Shipbuilding Catalogue Rev 6

Cutting and automationfor shipbuilding industries

We offer a wide range of cutting machines for processing outer plates and inner structure materials.

Koike’s cutting machines and welding carriages respond to various needs from the cutting to weldingof steel plates and stiffeners.

Marking

Steel Plates

Full-surface printing system

NC line marking device

Marking systemDevices that rationally printinfor mation regarding the nextprocess on steel plates prior totheir delivery to processingplants.

Full-surface marking systemLine marking deviceNC line marking device(KAMS)

Stiffener printing instrument

Line marking device

Panel, internal member

Flame planer Gas bevel cutting machine

Plasma cutting machine Laser cutting machine

Panel line cutting machine Portable cutting machine

Shaped steel cutting system

Shaped steel

Stiffeners

We provide high-precision,high-quality NC processing ofvarious angle steels, flat steels,and valve plate strip materials.

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ShipbuildingManufacturing process diagram

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Heating torch

Wel-Handy-Mini

Wel-Handy-Multi

Heat liner

Lug-Cut

Block assembly

Forming & Welding

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Processing marking data in the full sheet and mark alphanumeric information on to the plate simultane-ously to improve accuracy and efficiency.

A multiple number of printer heads travels across the steel plate and prints characters and diagrams.

Running costs and maintenance costs were cut downby reducing the number of heads to less than 1/4 compared to similar conventional methods.

Automated high-speed processing ensures high productivity (can process more than 120 plates per day).

With a printing speed of 36m/min, a 4.5M×25M steelplate can be processed in roughly 250 seconds using15 printer heads.

Steel plate full-surface printing system

Printing systems for next-process work information management

Dramatic increase in theamount of information that canbe written on a steel plate.

Elimination of writing errorsand misunderstanding thatpreviously occurred from hand-writing.

No need for onsite operators towork in a semi-crouching posi-tion.

Collective printing not only of processing information, butalso of assembly and rigging information.

Processing of multiple down-stream printing work is possi-ble with a single unit, wheninstalled in the upstream stageof processing.

No upper limit to characters,diagrams, and character size.

Improved cutting machine capacity with the incorporationof a line marking function.

Specific advantages

Printing sample: large characters

Printing sample: small characters and diagrams

Information no longer needs tobe handwritten

Full view of steel plate printing

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Automatic positioning, program rotationand other automatic function helps to improve quality, efficiency and accuracy in marking automation.

Marking shape: Diagrams and characterscomposed of straight lines and curves.

Marking method: Spray-type torch forwhite/blue background (set of two).

Rail span: 4,000 – 6,500mm (models available in 500mm pitches).

Printer head can be mounted.

The processing performance of cutting ma-chines can be enhanced by transferring themarking/printing process to the NC markingdevice.

KAMS series | NC marking device

Marking torch capacitance sensor

Printer head and edge detector

Printing specifications(1) Character size (height x width)a) PJ1B type 0 1) 21 x 23 (7 x 5 dots)2) 36 x 36 (12 x 8 dots)3) 48 x 48 (16 x 12 dots)

b) PJ1B type 2 1) 21 x 23 (7 x 5 dots)2) 16 x 17 (12 x 8 dots)3) 21 x 24 (16 x 12 dots)

(2) Printing distance (height)a) PJ1B type 0: 20mm from relevant surface to nozzle tip b) PJ1B type 2: 10mm from relevant surface to nozzle tip

(3) Character color: White(4) Character type

a) Alphabet: 26 characters from A to Zb) Numerals: 10 numbers from 0 to 9c) Symbols: 27 symbolsd) Katakana (extended character registration): to

, voiced sound mark, semi-voiced sound mark e) Special characters (extended character registra-tion): Up to 100 characters, including katakana characters, can be registered (optional)

(5) Max. characters printed per command:Approx. 200-250 characters (incl. spaces)

(6) Printing memory: 512 bytes (incl. control codes)(7) Printing speed: 20,000 mm/min(8) Paint drying time: Dry to touch in 50–70 sec (depending on temperature and humidity)

Specifications

Main unit structure Gantry style, dual side driveControl panel Stand-alone typeDrive system Rack and pinionRail span 4.0m/4.5m/5.0m/5.5m/6.0m/6.5mTotal rail length Extendable in 3m incrementsRail span 37kg/mPrinting range Effective width: Rail span–0.7m Effective length: Total rail length–2mNC unit FANUC Series 30i-MODEL AMarkable material Mild steel, high-tension steelMarkable surface treatment Zinc primer, wash primerMarkable plate thickness 2.3mm to 30mmMarking speed (on white) 24m/minMarking speed (on blue) 18m/minPrinting speed 20m/minRapid traverse speed 24m/minPower supply voltage 200V/220V 50Hz/60Hz Printing sample

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As one of the largest capacity laser cutting machinesof its kind, LASERTEX-Z provides high-precision cut-ting, high-productivity unmanned operation and otheradvanced thick-plate cutting performances.

