Flexible and Adaptable Machines Allow You to Compete in a Rapidly Evolving Landscape
User-friendly automated metal forming solutions are leveling the playing field for small to mid-size fabricators in several ways.
Posted: January 24, 2024
No longer the domain of larger manufacturers, easy to use automation processes available on ironworkers, bending, plate rolling and punching machines enable metal fabricators to lower costs without impacting the quality of their products. Operators can focus on other tasks, such as welding, while machines are performing repetitive tasks; operators can also simultaneously tend to several machines. The flexibility of these solutions creates efficiencies and an advantage in a global marketplace.
Robotic Bending System Supports Unattended Operations for Increased Efficiency
AMADA AMERICA INC.’s (Buena Park, CA) EGB 6013 ARce is an electric robotic bending system for precise, high speed, unmanned productivity. It made its Noth America debut at FABTECH 2023. The machine features an eco-friendly electric drive system. It also features an automated tool setup, gripper exchange, bending and stacking, which enables 24/7 operations. A 6-axis robot achieves high-precision processing for high-mix, low-volume parts. The machine includes the AMNC 4ie control, which is an easy to use control for operators of all levels. The control supports voice commands to direct and change bend information. The portable human-machine interface table displays bend information to support operator workability.
Other advantages of the EGB 6013 ARce include parts stations that can be moved to easily load workpieces. The two-sheet detection function prevents robots from taking multiple workpieces to ensure stable processing. Parts are unloaded onto a conveyor.
A three-finger backgauge ensures stability when positioning asymmetrical workpieces. The Bi-S II automatically measures and corrects the angle up to 85% faster than Bi-S.
New Automated Press Brake Cell Built for Optimum Accuracy
The BLM GROUP (Novi, MI) demonstrated its new automated ProBend press brake cell at FABTECH 2023. The compact work cell, with an overall size of (LWH) 281”-x-162’-x-122”, features the ProBend E-Series 205-60 and a 30 kg robot. It has the flexibility to process a variety of part sizes from 4”-x-3” up to 24”-x-32” and 33 lbs. with excellent reliability and high productivity. The E-Series 205-60 press brake has a bending force of 66 tons, and a bending length of 81”.
The system has two load and unload locations with the ability to integrate the unload pallets with an AGV as desired. The pre-load section is configurable for adaptation to part geometry, as well as allowing its removal to accommodate larger parts. The 3-axis Cartesian pick and place system with pivoting head allows the robot to continue processing parts while staging the next piece of material.
The automatic tool change capability requires minimal operator intervention. The cell features up to six meters of tooling storage. It can manage a variety of end-of-arm-tooling types — vacuum, magnet and gripper-style, for processing various types of materials.
The E-Series, with a ram tilt up to 3/8”, offers a generous open height, stroke and throat size, benefiting deep box or special forming needs. Built for optimum accuracy and high speeds on all 6-axes, the E-Series’ CNC-controlled backgauge handles the most complex sheet metal applications.
All-round, Worry-free Automatic Sheet Metal Bending Machine
Bystronic Inc. (Hoffman Estates, IL) has enhanced the Xpert Pro press brake to create a fully automatic bending solution. The bending cell enables varying order situations to be mastered efficiently and without errors.
The fully automated bending cell offers a maximum degree of efficiency and flexibility for both small and large companies. The modular design allows the bending cell to be individually adapted to a company’s requirements. It is just as ideally suited for the processing of long job lists as for changing orders — from small batch sizes right through to large series. In combination with the Xpert Pro press brake, the agile robot processes bending jobs fully automatically and without errors.
The 7-axis robot not only autonomously changes the grippers and bending tools, but it also knows how to process the job most efficiently. The intelligent software autonomously determines the optimal sequence of the bending tools for every job list. This saves up to 30% of the processing time.
After the initial offline programming, the bending cell operates completely autonomously. While the robot is bending, the operators can perform other tasks, for example the supply and removal of sheet metal and parts or operating a laser cutting system or welding system.
