Faster Cycle Times and Consistent Output Empower Fab Shops
The ability of press brakes and stamping presses to integrate with robotics, automation and IIoT ensures scalable and sustainable production solutions for metalworking shops.
Mobile Bending Cell Handles Order Surges and Combats Labor Shortages
TRUMPF Inc.’s (Farmington, CT) new, rapid mobile bending cell, the Flex Cell, offers highly efficient bending in combination with the TruBend 7050 press brake. In just a few simple steps, operators can dock the mobile robot cell onto the bending machine and operate it automatically. The machine can run autonomously for several hours. The combined footprint of the Flex Cell and the TruBend 7050 is less than 107 square feet, compact enough for any production environment.
The Flex Cell has a double-sized material buffer that ensures it has enough material to feed the TruBend 7050 throughout a night shift. A vacuum combination gripper on the robot arm enables fast and safe loading and unloading. Using the proven TRUMPF TecZone Bend software, a bending program can be created in just a few seconds. The operator is then able to program the robot by means of an app and the teach panel. This makes the TruBend 7050 quick and easy to set up. Thanks to automatic double-sheet detection, the Flex Cell is also able to recognize if unprocessed material has stuck together during loading and then eject it. This reduces rejects and saves resources.
The Flex Cell is suitable for components up to 23.6-by-15.75”. It can process sheet metal of between 0.03” and 0.23” in thickness. Companies with fluctuating orders of small and simple parts are particularly suited to benefit from this solution.
Fast and Precise Servo-electric Bending Solution
Prima Power’s (Arlington Heights, IL) eP Genius 1030 is a high-performance electric press brake that combines precision, speed and energy efficiency. It consists in the integration of the servo-electric eP-1030 with one automatic tool change storage. The eP Genius 1030 offers a versatile, fast and reliable bending solution, which eliminates the manual setup of the machine, and allows the operator to commit time and skills to the preparation of bending batches.
The eP Genius’ energy-efficient design minimizes power consumption, while the compact footprint optimizes floor space utilization. The flexible tooling system allows for quick setups and accommodates diverse applications, making it a versatile addition to any manufacturing facility.
Single-arm Feeder Boosts Speed and Capacity on Large-scale Press Lines
Meet roboSpeed: a single-arm feeder from Güdel Inc. (Ann Arbor, MI) that makes the automation of industrial-scale press lines even more efficient. Capable of handling payloads of up to 220.5 lbs. (100 kg) and with a capacity of 21 parts per minute, roboSpeed is used for loading the first press, unloading the last press, and handling the transfer of parts from one press to another.
roboSpeed is robust, but it’s compact too, allowing you to exploit the confined spaces of the tool room to the fullest. And it’s easy to use. roboSpeed’s intuitive, human-friendly interfaces ensure fast and effective deployments, reducing integration costs and lowering the total cost of ownership of your investment. Used in conjunction with the intelligent GMotion control system, roboSpeed’s benefits include increased speed, capacity, and throughput on large-scale press lines, shorter deployment times, and simplified jig making.
Designed to provide maximum flexibility in all axial directions and with shifting units integrated into the crossbars, roboSpeed delivers high efficiency in a compact footprint, maximizing space in any press room. Automatic tool change features make switching between applications as easy as can be, boosted by the system’s built-in usability.
Around the world, press lines choose automation solutions from Güdel – not only in the automotive sector, but also in major industries from aviation to white goods (major appliances), shipbuilding and modular construction, bringing the total to more than 400 units installed worldwide.
Compact Bending Automation System for Most Production Environments
Bystronic Inc. (Hoffman Estates, IL) closes a gap with the new, high-performance ByCell Bend Star M with the ByBend Star 120 press brake for processing small and medium-sized parts. Its compact, modular layout fits most any production environment.
Sheet metal processing companies must adapt to increasingly tough competition. On one hand, speed is required, on the other hand, quality. And this is in addition to constantly changing batch sizes. This means keeping production costs low without compromising on quality. At the same time, the increasing variability of shapes, sizes, and quantities means that more and more flexibility is required. This applies to all sizes of parts. To remain competitive, you should make your processes more flexible and, above all, automate them. The ByCell Bend Star M is based on the ByBend Star 120 press brake and fills the gap between the small mobile bending robot and the large bending cell. It offers the benefits of a fully-fledged bending cell but with the advantage of a compact, modular layout.
The new machine is just as ideal for processing job lists as it is for changing orders — from small batch sizes to large series. In combination with the ByBend Star 120, the agile robot completes bending jobs fully automatically and without errors. It is the missing link between the mobile bending cell with the ByBend Star 40 or 80 and larger automation solutions, e.g., with an Xpert Pro. With its passive reactive crowning system, the ByBend Star 120 offers outstanding performance and ensures that operators or robots never have to wait for processing.