A light, compact and strong CO2 laser resonator mountedon the traverse carriage of the cutting machine stabili-zes the light path. (World’s first).

Stability of the light axis increases cutting capacity and long-term stability (3-fold compared to conventionalmachines), and dramatically improves the processing performance of large spans and reduces maintenanceneeds. (Maintenance instances reduced to half).

The scope of application for cutting medium thicknessplates is largely expanded when equipped with a V-bevel cutting instrument.

LASERTEX–Z | Laser resonator-mounted cutting

KOIKE cutting machines for outer plate processing

Bevel torch block

Laser resonator mounted on machine

Specifications

Machine structure Resonator mounted on torch carriageEffective cutting width 3.5–5.5m (separate agreement needed for effective cutting widths over 7m)Effective cutting length Max. 47mRapid traverse speed Horizontal: 24m/min Vertical: 36m/min Vertical with option: 54m/minRail length Effective length +3mMarking speed 24m/minI-cut torch cutting capacity Mild steel: 25mmBevel torch cutting capacity Mid steel: 19mm 30°V, I-cut: 25mm

Features of KOIKE’s laser bevel cutting unit

The traverse mechanism is an endless system that isunrestricted by NC data, as with gas/plasma cuttingmachines.

A new nozzle capable of cutting both I and V grooves is adopted, developed based on the highly popular AFT nozzle.

An internal high-speed automatic focusing instrumentand high-speed, high-quality “HSQ piercing” allows forstable bevel cutting.

An anti-torch collision device prevents damages to thetorch block.

A plug-in lens holder makes it easier to clean the lens.

Sigma Box

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Versagraph boosts productivity by combining high-speedmotion with high-quality cutting performance.

Equipped with the new SUPER-400PLUS/600PLUSplasma system.

Shorter total processing time and increased productivityare achieved in combination with 3D Link, a lightweightand compact bevel torch block.

To more effectively reflect the natural high-speed cuttingperformance of a plasma cutting machine, all operationsof the cutting machine were reexamined, and productiontime was dramatically shortened in the Versagraph.

VERSAGRAPH | High-speed, high-productivity OXYGEN PLASMA BEVEL

Newly improved 3D LINK PLASMA BEVEL HEAD

Our former 3D Link heads,more than 100 units are inshipyard use.

Accumulating users voice, wehave improved our 3D Link.

Re-design the head evensmaller and lighter.

Double the bevel angle and positioning speed.

Decreased movement and distance in bevel motion to increase plate efficiency. It also made it possible tocut complicated bevel shapes.

Specifications

Main unit structure Gantry style, dual side driveControl panel Right-hand use (left-hand use is optional)Drive system Rack and pinionRail span 4.0m/4.5m/5.0m/5.5m/6.0m/6.5mEffective cutting range 3.1m/3.6m/4.1m/4.6m/5.0m/5.5mCutting speed 6m/minTravel speed (horizontal) 45m/minTravel speed (vertical) 48m/minMarking speed 36m/minRotating speed 60rpm (using 3D Link)Carriage vertical movement speed 20m/mCNC unit FANUC-300i 15” color LCDMemory 1,280mNumber of programs 1,000Rail 37kg/m (with CP15 rack), 15m (basic specification)Power supply voltage Three-phase 200V/220V 50Hz/60HzInstalled plasma system SUPER400PLUS/SUPER600PLUS

SUPER-400PLUS / 600PLUS

MYNUC is a large-scale NC plasma cutting machinesuited for cutting outer plates and inner structure materials.

KOIKE’s development of the world’s first oxygen plasmabevel cutting system began by incorporating a taperingcorrection function (aiming for zero) for cutting surfacesunique to plasma cutting. This, combined with suchhigh-tech functions as an automatic V-bevel torch anglesetting unit and an automatic torch rotating device helped dramatically improve motion speed and cuttingprocesses. With respect to the steel materials of a ship,MYNUC can perform bevel cutting continuously with atorch angle of -45 to +45 degrees for both front andback V grooves with high accuracy.

