In recent years, with the accelerated pace of urbanization and the booming real estate market in my country, elevator sales have climbed annually. my country’s elevator market has maintained a 20% annual growth rate, becoming the world’s largest market for new elevators. In 2013, China produced and sold over 620,000 elevators, accounting for over 60% of the global new elevator market. By the end of 2013, China’s elevator fleet had surpassed 3 million units, earning China the title of “the world’s most productive elevator manufacturing base.” With the rapid development of the elevator industry, traditional CO2 laser technology has been unable to keep pace. Fiber lasers, with their ultra-high speed, energy efficiency, and superior cutting quality, have emerged as a clear winner in this productivity competition.
Traditional processing methods
Traditionally, complete machine shops have primarily used multi-station presses to process sheet metal, involving turning, milling, planing, drilling, grinding, and wire cutting. These processes rely heavily on mechanical forces and rigid tools to remove excess metal layers. These processes are complex, prone to deformation, and consume significant manpower, material, and financial resources.
CO2 laser processing method
CO2 laser cutting machine is the first laser processing equipment used in the domestic elevator industry. It uses non-mechanical energy such as light, electricity, and chemistry to complete the material stripping process. It can process high-hardness materials with lower-hardness materials. Compared with traditional processing methods, this processing method has unique advantages such as non-contact, easy processing, safety and environmental protection. However, the optical fiber needs to rely on multiple sets of lenses for reflection and conduction, the optical path adjustment is complicated, the maintenance cost is high, and the energy conversion efficiency is relatively low, which makes the use cost high.
Fiber laser cutting machines occupy the elevator market
Elevator manufacturing primarily relies on stainless steel with a thickness of approximately 3mm. Using CO2 laser cutting machines for this process consumes a lot of power and gas. Due to their high cost and complex commissioning, CO2 laser cutting machines have been unable to keep pace with the development of the elevator industry. New fiber lasers operate solely on electricity, eliminating the need for additional laser-generating gases, resulting in significantly lower operating and maintenance costs. Their significant advantages, such as their ability to cut highly reflective materials like copper and aluminum and their lack of an external optical path, are gradually replacing CO2 laser cutting machines and becoming the preferred tool for the elevator industry.
Flat sheet metal in the elevator industry can be processed with flat laser cutting machines, but many three-dimensional sheet metal parts are still processed using wire EDM. For these applications, a 3D fiber laser cutting machine is a wise choice.
Example of escalator “faucet cover” processing
The “faucet cover” shown in the picture is typically cut using a press or laser cutting machine, followed by stretching and forming the holes using a bending machine. This method can easily cause the holes to deform, failing to meet the needs of high-end users. To address this issue, some manufacturers use wire cutting after stretching, but wire cutting is too slow, requiring nearly half an hour to cut a single “faucet.”
A 3D laser cutting machine performs 3D laser cutting (including cutting the holes and the ends) after the “faucet cover” is formed. Cutting a single “faucet” takes only two minutes, ensuring a guaranteed roundness of 0.1mm for the cut holes, and allows for easy adjustment to accommodate different products.
Specification Comparison
| Specification | 3-Axis Gantry Fiber Laser | 6-Axis Robotic Fiber Laser |
|---|---|---|
| Power output | 2–4 kW | 3–6 kW |
| Max cutting thickness (stainless steel) | 8 mm | 12 mm |
| Cutting speed (3 mm steel) | 4.5 m/min | 7.0 m/min |
| Positioning accuracy | ±0.05 mm | ±0.10 mm |
| Maximum workpiece size (length) | 6000 mm | 3000 mm |
| Maximum workpiece size (width) | 2000 mm | 1500 mm |
| Beam quality (M²) | <1.2 | <1.1 |
| Maintenance interval (operating hours) | 2000 h | 3000 h |
Frequently Asked Questions
What is the maximum sheet metal thickness your 3D fiber laser cutting machine can process for elevator car panels?
Our Intouchray 3D fiber laser cutting machine can process mild steel up to 25 mm thick and stainless steel up to 16 mm thick with a positional accuracy of ±0.03 mm, ensuring precise cuts for structural elevator panels.
What is the typical cutting speed for stainless steel escalator treads, and how does it affect production cost?
For 3 mm thick stainless steel escalator treads, the machine achieves a cutting speed of 8 meters per minute, reducing per-part cycle time by 40% compared to traditional plasma cutting, which translates to a cost saving of approximately $0.15 per cut meter.
Can the 3D laser cutting machine handle complex 3D geometries like curved elevator door frames without secondary finishing?
Yes, the system features a 6-axis robotic arm with a 1,500 mm working envelope and a 5-axis cutting head, enabling it to cut complex 3D profiles with a surface roughness of Ra 3.2 µm, eliminating the need for grinding or deburring in most applications.
What is the maximum workpiece size that can be accommodated for elevator guide rail brackets?
The machine supports a maximum workpiece size of 3,000 mm x 1,500 mm x 400 mm, and it can cut brackets with tolerances of ±0.1 mm, ensuring seamless assembly with elevator guide rails rated for 16 kN load capacity.
How does the machine reduce material waste when cutting escalator step chains from high-strength steel?
Using advanced nesting software and a 2 kW fiber laser source, the system achieves a material utilization rate of 92%, reducing scrap by 15% compared to conventional methods, and can cut high-strength steel up to 1,200 MPa tensile strength with a kerf width of just 0.2 mm.
What is the expected return on investment (ROI) when replacing a traditional punching and welding process for elevator cab production?
Based on a production volume of 500 elevator cabs per year, the Intouchray 3D fiber laser cutting machine delivers an ROI within 18 months, reducing labor costs by 30% and eliminating tooling expenses that typically run $8,000 per new part design.
