These high-pole servo motors are designed for high torques and have increased intrinsic inertia. This means they can dynamically accelerate larger loads as direct drives without a gearbox, significantly increasing the machine's productivity. The magnets in the rotor are inserted and fixed by plastic overmolding. This additionally protects them from dust, gases, and moisture while ensuring permanently stable magnetic values. The Z-axis is positioned by an ihXT4 synchronous servo motor with an integrated inverter. The shock- and vibration-resistant drive unit, with a torque of 2.6 Newton meters, is housed in an IP65-protected casing, making it suitable for direct installation in the machine. Functional safety in the form of Safe Torque Off (STO) is standard.

In the control cabinet, there is only the space-saving KEN feed module, which generates the DC link voltage and supplies power to the connected decentralized compact inverters via the KHY hybrid distributor. This simplifies the integration of various signals and supply voltages from the central drive level. It serves as an intelligent interface between the central and decentralized drive systems. Through the iX, the DC bus, the drive-integrated safety function STO, and 24 volts are passed on to other decentralized controllers. Real-time communication takes place via a separate fieldbus line. The standardized interface is built as a modular unit, allowing for easy expansion of central control cabinet devices. Fuse protection for short circuits and overload is integrated. Additionally, the KHY monitors the DC link current and decentralized drive system via an I²t counter. Its shutdown behavior can be configured individually. The KHY is wired to the decentralized servo inverters of the synchronous servo motors following the daisy-chain concept.

Reliable Collaboration on Equal Footing

"With the decentralized setup, we save space in the control cabinet, have eleven fewer cables in the energy chain, and thus overall a reduced wiring effort, allowing us to design the entire setup more efficiently while still meeting our requirements for dynamics and precision," summarizes Jacobi. "Thanks to the direct connection with the development department at AMKmotion, the collaboration went very well, smoothly, and always on equal terms," adds Krebs. "I must also give credit to Mr. Ochs. He always helped us find a solution." Another advantage is the on-time delivery reliability of AMKmotion. "This is a very important aspect because delays in building a machine due to missing components directly impact subsequent orders. With AMKmotion by our side, we can reliably meet our delivery deadlines," says Markus Beier, buyer of electrical components at Bystronic, with satisfaction.

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• How to size your laser cutter for current and future production needs

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• Key differences between entry-level and high-performance cutting systems

• When to consider tube laser cutting and how to evaluate its ROI

• Why automation readiness is essential for operational efficiency in 2025

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