Press Brakes Compliment High Speed Fiber Laser Cutting Systems

The innovative Xcite 80 E electric press brake from Bystronic Inc. (Elgin, IL) exemplifies both speed and ease of operation. Powered by dual electric motors, the Xcite 80 E is capable of high acceleration and seamless speed transitions without lag times. It is 2.5 times faster than a hydraulic press brake in completing comparable bends. Using the Fast Bend+ safety system, the upper tool can be quickly positioned very close to the metal sheet without placing the operator in any danger. Only when ready to process does the machine seamlessly switch over to bending speed. This high speed press brake is capable of meeting the most demanding of part volumes generated by very fast fiber laser cutting machines that can produce blanks about twice as fast as the classic CO2 system. With its 88 tons of bending force capability, the Xcite 80 E is also powerful enough to meet the full range of sheet metal applications across the entire table length.

The Xcite 80 E is highly accurate thanks to its proprietary Force Dynamic Drive that provides speed, power and constant pressure along the entire bending length to ensure that minimal deflections occur in both the upper and lower beam, enabling bends within a top-of-class tolerance of ±25 arc minutes, and with an incredible repeatability of ±0.000098 in. This user-friendly electric press brake takes advantage of the advanced ByVision control package that is already used with laser cutting and waterjet cutting machines to give every user the ability to obtain excellent results with only a few entries on the Xcite 22 in HD touch screen control panel. Prior training requirements are minimal: beginners are guided safely through the programming operation and supported with a high level of automated features. Designed for flexibility and high performance, ByVision also provides more experienced professionals with the ability to apply their knowledge and skills, and define their own limits for the bending technology.

For complete process integration, Bysoft 7 programming module provides off-line programming software offers users advanced synchronization of press brake, laser and waterjet processes. Bybend, an integrated Bysoft software module, provides off-line programming capabilities including, automatic bend deductions, bend reliefs, bending sequences and back gauge placements for press brake users. With a 3D-simulation feature, visualization of the bending sequences as well as automatic collision detection is performed before the part is sent to the operator for processing, reducing set-up time and the need for test bending.

Bystronic also introduces the new Xpert 40, a compact portable high speed press brake that is “moveable on demand” to where you need it, when you need it. The Xpert 40 is ideal when space is limited and capacities vary. With its integrated tool storage, this is the first press brake to combine the entire setup and production from one single station, greatly reducing non-productive bending times. The “turbo charged” back gauge and ram speeds on the Xpert 40 ensure the highest process efficiency to keep pace with high speed fiber laser cutting systems.

Typical press brake production vs. Xpert 40 press brake:
Typical press brake production = 622 BPH*
Typical high dynamic electric or hybrid press brake production = 916 BPH*
Xpert 40 production = 1,028 BPH*
*Bends per hour (BPH)

With flexible tool selection and press capacity up to 44 tons, the Xpert 40 press brake offers a wide range of applications for thin and thicker materials. The ultra-high performance back gauge system, with optional functions up to 6-axis, enables the cost-efficient production of highly complex sheet metal shapes. Other benefits of this press brake include the process-controlled drive unit that reduces power consumption by up to 30 percent, and the high operator efficiency achieved through ergonomic design and individual adaptable workspace.

Bystronic also offers the larger Xpert press brake with ByVision Bending control on a 22 in HD touch screen that displays realistic 3D part animations and software driven menu selections for unmatched efficiency and productivity. Bending profiles can be either imported or drawn directly on the touch screen and then automatically converted to a bending program with proper bending sequences and tool selections. A comprehensive database of material bend angles and bend allowances enables the ByVision Bending control to make a bending professional of every user from the very first experience.

The enhanced version of the Xpert press brake incorporates a high speed ram positioning system and Fast Bend+ safety system for reduced bending cycle times. The high speed ram positioning system is capable of reducing bend cycle times by 15 percent to 35 percent in reaching approach speeds of up to 600 ipm and bending speeds up to 47 ipm without sacrificing accuracy. This is the only press brake on the market that introduces no angle errors itself, with a ram positioning accuracy of .00015 in. If a tool is not recognized by the Fast Bend+ system the machine stops, making it nearly impossible to use an incorrect tool, which increases the safety even more.

