After an extensive search, Peters Werft chose MicroStep's CombiCut with several processing options
"The overall package of price, competence and persuasiveness tipped the scales"
The traditional Peters Werft GmbH relies on a plasma oxyfuel cutting system of the CombiCut series for 3D cutting of large-format sheets
Published 17.09.2018 | Erich Wörishofer
Company profile:Peters Werft GmbH
Am Hafen 625599 WewelsflethGermany
Peters Werft is a medium-sized company that offers its customers construction of new ships as well as conversions and repairs. The roots of the shipyard go back to the year 1871. Today the shipyard builds, for example, container ships, multipurpose freighters, passenger ships, special ships and mega-yachts.
Peters Werft opted for a plasma oxyfuel cutting system with a working area of 12,000 x 3,500 mm for large-format sheet metal.
The Peters Werft has accompanied the history of seafaring for nearly 150 years. Almost 700 ships have been built in Wewelsfleth in Schleswig-Holstein and many hundreds have been converted or repaired. In order to be able to work more effectively and productively in the future, the medium-sized company has consistently modernized its production in the recent past. Since then, it has relied on MicroStep technology for the cutting process. The CombiCut series has been in use since November 2017 – flexibility was decisive for the 3D plasma oxyfuel cutting solution.
The products of Peters Werft GmbH navigate rivers and seas worldwide. The roots of the medium-sized traditional company go back to the year 1871. Since then, almost 700 ships have been launched from Wewelsfleth. From tugboats and ferries to container ships, passenger ships, dredgers, government or water protection vessels; from sailing ships to mega yachts, the most diverse types of ships have been handled in the community located 60 kilometers northwest of Hamburg, directly at the point where the Stör flows into the Elbe. National and international customers rely on the shipyard's services - many of them for many years. The company has attracted a great deal of attention with the construction of the "Al Mirqab", at 133 meters one of the longest motor yachts in the world, and currently with the restoration of the historic four-mast steel barque "Peking" for the Hamburg Harbor Museum. "With our flexible, committed and qualified employees we create innovative and customized solutions in shipbuilding," says Sebastian Dethlefs, Assistant Manager at Peters Werft GmbH, explaining the strengths of the shipyard. All core operations with the corresponding workshops are located directly on the shipyard premises. "This means short work and decision paths for different customer needs", says Dethlefs.
More effective and productive with flexible cutting solution using plasma, oxyfuel and marking technology
Behind the traditional shipbuilder lies a time of modernization. Extensive investments have been made in new operating facilities in recent years. Among other things, new and flexible weather shelters have been built above the dry docks and a more than 20-year-old cutting system has been replaced. The aim in the search for a replacement was to be able to work more effectively and productively in the future in order to remain competitive. A number of technologies were examined in detail, solutions compared and needs analyzed. After an extensive search, the company decided on a CombiCut series from MicroStep. The decisive factor for MicroStep was "the total package in terms of price, competence and persuasiveness", Dethlefs looks back on the purchase decision in mid 2017.
"The decisive factor for MicroStep was the overall package in terms of price, competence and persuasiveness. The system was quickly installed and connected. The communication was very good".
Assistant Manager | Peters Werft GmbH
Machine profile:MicroStep CombiCut series
- Working area 12,000 x 3,500 mm
- Plasma rotator for weld preparation up to 45°
with auto-calibration feature (ACTG®)
- 2D oxyfuel
- CCD camera for scanning of templates and contours
- Inkjet marking
"We were and are satisfied with the implementation of SigmaNest software and the software itself"
The robust and flexible cutting solution combines several technologies on one gantry for plasma cutting, oxyfuel cutting, bevel cutting and marking on a working area of 12,000 x 3,500 mm and is used in multi-shift or single-shift operation depending on the order volume. With its cutting center, Peters Werft processes stainless steel, steel and aluminum plates up to 80 mm with plasma technology and up to 120 mm with oxyfuel technology. "The system was quickly installed and connected. Communication was very good," says the assistant manager of the shipbuilding company.
In terms of software, Peters Werft GmbH relies on the solutions of MicroStep partner SigmaNest. These were implemented with the CombiCut plasma oxyfuel cutting system in November 2017. "We were and are satisfied with the implementation of the software from SigmaNest and the software itself", says Dethlefs.
Now the new system has been in operation for several months, numerous cutting orders have been processed, the decision to modernize paid off, as Sebastian Dethlefs assures: "The system and also the new halls increase the quality and competitiveness of the shipyard sustainably, they are a great help to us".
OVERVIEW OF THE HIGHLIGHTS OF THE PLASMA OXYFUEL CUTTING SYSTEM COMBICUT 12001.35 PRCKGI
CombiCut Baureihe | Robuster Produktionshelfer mit einer Bearbeitungsfläche von 12.000 x 3.500 mm
The CombiCut series is a flame cutting system with an extremely resistant and robust design, which can combine numerous technologies and torches on one gantry. Peters Werft invested in a plasma oxyfuel cutting system with a working area of 12,000 x 3,500 mm for large format sheets. A filter system from the German manufacturer Teka, a ZPF 9H with 15 kW, is connected to the CNC oxyfuel cutting table with energy-saving and efficient section extraction.
MicroStep R5 rotator | 3D processing, for example for weld preparation up to 45°
For 3D processing of small and medium material thicknesses, the CombiCut cutting solution at Peters Werft was equipped with a MicroStep R5 rotator. The endlessly rotating bevel head enables the processing of simple and complex seams, for example, bevels can be cut up to 45° for weld edge preparation. The plasma source is a HiFocus 360i neo from Kjellberg with automatic gas console and Contour Cut Speed technology. In addition, an glare shield was placed on the plasma support.
Oxyfuel flame cutting | Additional support for cutting high material thickness
In order to be equipped for cutting thicker materials, the CombiCut has been expanded to include a technology for oxyfuel flame cutting. Thus, a machine cutting torch type FIT+ from GCE is available.
CCD camera for digitizing templates
Another technology within the multifunctional cutting system at Peters Werft is a CCD camera. The drawings captured by the CCD camera in a 1:1 scale are then converted into an NC code or can be further processed as a DXF file after conversion.
Fully automatic inkjet marking
Also integrated in the system is an inkjet marking unit for automatic inkjet marking.