bending - metanox file2 3 innovation records. the past and future of sheet metal processing all...

BENDING

Productivity, innovation, efficiency: three records in bending.

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Innovation records.

The past and future of sheet metal processing all wrapped up in one.In fact, for over forty years Salvagnini has been offering solutions that are true innovative “records”. This occurred in the sixties when Salvagnini showed it was ahead of its time by adopting the concepts of lean manufacturing, developing automatic and totally flexible processing systems.It also happened when Salvagnini designed a totally automatic press-brake cell run by a single controller and a single program.And it’s happening again today, with three great innovation records that are changing the world of press-braking:

the fast, efficient and economic electric press-brake cell;

the KinEtic revolution in the press-braking world;

sustainable quality to meet everyone’s pockets;

the press-brake cell with a single controller and single program, ideal for automatic lights-out solutions.

When defining its machines and systems, Salvagnini prefers to refer to “solutions” and not products: in fact, each technology is accompanied by a service that works according to the same criteria of excellence.For press-braking, Salvagnini offers its extensive know-how in the various disciplines and technologies: from the study of tools to product redesign, process optimisation and integration with management systems and/or software (ERP) for efficient factory logistics.

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ConsumptionEnvironmentSafety

KERSSpeedMorphingTechnical specificationsAir bending tonnage chart

Precision and repeatabilityAccessories are standard Closed structure

AMSCustomization

ControlProprietary management software

Productivity High qualityFlexibility Automation Ethics

B3 KinEtic: innovation and ethics in bending.

The B3 press-brake series represents a one-of-a-kind market solution. The distinctive feature is given by the proprietary technology, developed on Salvagnini know-how for higher productivity, improved precision and high safety standards while limiting consumption.

The distinctive features of this line of press-brakes are:z innovative operating principle;z direct drive transmission;z KERS energy recovery;z AMS angle measurement;z Salvagnini SiX numerical control;z PressStudio programming console.

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Model 100/3000 100/4250 135/3000 135/4250 170/3000 170/4250 170/4250XLMax. power (tonnes) 100 100 135 135 170 170 170Table length (mm) 3000 4250 3000 4250 3000 4250 4250Maximum stroke (mm) 300 300 350 350 350 350 450Open height (mm) 550 550 600 600 600 600 700Max. speed (mm/s) 250 220 250 220 250 220 220Bending speed (100% power) (mm/s)* 10 10 10 10 10 10 10Bending speed (70% power) (mm/s)* 15 15 15 15 15 15 15Max. power consumption (kW) 12 12 16 16 20 20 20Model 220/3000 220/4250 220/5100 320/3000 320/4250 320/5100Max. power (tonnes) 220 220 220 320 320 320Table length (mm) 3000 4250 5100 3000 4250 5100Maximum stroke (mm) 450 450 450 450 450 450Open height (mm) 700 700 700 700 700 700Max. speed (mm/s) 220 220 220 220 220 220Bending speed (100% power) (mm/s)* 10 10 10 10 10 10Bending speed (70% power) (mm/s)* 15 15 15 15 15 15Max. power consumption (kW) 26 26 26 39 39 39

Average thickness of a human hair 80 µmPrecision on a traditional press-brake 10 µmPrecision on the B3 2 µm

Recovering energy so that it can be reused later, optimizing speed, reducing cycle times. Using intelligence to improve productivity.

The Kinetic Energy Recovery System recovers energy that is usually wasted and reuses it later, obtaining higher speeds and accelerations with the same consumption.

KERS.

The “fast” movements of the top-beam (both up and down) can reach a speed of 250 mm/s, thanks to two independently managed brushless motors, direct drive transmission and a system that changes the transmission ratio as required.

Speed.

The proprietary Salvagnini SiX controller, teamed with the consolidated P4Xe technology, allows the B3 to switch instantaneously from fast to power mode and vice-versa as required, considerably reducing bending cycle times.

Morphing.