With a cleaner vertical plasma cutting surface and longerlife of consumables such as electrodes and tips, thenecessary man-hours have drastically decreased.

The rigid machine structure allows a dust collector to be mounted on the machine.

With a capacity to process large-span plates, MYNUCcan cut two components from a single plate.

Installation of the lightweight and compact 3D Linkhelps shorten total processing time and improve productivity.

KOIKE succeeded in developing the world’s first cuttingmachine with an onboard dust collector.

Delivery performance: The world’s largest number ofunits has been delivered to date.

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MYNUC | NC Plasma cutting machine

KOIKE cutting machines for outer plate processing

On-board dust collector

Specifications

Machine structure Gantry style, dual side driveControl panel Right-hand use (left-hand use is optional)Drive system Rack and pinionRail span 4.5m/5.0m/5.5m/6.0m/ 6.5m/7.0m/7.5m/8.0m (9.0m or greater spans are optional)Effective cutting range 3.5m/4.0m/4.5m/5.0m/ 5.5m/6.0m/6.5m/7.0mCutting speed 6m/minRapid traverse speed 54m/min (Stand-alone dust collector type) /36m/min (On-board dust col- lector type)Marking speed Max. 36/minCNC unit FANUC-300i 15” color LCDMemory 1,280m (basic specifi cation)Number of programs 1.000Rail span 37kg/m (with CP15 rack) or 50kg/m (with m5.5 rack)Power supply voltage Three-phase 200V/220V 50Hz/60HzInstalled plasma power supply SUPER400PLUS/SUPER600PLUS

Stand-alone dust collector: With a rigid machine structure,MYNUC can achieve faster speeds and respond to a maximumrapid traverse speed of 45m/min.

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Versagraph boosts productivity by combining high-speed motion with high-quality cutting performance.

Equipped with a function for simultaneously cuttingtwo different gentle curves, VERTEX can cut two plates of symmetrical components, such as the starboard and portside outer plates of a ship, at the same time.

CNC control provides functions not only for cutting gentle curves with 2 axes and 3 axes, respectively, but for cutting molds, preliminary line marking, andlabor-saving cutting of four-sided surfaces as a CNC flame planer.

VERTEX | NC gas bevel cutting machine

Specifications

Main unit structure Gantry style, dual side driveControl panel Right-hand use (left-hand use is optional)Drive system Rack and pinionRail span 5.5m/6.0m/6.5m/7.0m/7.5m/8.0m/8.5m/9.0m/9.5m/ 10.0m/10.5m/11.0m/11.5m/12.0mEffective cutting range 3.5m/4.0m/4.5m/5.0m/5.5m/6.0m/6.5m/7.0mCutting speed 6m/minRapid traverse speed 36m/minMarking speed Max. 24m/minCNC unit FANUC-300i 15” color LCDMemory 1,280m (basic specification)Number of programs 1,000Rail 37kg/m (with CP15 rack) or 50kg/m (with m5.5 rack)Power supply voltage Three-phase 200V/220V 50Hz/60Hz

The combination of manual angle setting and an-X-bevel block makes it possible to cut I, V, Λ, Y, �, X, K,etc. grooves.

Various types of bevel cutting are made possible by anautomatic angle setting bevel block.

An automatic feed rate setting device automatically adjusts the flame, a task that previously required much skill.

Manual angle setting X bevel block Automatic angle setting bevel

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KOIKE systems for effective utilization of scrap materials

A CCD camera and KAP system work together for the effective utilization of remnant plates and scraps.

An image of a material placed on the cutting table iscaptured with a CCD camera, and the KAP system analyzes its shape and dimensions with high accuracy.Part shapes are nested within the outline and convertedto NC data in a short time.

The system automatically corrects any distortions in theimage produced as a result of the unique characteristicsof the camera and creates an accurate data of the ma-terial’s shape to allow for high-precision nesting.

Navigation system for remnant plate processing

A CNC or NC cutting machine can be flexibly combinedwith the system.

The “stand-alone type” allows the CCD camera to be installed on a pillar inside a building, and the “on-board type” allows the camera to be mounted on astandard cutting machine.