Cobots at Work in Press Brake Tending Address Labor Shortages
The robotic machine tending system AutoTend from Mid Atlantic Machinery Inc. (Harrisburg, PA) takes over repetitive, labor-intensive tasks in manufacturing environments. By utilizing advanced robotics and user-friendly software, AutoTend machine tending systems enable companies to automate key production processes, traditionally requiring human oversight. This automation leads to enhanced operational efficiency, improved product quality, and scalability — all while reducing the dependence on manual labor.
AutoTend machine tending systems are designed to integrate smoothly into existing equipment. Whether you’re looking to automate one step or an entire workflow, these systems can be tailored to fit your needs without requiring a complete operational overhaul. At FABTECH 2024, Mid Atlantic Machinery demonstrated a press brake integration solution featuring a UR10e cobot. AutoTend demonstrated the bending of a candy dish part from type 304 stainless steel. The demonstration showcased Mid Atlantic’s patented rotary end-of-arm tooling while demonstrating the ability of the cobot to bend complex parts while interacting directly with the press brake touch screen control.
Press Brake Clamping Solutions
From converting tool styles to increasing efficiency with faster tooling changeovers, look to Wilson Tool International’s (White Bear Lake, MN) clamping solutions to give your current press brake an upgrade. options including push-button hydraulic clamping systems, the Express Clamping System® with a simple lever action, crowning holders for deflection control, and the world’s newest innovation in clamping.
The eClamp is modular by design for versatility and simplicity in maintenance. LED lighting built into the body of the punch holder shines light on the working surface, not the front of your brake. Prominent clamping indication lights give you a clear visual that your tooling is clamped and ready to bend.
Energy Efficient Hybrid and Electric Press Brakes
Machitech’s (Saint-Marc-des-Carriéres, Québec) hybrid and electric press brakes are specially designed for today’s environmental and energy concerns. They reduce energy consumption, lower operating costs, while maintaining a high level of performance. Machitech has installed over 2,000 machines, achieving a 97% customer satisfaction rating.
Machitech E-Series Electric Press Brakes use energy efficient servo motors, saving up to 72% compared to more traditional motors and drives. With Machitech Press Brake speed, their advanced user-friendly CNC Controller environment, and the ability to quickly change tooling, users benefit from increased production as well as lower costs. In total, by incorporating either Machitech Hybrid or Electric Press Brakes, users can count on productivity increases of at least 60% and up to 72% energy savings.
These press brakes have a 40-ton to 200-ton capacity. Machitech’s H-Series Hydraulic Press Brakes have a 40-ton to 2,000-ton capacity. Both feature advanced intelligent bending aids and provide advanced automation capabilities. Both are engineered for precision bending, while providing consistently accurate results for complex sheet metal applications. Both are equipped with cutting-edge CNC Delem controllers and automation features, enhancing operational efficiency while reducing human error. In addition, all Machitech Press Brakes are designed with built-in safety systems to ensure a safe working environment for operators.
Customizable options are also available. Customers can count on ongoing technical support, training, and service across North America.
MC Machinery Systems Partners with Acieta on Robotic Bending Cell
MC Machinery Systems (Elk Grove Village, IL) has entered into an exclusive partnership with Acieta (Maumee, Ohio) to offer the FastBEND Robotic Bending Cell. The robotic cell features the Acieta FastBEND robotic solution and MC Machinery’s Diamond BB Series of electric press brakes.
Helping fabricators eliminate production bottlenecks in downstream operations is the focus of MC Machinery’s newest FABTECH-revealed equipment and technology, including the FastBEND cell.
“The overwhelming majority of fabricators struggle with bottlenecks in material handling and bending due to the proliferation of high-volume fiber lasers,” said MC Machinery Fabrication Division Vice President of Sales Shane Herendeen. “Partnering with Acieta allows us to offer our customers the most advanced technology to eliminate costly gridlock in press brake operations.”
The new FastBEND Robotic Bending Cell is designed for small- to medium-parts and medium- to high-volume production. This seamless, automated bending solution can increase production capacity, reduce labor costs, improve safety and maximize workflow efficiency.
“We are excited to collaborate with MC Machinery to develop an innovative solution that addresses key challenges faced by today’s fabricators,” said Greg Morehouse, Acieta vice president of sales. “This collaboration leveraged our collective strengths to deliver a product that will set a new standard for robotic bending in the industry.”
New Interface for Press Automation Controller, and Machine Monitor Hardware
Bottom: SFC ShopFloor Tracker with data examples (size of device is approximately 3″ x 6″ x 1″).
Wintriss Controls Group (Acton, MA) offers connections to a smarter factory, including when remote monitoring is required, with its new functionality in SmartPAC PRO Press Automation Controller and ShopFloorConnect (SFC), which gives fabricators and metal formers efficient and easy-to-use tools to control, automate and track their operations.
The new SmartView PRO Network Interface allows any PC or mobile device on a network to access and download information from networked SmartPAC PRO controls. It displays the current job status, press tonnage, percent of job complete, and estimated time until job completion. Users can also view error and event logs, send an on-screen text message to the press operator, and download the installed option list, tool list, and individual tool programs.