KERS

DIRECT DRIVE

BRUSHLESSMOTOR

TEMPERATURECONTROL UNIT

Technical specifications.

With its proprietary control system and innovative construction, the B3 can achieve accuracy measured in μm, which was previously only possible on small electric press-brakes.

Precision and repeatability.

No options are necessary:the machine is complete as it is.

Accessories are standard for maximum bending quality.The B3 press-brake is designed according to the highest quality standards and guarantees the production of the widest range of products without the need for special solutions: the dimensions, opening, top-beam stroke, groove depth and structural dimensioning are, in fact, naturally ample and satisfy a wide range of demands.

Table of metric comparison

* Bending speed regulated by current standards.

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Traditional

time time

“KinEtic” incorporates the ethical values that go beyond machine innovation: guaranteeing high unit productivity with intelligent energy consumption; achieving excellent work safety, thanks to selective safety systems and machine ergonomics; ensuring easy use and maintenance for workers.

We wanted a machine that would be ethically responsible. That is why the B3 recovers energ y, maximizes safety and respects the environment.

The absence of proportional valves, together with the use of direct-drive transmission and brushless motorization, ensures that energy consumption is proportional to the real intensity of use. In particular, energy consumption during non-production phases has been eliminated, allowing the B3 to deliver extremely high performance yet keep consumption and power levels low. Likewise, the KERS technology recovers energy and allows it to be reused later.

Consumption.

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1 energy saving with direct-drive transmission2 energy saving with KERS

Environment.

Salvagnini adopts design solutions that are environmentally friendly without impairing machine process quality. Thanks to “intelligent” hydraulics, the hydraulic circuit is used as a flexible and efficient transmission system, consuming just 25% of the oil required by a traditional press-brake with the same force.

B3, born KinEtic.

Extremely low noise levels.The highly efficient KinEtic technology makes the B3 particularly quiet, enhancing operator comfort and reducing noise pollution.

Consumption on the two press-brakes during bending

Comparison between consumption on a B3 and a press-brake with the same (max.) force and the same bending cycle.

Real-time workpiece checking: flexibility provides the very best result possible.

Based on algorithms that simulate neural processes, the AMS system performs real-time checks on parts during bending. In the case of kit or batch one production, effectively achieving and maintaining the angle programmed requires the system to be flexible, capable of working with a number of dies and positioning itself at the point of measurement. AMS works in real-time, without increasing the cycle time. It can work with different height dies, interacts with the SiX controller to obtain the springback values previously recorded and, if necessary, can detect the springback value of the material.

AMS.

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DynamicsTechnical specificationsAir bending tonnage chart

LSAC and Expert DatabaseReliability and durabilityPrecisionClosed structure

Customization ControlProprietary management software

EnvironmentErgo PackConsumptionSafety


E3: high productivity, low production costs, quality and ease of use.

The Salvagnini E3 electric press-brake range is the winning solution for environmentally friendly companies that want to maintain high levels of productivity and efficiency.The SiX controller further improves precision, simplifying press management to make this system peerless in terms of productivity.The E3 is the perfect solution for producing small parts.Satellite roller screw technology combines excellent productivity with superior precision and efficiency.

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Traditional time

pinching point

The E3 electric press-brake combines superior productivity with maximum respect for the environment: the use of electric drives allows the E3 to eliminate idle times, reducing the bending time by up to 30%. The E3 also offers high dynamics on short strokes, minimizing risk while guaranteeing significantly improved productivity.

Dynamics.

Model 20/1250 40/1250 40/2000 40/2500 80/2500 80/3000Max. power (tonnes) 20 40 40 40 80 80Table length (mm) 1250 1250 2040 2500 2500 3060Maximum stroke (mm) 200 200 200 200 200 200Open height (mm) 450 450 450 450 450 450Max. speed (mm/s) 160 160 160 160 120 120Adjustable bending speed (mm/s)* 0 to 30 0 to 30 0 to 30 0 to 30 0 to 30 0 to 30


Technical specifications.