Stand-alone navigation system On-board navigation system

Navigation system operation procedure

1 Place remnant plate on the cutting table

2 Start up the CCDcamera

3 Capture an image ofthe remnant plate withthe CCD camera

4 Download the image to the NC control panel or the KAP (PC)

6 Cutting begins with apress of the START button

5 Parts (products) are automatically nested in the image

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KAP-8030N is a CAD/CAM system incorporating KOIKE’s wealth of cutting expertise.

KAP8030N is a Windows OS compatible software configured as a CAD/CAM system which integrates the CAD function of FIGDEF8 and the CAM function ofKAP8030N.

Graphic interface: Using pull-down menus, screenmenus, and icons, the system flexibly adopts variousWindows functions for increased speed and easy to understand functionality.

KAP-8030N | NC automatic programming system

Increased work efficiency: The system aims to increase the work efficiency of cutting machines, and takes a flexible approach to processing materialsin accordance with cutting machine operations.

Response to cutting technologies: The multiple num-bers of tables within the unit is the latest technologyKOIKE offers as a leading cutting machine manufac-turer. Know-how for responding to various changes incutting technologies can be easily installed and utilized in daily operations.

Operation issimple, even for a

beginner.

The wide range offunctions is sureto satisfy evenskilled operators

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KOIKE cutting machines for strip steel processing

Stiffener inject marker

The device takes the place of an on-site operator’shandwriting task, and automatically prints the name of the material, assembly instructions, and other suchinformation on strip steel materials.

When incorporated into a conveyor line, the necessaryinformation can be printed while the material is beingfeeded to the processing line.

The processing capacity of the AB-GRAPH system can be improved by transferring the printing processprevious conducted by the cutting machine to the stripmaterial printing machine.

3D strip steel materials can be accurately marked orcut in accordance with their warpage and curves.

The device can make inverse line markings and circularmarkings around web faces.

Stiffener inject marker sampleStiffener line marker

Strip steel marking sample

Output stage

Small scrap elimination pil

Shaped steel NC cutting machine

Cutting stage

Central control room

Shaped steel NC printing machine

Printing stage

picking stage

Input stage

Circulating carriage

Picking machine

Short material sorting stage

Return scraps

Picking machine

Long material sorting stage

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AB-GRAPH provides a comprehensive processing sys-tem for angle bars by combining automatic programswith an NC processing machine.

3D strip steel materials can be accurately marked orcut in accordance with their warpage and curves.

The device can make inverse line markings and circularmarkings around web faces.

Stiffeners (various angle steels, flat steels, and valveplates) can be NC processed with high accuracy andhigh quality.

AB–GRAPH | NC angle barautomatic cutting system

A free clamp inclination table (patent) is adopted to achieve high precision and high productivity.

The system can be used in conjunction with an air sensor or laser sensor.

Specifications: Stand-alone dust collector type / On-board dust collection type

Main unit structure Inclined (20°) gantry style or cantilever styleRail span 1.7mCutting speed 6m/minRapid traverse speed Horizontal: 36m/min Vertical: 36m/minMarking speed Max. 12m/minCNC unit FANUC-300i 15” color LCD; X, Y, Z, U, A (5-axis control)Cutting shape (unequal-sided shaped steel) 100L to 600LCutting shape (equal-sided shaped steel) 100L to 200LCutting shape (valve plate) 170L to 250LCutting shape (flat bar) 100L to 450L

BEAVER | Handy automatic gas cutting machine

IK–92 PUMA | With plate edge guide roller

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IK–72T | 3D cutting machine

The ultimate all-position cutting machine.

Conventionally, the cutting of 3Dstructures and 3D curves in particular,depended on hand-held cutting equip-ment. IK-72T not only simplifies 3Dcutting but also promises high accuracy.

In addition to straight cutting andcurved cutting of flat boards, IK-72Tcan also cut various types of steel,including walls and slanted surfacesof structures and even steel plateswith a rounded surface.

To maximize its features, the machineis principally made of aluminum alloyand weighs a mere 4.5kg. This allowsfor outstanding workability and simplesetup and operation.

A degree scale allows IK-72T to per-form high accuracy bevel cutting simply by tilting the blowpipe to thedesired position on the scale.

Wide-ranging KOIKE products for all types of needs

The BEAVER is a portable automaticgas cutting machine with a uniquestructure, which can be used in two different functions – that is running stability of straight line cutting andtracing accuracy of curved line cut-ting. Try our BEAVER, and you willsee why we call it unique, how well itworks, how easily it can be operated.