Bringing Automation to the Shop Floor Through Cobots
CINCINNATI Inc. (Harrison, OH) is making automation more accessible for many small to mid-size manufacturers. By incorporating cobot technology into its line of press brakes, CINCINNATI is boosting shop floor efficiency while offering a cost-effective solution for manufacturers seeking to enhance metal forming capabilities without added equipment or resources.
CINCINNATI’s EZ BEND advances the effectiveness of press brake machinery and its operator. Designed to automate repetitive tasks, the solution allows operators to focus on more complex responsibilities and empowers operators to run multiple press brake applications simultaneously. It can even support lights-out operations.
EZ BEND automates the bending process to simplify production workflow, saving time and optimizing resources. Its user-friendly interface makes it easy to learn and operate, ensuring a smooth and efficient operation for a wide range of bending tasks.
Whether it’s adapting to changing production needs or streamlining operations, EZ BEND provides the flexibility and convenience needed to meet the demands of the manufacturing industry. Built upon low-code programming, EZ BEND eases the transition to automation allowing manufacturers to incorporate bending automation easily and at a comfortable price point.
EZ BEND is compatible with a wide range of CINCINNATI press brakes, which eliminates the need for added equipment investments. Among other features, the system features simple, intuitive programming, checks for double blanks, includes pneumatic part gripper, and features an optical scanner guard without physical barriers.
Fully Electric Plate Roller Offers Unprecedented Performance
Davi Inc.’s (Addison, Texas) new fully electric e-POWER plate roll machine embodies the highest levels of precision, productivity, ease of maintenance and energy efficiency all within a quiet, compact machine that ensures hassle-free installation. Because it is electric, the machine achieves a positioning accuracy of five hundredths. This is compared to the typical one-tenth precision normally offered. With such precise control and positioning, the machine ensures repeatable and reliable results for a variety of applications.
For increased productivity, e-POWER’s smooth and simultaneous movement across multiple axes allows the machine to execute multiple tasks concurrently, saving valuable time and effort. This capability overcomes the limitations of traditional methods for a more streamlined and efficient workflow and higher output.
With e-POWER maintenance tasks are cleaner and more straightforward, thanks to the system’s single actuator component. Instead of having to disassemble the actuator, users can easily replace it and ship the actuator back to Davi for rebuilding. This means that a licensed electrician can handle the replacement, eliminating the need for a specialized technician in certain phases.
e-POWER also minimizes the need for interventions and eliminates points of leakage commonly found in traditional machines. All of which translates into improved reliability and decreased downtime.
e-POWER also eliminates the need for hydraulic control units, which significantly contributes to its compact design and makes it more space-efficient; it also makes for easy integration into various production settings.
As an intelligent system, e-POWER utilizes energy only when necessary, much like the efficient start-stop function commonly found in automobiles. This innovative approach to energy management proves to be particularly advantageous in plate rolling processes where there are frequent idle times during the operation.
Five Plate Roll Series Rolls out all the Stops
KAAST Machine Tools, Inc. (Aldan, PA) carries a diverse lineup of plate rolling equipment with five models of plate rolling machines: the RBD-3M; the RBD-3HL; the RBD-4H; the RBD-4HD; and the RBD-4HL. The RBD-3M is a plate roll series designed for light to medium jobs, accommodating materials up to 10 gauge in thickness. Applications include creating aluminum bendings, air conditioning channels, advertising panels and sheet metal covers. This series of plate rolls is offered in 3’-to-6’ length and features top rolls fixed via a locking lever, with adjustable side and bottom rolls. Each model includes wire grooves on the bottom rolls and left-right rotation on the dual footswitch.
The RBD-3HL plate roll series is intended for medium and heavy bending tasks. The frame is constructed of solid, welded steel, with all rolls mated to high quality, heavy duty bearings, ensuring minimum friction and even rotation throughout the bending process. The hydraulic rollers are driven by independent drive motors and planetary gearboxes. Available lengths are 6’-to-13’ and can accommodate plate thickness between ⅛”–⅝”.