Low energy consumption, less machine noise, and less heat characterize the Energy Saver on this press brake. As soon as the upper beam has reached the top dead center position after a bend, the main motor of the Xpert switches off automatically until the next bend process is started. This does not change the operational flow and the process speed remains as high as usual. However, it saves up to one-third of the energy, produces less noise, and does not produce any excess heat. The Xpert adjusts ram position and crowning during the bending process in response to material properties. With the touch of a single button, the bending sequence and the positioning of the backstops are determined, the tool plan is created, and the process data is generated – all automatically. Other options include:

• Voice Control enables operators to utilize voice commands via a headset for typical manual functions.
• Optical Bend Guiding guides operators of press brakes safely through all bending applications. LEDs indicate the correct position of the tool stations, back gages and bending sequences.
• RF-A and XPT Tooling and clamping systems provide users with front-loading, light weight precision segmented tools for faster tool setups, maximum operator ergonomics and 100 percent compatibility with the bending database at the machine control.
• PartID laser-etched part code can be registered by an optional scanner unit at the brake and the desired bending program can be loaded automatically.

All of these unique press brake features, combined with the powerful ByVision Bending control, provide users with the benefits of “the ultimate bending experience” that include:

• Automatic bend sequence calculation and back gauge positioning.
• Automatic setup plan and tool selection.
• Dynamic material thickness detection.
• Automatic compensation for tensile strength variations.
• Dynamic crowning and frame deflection compensation.
• Increased manufacturing efficiency through reduced set-up times and reduced scrap.

Bystronic also introduces the Xact Smart 160 press brake that easy to set up and program. It combines high bend accuracy with advanced features in an affordable, high-value package that enables a fast entry into bending technology. Bysoft 7 software solutions integrate the Xact Smart press brake seamlessly into the shop production environment. This press brake also incorporates the powerful ByVision Bending control system on several models with capacities between 100 tons and 225 tons and up to four axes on the back gauge – which, depending on the combination selected, enables the processing of simple angles through complex bent parts. This press brake offers a high level of flexibility for fast job changes and can also be used as a fixed bending station. Standard active hydraulic crowning capabilities deliver accurate bend angles across the entire bed length.

Designed for easy tool integration, the Xact Smart press brake can easily accommodate all types of punches and dies. A wide selection of Bystronic bending tools can be set up in a few simple steps. Tools from third-party manufacturers can also be used. Bystronic offers a line of press brake tooling, the XPT and RF-A Tooling Series, which is compatible with existing Wila® NSCL ll type hydraulic clamping and tooling systems.

XPT Tooling offers customers the flexibility to expand upon existing tooling systems while taking advantage of the expert applications and superior press brake support from Bystronic. RF-A Tooling is a revolutionary new tooling that maintains high quality tooling features with the added benefit of increased open height and 100 percent compatibility with the Bystronic bending database at the machine control. Features include self-seating and segmented front-loading tooling technology, precision ground and hardened surfaces for long tool life and the RF-A upper and lower hydraulic clamping systems. RF-A Tooling is offered as an option on new Bystronic press brakes.

The Optical Bend Guiding System encompasses LED technology that greatly enhances press brake operations and reduces setup times. The LED bar located above the tool clamping in the ram enables easier tool positioning, more effective station guiding, clear back gauge positioning, clamping open, error, and end of job indications. The system guides the operator through all of the machine setup and bending sequences, reducing setup times and ensuring part quality. When a shop must absolutely have the highest part accuracy from the very first bend, the Laser Angle Measuring System (LAMS) automatically positions depending on the bending station and uses a laser measuring system for each angle that is produced to ensure the highest part accuracy to within nearly a quarter of a degree of the programmed angle. Combining the Optical Bend Guiding System with LAMS greatly enhances press brake operations, increases productivity and increases part accuracies.

Bystronic Inc., 200 Airport Road, Elgin, IL 60123, 847-214-0300, [email protected], www.bystronicusa.com.