Versatility When Shaping Metal Results in Wider Range of Parts Production
Produce simple to complex parts with accuracy, precision and consistency.
Posted: February 19, 2024
Conduct faster, more precise bends and pressing of materials by utilizing machines with a broader range of options, including automation, as well as energy-saving efficiencies — all of which will result in a lower cost of operations.
New Servo Presses with AIDA/Allen-Bradley Controls
AIDA-America Corp. (Dayton, OH), a metal stamping press manufacturer, has introduced its next generation servo presses. The DSF-N2-AB Series direct drive, two-point, unitized frame servo presses are available in 200- and 300-metric ton models. Some standard features for these DSF-N2-AB Series presses include:
- Exclusive AIDA/Allen-Bradley servo control system featuring CompactLogix PLC, GuardLogix control, and Common Industrial Protocol (CIP) safe technology
- Ergonomically designed 12” swing-arm mounted color touch screen HMI with optical run buttons
- Hand-held step feed pendant for ease of die setup
- Ample, accessible die space
- Allen-Bradley PowerFlex servo drives with CIP motion
- Eight channel die protection with both PNP/NPN signals
AIDA is a global leader in the design, manufacture, sale, service and support, refurbishment, and modernization of metal stamping presses and metal forming automation equipment.
Eco-Conscious Bending and Blanking Solutions
AMADA AMERICA INC.’s (Buena Park, CA) latest generation of servo-controlled press brakes, the EGB 6020 ATCe, is equipped with a high-performance 65-ton electric drive system combined with an Automatic Tool Changer (ATC) and voice command control. These production-enhancing features ensure high-speed bending and repeatable accuracy even if an operator lacks experience. In addition, a compact, newly-redesigned ATC can precisely load complex tool layouts within minutes — making it the ideal solution for variable lot sizes and the seamless introduction of rush jobs.
An integrated HMI control tablet is positioned above the tooling bed to provide convenient access to bending data, thereby maximizing efficiency and productivity. A backgauge camera connects to the HMI tablet and AMNC 4ie control to ensure the correct bend position. The intelligent AMNC 4ie control provides operator face recognition and allows voice commands to request, change, and verify bend information while the operator is on the move — all as an automatic foot pedal slides to the next bending position to ensure continuous operation.
To further boost productivity, Bi-S II Bend Indicator Sensors automatically measure and correct bend angles up to 85% faster than Bi-S technology. And a new electric Auto-Crowning system maintains longitudinal accuracy throughout production. Additional EGB e models are also available.
In adherence to the primary section of AMADA’s Basic Policy on Sustainability, the company is committed to treating people and the global environment with respect. It achieves this goal by reducing CO2 emissions, promoting the reduction and reuse of waste, and protecting the global environment, including biodiversity in all processes. The company also offers environmentally friendly products and services through its business activities.
Faster and More Precise Bends with Even More Options
Bystronic Inc.’s (Hoffman Estates, IL) ByBend Smart press brake offers innovative bending technology and numerous new functions at an affordable price. One of the ByBend Smart’s flexibility-enhancing features is the “Daylight and Stroke Expansion.” This feature, which is available with the purchase of a new machine, extends the daylight and stroke from 18.9”-to-22.9”, which means that it can use taller tools, enabling users to produce parts with taller bending sides. This is particularly useful when bending boxes and drawers.
The Efficiency Booster option increases not only the bending speed, but also the ram retract speed by up to 20% over conventional ram retract speeds. With the Energy Saver option, the machine’s main drive is only active when the machine is actually in operation, reducing energy consumption by 40%.
The Fast Bend M Safety System option consists of a laser safety system that allows the upper beam to move almost all the way to the part that is being processed at rapid movement speed. The high-precision laser sensor allows the ByBend Smart’s control to reduce the upper beam’s speed from up to 7” per second (rapid movement speed) to 0.74” per second (bending speed) just before reaching the metal sheet. The laser safety system functions like an intelligent brake assistant that permits the machine to move at a higher speed for longer. This offers users a speed advantage of up to 30%.