Best cutting of straight and curvedline by shifting guide wheel.

Easy to operate.

Standing type – needs little space tokeep and easy to change cutting tip.

• Cutting thickness up to 150mm.

• With attachment possible to cutcircles up to 700mm.

• Available in 42, 100 and 220Vpower supply.

Portable automatic gas cutting machine.

This unique handy-type machine is well known as a highly accuratestraight line cutting and semi auto-matic (manually guided / circular) cut-ting with one hand. To meet shipyardrequirement, the IK-92 PUMA can beequipped with the option Plate EdgeGuide Roller. Features Edge GuideRoller:• No rail alignment (saving time).• Machine direction only backwards.• Accurate Bevel up to 45°.• Accurate and reliable drive system.• Perfect heat prevention system.• Secure and easily adjustable torchholder.

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HEATLINES | Portable automatic heater

IK–05 | Revolutionary lifting piece cutting machine

WEL HANDY MULTI | Multiple purpose welding carriages

Twin Torch option. The wel Handy Multi Standard.

It is easy to set up with 2 torches.

Increase your productivity while de-creasing heat distortion.

The torch can slide to get optimumtorch position.

It can easily weld 350mm x 100mmstiffeners.

It is equipped with an automatic startand stop of the weld to make automa-tion and multiple use of the machineeasier.

Robust & Stable frame.

Small, lightweight, and portable: Heatliner promises a strong pullingforce (16kg) with KOIKE’s patented strong magnet technology and high-reliability stable motion.

The heating torch has two heads.By setting the tip position by turningthe heat torch, an effective heatinglayer can be easily obtained.

Equipped with two heating torchesfor two-handed use, the simultaneousheating of two flat areas is possible.

The torch block is supported by a linkmechanism and a guide roller so thatthe tip is maintained at a certainheight in relation to any warpage onthe steel plate. Fine adjustments ofthe torch height can also be madefrom the handle of the torch holder.

An adjustment valve and one-touchvalve are used together for fluidstructures.

After adjusting the flow rate, the oxy-gen, LPG gas, and refrigerant valves

can be opened and closed with a singletouch of a button.

A heat-insulating plate moves up and down near the heating area andeffectively insulates heat in responseto any warpage of the steel plate.

The cutting process of lifting piecesfor shipbuilding, bridge constructionand various block mounting is madepossible with minimum labor.

Automatic cutting allows anyone toeasily achieve high quality cuttingsections. Increase your productivitywhile decreasing heat distortion.

It is easy to set up with 2 torches.

The torch can slide to get optimumtorch position.

It can easily weld 350mm x 100mmstiffeners.

It is equipped with an automaticstart and stop of the weld to make automation and multiple use of themachine easier.

Robust & Stable frame.

Compared to manual cutting, thecutting section is clean, so the grinding work can be minimized.

The finishing cut that was previouslyneeded when reusing a lifting piececan be eliminated.

Based on an extensive study ofusers’ onsite activities, IK-05 isequipped with a wide array of func-tions that only KOIKE can offer.

A spring drive is adopted to allow forstable cutting even in a severe out-door work environment.

KOIKE’s original preset valve deviceeliminates the troublesome gasvalve operation for flame adjustment.

In consideration of the rusting ofwork pieces, cutting speed is main-tained at a constant 400mm/minusing a spring drive method.

Lifting pieces of various thicknessescan be cut by adjusting the flame.

KOIKE – the spirit of cutting.

Advanced technology combined with face to face relationship and an in-depth

understanding of customers cutting needs – that’s what KOIKE as a Japanese manufacturer

of oxy-fuel, plasma and laser cutting technology stands for.

Customers are companies active in shipbuilding, steel construction, vehicle manufacturing, fabrication

and other heavy metal industries – they all trust on more than 90 years of KOIKE’s cutting expertise.

KOIKE Engineering Germany GmbH Pappelweg 8 • 61169 Friedberg, GermanyPhone +49 (0) 6031 161571 -00Fax +49 (0) 6031 161571 -01www.koike-engineering.com • [email protected]

KOIKE EUROPE B.V.Grote Tocht 19 • 1507 CG Zaandam, NetherlandsPhone +31 (0) 75 6 12 72 27Fax +31 (0) 75 6 70 22 71www.koike.nl • [email protected]