The RBD-4H series rollers are heavy-duty plate rolls, accommodating the needs of a variety of businesses, including shipbuilding, trucking, wind-power and construction sectors. The four rolls of this hydraulic plate bending machine are equipped with high-quality, heavy-duty ball bearings, ensuring minimum friction while assuring even rotation of the rollers. The RBD-4H series accommodates 14 Ga-3/8” plate thickness and is available in lengths between 2’-to-13’.
The RBD-4HD/4HL hydraulic plate bending machines are ideal for medium and heavy bending tasks, featuring a solid, welded frame, a hydraulic roller driven by an independent drive motor and planetary gearboxes. Torsion bars work simultaneously with hydraulic units to ensure maximum machining accuracy, while accommodating production flexibility. The RBD-4HD/4-HL is available in lengths between 6’-to-13’ and accommodates workpieces between ½”-to-1-3/4”.
Newly Redesigned Series of Five Hydraulic PressPro Models
Scotchman Industries’ (Philip, S.D.) PressPro Series of five hydraulic press models were redesigned with improved hydraulic configuration, a heavier-duty base, and forklift accommodations (except model 176MT) to assist with installation or repositioning of the machine. “We really like the overall design of this machine from our partners in the Netherlands, but felt it needed improvement for robustness and to provide our customers with flexibility to move the machines more easily, similar to our Ironworkers,” said Mike Albrecht, national sales manager, Scotchman Industries. The lineup of five models ranging from 66 ton, 110 ton and 176 ton are USA manufactured presses for industrial-grade fabrication, bending, forming, straightening, assembly, maintenance operations, testing and quality control. Versatile, smooth and precise; Scotchman’s H-Frame PressPros combine a heavy-duty, quality welded, all-steel frame with an industrial grade hydraulic system to provide maximum strength, durability, and a long life. They are equipped with movable ram cylinder, pressure regulator, 3 ram speeds with ram cylinder that moves from side to side, an easy-to-use joystick operation, and a set of standard V-blocks.
The presses are simple to use and solve a variety of demands to improve user’s productivity. Built for the big jobs as well as the small ones, the adjustable H-frame bed height and extra wide working width offers increased versatility with its ability to raise and lower the table for the best working distance. All models come with a three-year warranty.
Automated Channel Processing System has a Cycle Time of Four Seconds
Trilogy Machinery, Inc. (Belcamp, MD) the exclusive United States distributor for Sunrise, is pleased to introduce the all new ACPS, Automated Channel Processing System. This innovative solution is capable of processing up to 50 foot lengths of C3 through C6 channel, including punching in the channel web with up to three different punch shapes or sizes plus shear to length and marking capability. With a process cycle time of only four seconds, the Sunrise ACPS is the fastest and most efficient way to process channel on the market today. Standard features include high strength precision rack and pinion drive (no indexing required), hydraulic hold downs for punching and shearing, interchangeable shear cartridges based on the channel size, a robust software package developed by Sunrise to include NC1/DST import, offline software, remote diagnostics and all with an industry leading two-year warranty.
Ideal for racking systems, structural steel fabricators, conveyor manufacturers and more, the Sunrise ACPS can be fitted with custom tooling allowing two or more holes to be punched at once, further increasing productivity and reducing cycle time. After having successfully deployed several machines across the United States, Trilogy and Sunrise are further expanding the channel processing system by introducing a new auto loading version in 2024. Learn more about Sunrise and the ACPS at the Trilogy Machinery website.
Punch and Bend Like an Expert
Now available: two free web tools from TRUMPF (Farmington, CT) — the PunchGuide and BendGuide — are designed to increase your punching and bending knowledge and productivity. Leveraging decades of technical experience, these programs provide customers with access to seminars, workshops and application information that builds expertise in punching and bending.
TRUMPF’s PunchGuide web application features clear and practical tips and tricks, as well as step-by-step instructions to inspire creative sheet metal part designs that save time and money. The PunchGuide app can also perform specific sheet metal production calculations. TRUMPF’s BendGuide app provides virtual assistance by facilitating calculations of press force, tool weight, die width, open height check, and other suggestions for innovative sheet metal bending.
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