Y axis comparison between the E3 system and a traditional hydraulic press-brake

In a single press-brake, Salvagnini combines a multitude of features to create an extraordinary machine: elevated speed, high dynamics and absolute accuracy.

No maintenance, maximum comfort and even lower consumption.

Depending on the conditions of use, the E3 guarantees energy savings of up to 70% since its consumption is proportional to the work actually performed, eliminating energy consumption for non-production phases.

Consumption.

“KinEtic” incorporates the ethical values that go beyond machine innovation: guaranteeing high unit productivity with intelligent energy consumption; achieving excellent work safety, thanks to selective safety systems and machine ergonomics; ensuring easy use and maintenance for workers.

E3 becomes KinEtic.

The ergonomic version improves productivity thanks to operator comfort, maintaining the multiple functions and flexibility of the E3-40/2000. Also available 1250 mm long.

Ergo Pack.

The E3 greatly reduces both maintenance and waste disposal operations, proving once more that the most innovative technology is on the side of the environment.

Environment.

Δy = +/- 0,015 Δy = +/- 0,002

E3

1°MAX

MIN0,13°

MAX

MIN

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TRADITIONAL

Angle as a function of accuracy “Y” : V = 6 Thickness = 0.8-1.0 mm

LSAC and Expert Database: controlled accuracy and repeatability.The LSAC option monitors the bend angle to ensure consistently accurate parts. The angle control device uses laser technology and can be integrated with the Expert Database option which allows each system to learn and correct the bend parameters according to the material and tools being used.

The satellite roller screw guarantees superior reliability and durability than ball solutions; a satellite roller screw has idle time up to 3 times higher than a ball screw of the same size since the load is evenly distributed along the entire length of the roller and not just on the balls that occupy the first principles.

Reliability and durability.

Technology at the service of quality.

The screw drive, combined with the SiX controller, achieves top-beam positioning precision on the upper Y axis equal to +/- 0.001 mm, guaranteeing absolute part quality.

Precision.

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Technical specificationsAir bending tonnage chart

Closed structureCustomization ControlProprietary management software

ESITSafety


B2. Perfect part synchrony: the source of quality.

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The B2 structure is stable and balanced; this extremely versatile press-brake can be set according to customer needs, guaranteeing energy savings and operator safety.

ESIT: intelligent energy is only activated when it’s needed, saving money.All B2 press-brakes can be equipped with the efficient ESIT energy-saving system so that they use only the current required for processing and remain on standby during set-up and bend/cycle changes. While dramatically reducing consumption, with energy savings of between 40% and 70%, ESIT also makes the system quiet, reduces mechanical stress and improves machine productivity.



Model 200/4250 200/5000 320/3000 320/4250 320/5000Max. power (tonnes) 200 200 320 320 320Table length (mm) 4250 5100 3060 4250 5100Maximum stroke (mm) 400 400 450 450 450Open height (mm) 700 700 700 700 700Max. speed (mm/s) 160 160 200 200 200Adjustable bending speed (mm/s)* 0 to 10 0 to 10 0 to 10 0 to 10 0 to 10


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SoftwareEase of use and programmingHigh productivity

B3 Press-brakeE3 Press-brakeB2 Press-brakeClosed structure

CustomizationSelective safety devices

RobotConnectionsConfigurations

Safety


ROBOformER: from design to end product, with a single controller, a single program and no need for robot teaching.

ROBOformER is the fruit of the synergy between leading companies, who base their competitive advantage on automation and flexibility. The result is a personalized high-throughput solution, complemented by service that satisfies the needs of each and every customer.

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Optimized cycles and zero standby times: a milestone in productivity.

Software.ROBOformER is the best solution for all applications and production needs thanks to its high configurability. It provides the most extensive range of presses, robots, connections and options supplied turnkey by a single manufacturer.It is the winning production choice for all those companies who want to expand by implementing automation solutions, be they simple and accessible or innovative and sophisticated.