Wintriss’ new, compact SFC ShopFloor Tracker hardware device, an economical way for its ShopFloorConnect Software to automatically collect production data from virtually any machine. This wireless machine monitor can be installed on any machine or production line to track machine parameters such as run time, idle time, production counts, production rate, uptime efficiency, temperature, pressure, humidity, and more without requiring any operator input. The most outstanding trait of the SFC Tracker is its versatility, featuring 4 inputs that can be configured to accept input from a variety of digital or analog signals.
Press Brake Delivers Speed, Repeatable Accuracy and Precision
The ProBend Press Brake from BLM Group (Novi, MI) is an all-electric, direct-drive design of the ProBend press brake, which features a ball screw directly connected to the torque motor, eliminating gear boxes and belts for fewer moving components. The precision Y1/Y2 press brake with positioning and repeatability of ±0.0001″ is energy efficient, provides quiet and maintenance-free operation, as well as extremely fast approach, bending and ram return speeds. It can be equipped with up to 6-axis backgauge, allowing for bending of simple to complex sheet metal geometries or tapered bends. Available with a bending force range of 22-to-310 tons and a bed length range of 3-to-17’, this press brake product line offers reliability, high productivity and is a perfect complement to flat sheet lasers.
The ProBend comes with a 21.5” touchscreen console, enabling graphical or direct mode programming directly on the machine or offline. An optional second touchscreen is also available for multitasking. The console includes integrated views for various OLP software applications. The software automatically generates the part program from the imported CAD model and calculates the optimal bend sequence, stop positions, and tooling setup. A complete bending simulation, with automatic validations and checks, allows the user to verify the entire bending cycle and begin producing parts correctly, from the start.
The Future of Precision Metal Fabrication
CINCINNATI INC.’s (Harrison, OH) groundbreaking XFORM is the next generation of CINCINNATI press brake technology. This cutting-edge machine features innovative advancements including faster ram speeds, a quieter drive system, larger control screen, larger standard stroke and throat, and a standard 5-axis backgauge.
Available in various models to suit any fabrication requirement, with specifics on dimensions, approach speed, forming speed, and more provided to ensure you find the perfect match for your workshop. Enhance your XFORM experience with software offerings like BendSim PRO for collision-free, efficient 3D part simulation, and CIberDash for real-time insights and optimization. Premium options include the OMNI-ARM technology, which enables unprecedented mobility and flexibility during operations, and a 6-axis backgauge to assist with more complex fabrications.
At FABTECH 2024, CINCINNATI partnered with Folds of Honor for its custom designed 90 ton XFORM Eco. The sale of these machines resulted in a significant donation to the Folds of Honor charity at the show. Folds of Honor provides scholarships for families of the military and first responders who have been lost or disabled in the line of duty.
Compact Electric Press Brake Increases Safety and Productivity of Small Parts
AMADA AMERICA INC.’s (Buena Park, CA) EGB 4010e made its debut at FABTECH 2024. The EGB 4010e is a high-speed 44-ton compact, eco-friendly electric press brake. The ERGO model includes multiple features facilitating operator safety while increasing bending productivity of small parts. It is ergonomically designed for maximum operator efficiency and comfort. This compact electric press brake excels in producing small, precise sheet metal components. The EGB 4010e ERGO is also equipped with a Tool Setup Assistant, which boosts productivity. The tool cabinet provides quick access to tooling to improve setup time, and extra storage is provided at the bottom of the cabinet.
On this machine, the punches and dies slide easily into the bed to improve loading efficiency. The AMNC 4ie control provides efficient operation for operators of all skill levels. What’s more, the backgauge ensures stable positioning of asymmetrical workpieces.
Industry-leading Servo Stamping Presses
AIDA-America Corp. (Dayton, OH), a metal stamping press manufacturer, demonstrated two servo presses at FABTECH 2024. For one demonstration, AIDA-America partnered with A-G Tool & Die, Dallas Industries, and Pax Products, Inc., to demonstrate a 200-ton straightside servo press as part of a full progressive die production line stamping parts. This two-point, direct-drive DSF-N2-AB servo press includes AIDA’s exclusive Allen-Bradley servo control system, locally developed, manufactured, and supported by a team of AIDA Controls Engineers based in Dayton.
Like all AIDA servo presses, this press includes an AIDA designed and built, low speed, high torque servo motor specifically manufactured for stamping press applications. It combines the rigidity of a unitized frame with the flexibility of freely programmable servo motion. These presses are offered in 200- and 300-ton models.
In the second demonstration, AIDA’s single-point, direct-drive DSF-C1-A gap frame servo press was blanking parts with AIDA’s optimized silent blanking stroke motion profile, which can only be achieved on a servo press. This press also features the Allen-Bradley control with many of the same features noted on the DSF-N2-AB control system. These presses are offered in a range of tonnages from 80-to-250 tons.