Other features include an electric lifting aid, intelligent ByVision Bending, and Active Hydraulic Crowning.
Putting Technology to Work
Whether you call it Smart Manufacturing, Industry 4.0, or the Industrial Internet of Things, automation is revolutionizing manufacturing. Smart technologies have become increasingly accessible to smaller manufacturers, leveling the playing field. Through an affordable innovation, the EZ BEND solution, CINCINNATI Inc. (Harrison, OH) is turning press brake operations into a competitive advantage for a growing number of small to mid-size manufacturers by adding cobot technology.
With a reach of 68.9”, EZ BEND is capable of lifting and moving parts weighing as much as 44.1 pounds. The six rotating joints of the robotic arm provide a wide range of motion allowing configuration in even confined spaces.
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. Its flexibility eliminates the need for added equipment investments, ensuring that you can take advantage of the benefits of EZ BEND, regardless of the specific type of CINCINNATI press brake you have in your facility. Because EZ BEND is portable, it can be moved between press brake machines or stored when not in use.
There are many features on the EZ Bend that ensure efficiency. Before making the initial bend on each part, EZ BEND utilizes a double-blank detector to confirm that only a single piece has been picked up from the inbound stack. Interchangeable pneumatic/magnetic suction cups ensure secure yet gentle handling of your materials, eliminating the risk of marking or damaging the parts. Operators also have the flexibility to set up and run the machine during off-shift hours or over the weekend, which increases productivity and efficiency.
Wide Selection of CNC Press Brakes, Up to 2,000 Tons
KAAST Machine Tools, Inc. (Aldan, PA) offers a wide selection of CNC press brakes, ranging from 3’-to-20’ in length and featuring tonnage options ranging from 40-to-2,000 tons. The HPB CNC series of press brakes are ideal for complicated, sensitive, single or multiple bendings at high speeds.
These European built brakes offer the bonus of higher productivity at lower production cost thanks to the user-friendly CNC controller and low-cost hydraulic maintenance. Standard features include sliding front support arms for easy height adjustment, Promecam type top clamps for simple loading, and
Delem touch screen control.
The AKAS Pressbrake Safety System is recommended to all customers who purchase an HPB CNC, which meets the safety requirements of category 4 according to EN 954 and prEN 61496, and the most recent requirements of prEN 12622. The safety integrity level is SIL 3 (IEC 61508), performance level PL e
(ISO 13849-1), and safety category Kat 4 (EN 954-1). The innovative finger guarding system for press brakes uses laser optical safety light grids in front of the tooling and the finger guard works during foot pedal controlled bending processes, so hands remain free for the operation with the slug.
Nibbler Provides Larger Breadth in Cutting Applications
Shears are most common on the jobsites, but they are limited to only straight cuts and leave contractors unable to accommodate unique cuts in spiral duct, sheet metal or corrugated metal materials. Milwaukee Tool’s (Milwaukee, WI) M12 FUEL™ 16-Gauge Variable Speed Nibbler uses a punch and die to take small punches out of the material. This gives the user a larger breadth in cutting applications such as curved cuts, 90° cuts, and straight cuts, plus the ability to navigate corrugated metals.
Delivering fast, clean cuts in 16-gauge mild steel, the nibbler allows contractors to cut up to 7’ per minute when paired with an M12™ REDLITHIUM™ XC 4.0 Battery. The POWERSTATE™ Brushless Motor provides the power to cut in heavy applications such as 22-gauge spiral duct seams. The lightweight design gives a balanced and comfortable metal cutting experience and offers users greater access and mobility during the application. For maximum control and productivity, Milwaukee’s nibbler features a variable speed dial, an LED work light, and a tool free, 360° die holder rotation. A chip collection bag comes with the nibbler and can be attached to the die holder to collect the metal punches for quick jobsite cleanup.
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