Customization.METALStudioMETALStudio represents the CAD platform that the Salvagnini CAM applications draw from. Using a solid modeler, METALStudio automatically calculates flat developments and bending tolerances for the material used.

CAMformERCAMformER generates the full program for the production process, whether or not the robot is to be used. Programming is run in a single environment, so the user does not need to learn different software tools in order to control the press and the robot. Optimal bending sequences, press positions and robot trajectories are calculated automatically. The complete job program is then sent to the cell’s single controller for execution.

TOOLformERThe TOOLformER module is responsible for the integrated management of tools, gripping unit, rods, etc., providing a guide for the set-up best suited to the part.

The answer to all your production requirements.

The operator can choose between offline and teach-in programming modes according to the production type.If required, the robot can be bypassed.

The cell achieves levels of productivity that would be difficult to achieve with traditional solutions, thanks to the dynamics guaranteed by the electric press-brake and optimal robot-connection combination.The cell has a single controller which perfectly synchronizes the movements of the press and the robot, eliminating dead times and optimizing the bending process.

Salvagnini machines are produced within a company that is committed to minimizing energy consumption and to handling and disposing of waste correctly, as well as providing a totally safe workplace (for which it has been awarded OHSAS 18001 accreditation). The machines are all EC or UL/CSA certified and equipped with adequate safety devices. The machines are so innovative that they can selectively inhibit some areas for tests or work without shutting down the entire production line, ensuring complete operator safety.

Selective safety devices.

Ease of use and programming.

High productivity.

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The robot: the protagonist of automation.

Robot.Thanks to the service robot and automatic loading/unloading devices, the cell with two levels of automation - process and operation - is a reliable solution for unattended production, even at night. All risks associated with part handling during bending are faced by the robot and not by the operator.

Model KR16 KR60L45 KR150L110 KR240L180 KR240L210

Fast, high dynamics

Flexible, suited for small-sized part handling

Versatile, suited for medium-sized part handling

Powerful, suited for medium-sized part handling

On tracks, specific for heavy duty handling

Payload (kg) 16 45 110 180 210Max. range of action (mm) 1610 2230 3100 3100 2900

The ROBOformER can be equipped with different types of loading and unloading connections, depending on the client’s production requirements.z Loader from a precentred pack.z Loader from a Cartesian feeder in masked time.z Cartesian feeder with controlled axes.z Feeder/unloader for connection in line with Salvagnini systems.z Unloader.z Carousel unloader.z Roller-surface unloader for pallets.z Roller-surface unloader for pallets and crates.

Connections.

Configurations.

LEAN-A CONFIGURATION:Automatic multi-pack loading, carousel unloading.

AUTO CONFIGURATION:Loading with Cartesian robot and highly autonomous multi-purpose unloader.

FLEX CONFIGURATION:Loading with single-part line feeder and unloading on conveyor belt.

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The B3, B2 and E3 press-brakes provide maximum configurability in terms of: tooling (Promecam, Wila, etc.), accessories, punch clamps, front supports, accompanying devices, safety systems and workplace ergonomics.

Precision measured in μm, a stable structure, consistent back gauge positioning: quality is the sum of a number of excellent parts.

The structure is one of a kind in that both the top and the bottom of the press are completely closed. This makes it extremely stable and ensures that the positions of the references remain constant throughout the entire bending phase, generating a remarkably high degree of precision. It also minimizes deflection during processing, enhancing accuracy and eliminating the need for foundations or anchor bolts.

The robustness of the structure allows the user to choose the most suitable bending technology: air bending, bottoming or coining.

Closed structure.Customization.

Configurability without limits.

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Easy operation, new console, user-friendly graphical interfaces: automation is exceptionally simple when you work with a B3 or an E3.

The B3 and E3 employ effective solutions that are extremely easy for the operator to use:z a new 21” wide touch-screen console to keep all information

under control. The operator is free to use either the touch-screen, keyboard

or mouse.

Control.Salvagnini has developed easy, user-friendly graphical interfaces to program, control and manage its systems.

PressStudio is the press-brake programming software, based on a native 3D model, which is used for graphical and numerical programming and for production management. Like all Salvagnini products, PressStudio has been developed to allow perfect integration with other Salvagnini systems, in accordance with factory logistic requirements.The software can be completed with the Expert Database

Proprietary management software.

feature, which allows it to learn and subsequently correct the bending parameters according to the type of bend, the material and the tools used.

z the high-performance SiX controller for simple operation using the Maintenance Manager and Easy Data software.

Ethics is obtaining the maximum without any waste.

All Salvagnini machines are equipped with the very best technology for totally safe use. The LSB (Lazersafe Block) system installed on the B3, B2 and E3 offers maximum safety and productivity: with the tool performing a fast, controlled descent until it is 2 mm from the work piece, processing times are extremely short. The lateral protections that slide along the structure give fast, safe access while minimizing floor space.

Safety.

F

F

B B

V

V

S

S

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Tons per meter of work piece

Minimum flange

V-die opening

Inside radius of formed part

Material thickness

4 210 8 5.5 4.516 12 9 7

20 14 11 8 622 15 11 9.5

25 19 15 1128 22 17 12

44 33 22.5 1755 37 29 22

58 42 4483 65 45 35

110 75 57 45116 85 68

121 91 68143 112 79168 131 90

172 119222 150

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0.511.21.522.5345681012141516182025

4 6 8 10 12 16 20 24 30 40 50 60 80 100 120 1600.157# 0.236# 0.315# 0.394# 0.472# 0.630# 0.787# 0.945# 1.181# 1.575# 1.969# 2.362# 3.150# 3.937# 4.724# 6.299#

2.8 4.2 5.6 7 8.6 11.5 14.4 17 21 29 36 42.4 56.5 71 85 1140.6 1 1.2 1.5 1.8 2.4 3 3.6 4.5 6 7.5 9 12 15 18 24

V (mm)V (inch)B (outside mm)ri (mm)

TO

NS P

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TE

R

Material thicknessmm

Air bending tonnage chart.

Required press force at 90° air bending, force in ton/mt. The chart gives the appropriate tonnage to air bend mild steel.

Bending force for other materials: z Soft aluminium: F x 50%;z Heat-treated aluminium alloys: F x 100%;z Stainless steel: F x 150%;z Bottoming/coining: tonnage requirements are three to five times greater than for air bending.

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Salvagnini believes strongly in the value of educating those who use its systems, and considers this principle of ever increasing importance to the concept of automation. For this reason, Salvagnini’s training program is the synthesis of the company’s extensive know-how and of direct experience in processing sheet metal. In addition to standard courses, Salvagnini offers, on request, specific individual training courses on machines and processes at a customer’s facility.

Training.

The installation of Salvagnini systems is always carried out by highly specialized personnel trained in-house. Thanks to the sophisticated yet intuitive technology of Salvagnini systems and software, customers can always expect a quick response to their questions and can keep their machines up and running with little or no interruption. With recommended preventative maintenance programs, Salvagnini can keep a customer’s machines at the peak level of efficiency.

Technical support.At some point, all industrial machines require part replacement. Effective preventative maintenance programs help to identify component wear before a breakdown occurs.However, it is critical to have the necessary spare parts, close to users and ready for immediate installation. In order to fulfill this need for accessibility, Salvagnini has built a worldwide network of spare parts warehouses, with constantly updated selections, ready for immediate delivery, when you need them, wherever you need them.

Spare parts.

Beyond the machine, you will find even more Salvagnini excellence: innovative training programs, specialized personnel trained in-house and a worldwide customer service network.

4 production facilities 20 operational sites 75 countries in which at least one system has been installed

5 product lines 79000 m2 of covered production space

160 different application sectors

salvagninigroup.com

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Laser cutting

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Panel forming

Bending

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bending - metanox file2 3 innovation records. the past and future of sheet metal processing all...

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