The ever-increasing demand for skilled pressbrake operators, who possess both practical know-how and a deep understanding of the theoretical aspects of bending, has solidified our commitment to providing comprehensive training opportunities. In collaboration with an Italian school, we are proud to offer a unique theoretical/practical BENDING CLASS. The program attracted a diverse group of participants, including experienced, as well as young PB operators eager to learn, and drawing department personnel seeking to enhance their knowledge. The enthusiasm for learning and the need for technical expertise were palpable throughout the course. Many companies have recognized the importance of investing in training to unlock the full potential of their workforce and technology. By empowering their employees with the necessary skills and knowledge, they can achieve a significant competitive advantage. The ongoing industrial change requires making the production cycle increasingly efficient, keeping production costs low without compromising quality and safety. Factors such as the growing demand for product customization, on one hand, and the difficulty of finding qualified labor, on the other, are pushing companies to reorganize their production departments to remain competitive. One of the fundamental elements on which companies are trying to act to contrast the shortage of labor is to enhance internal resources by training, stimulating, and retaining them. Training plays a key role because it allows us to acquire an awareness of the difficulties and the most practical aspects of bending thanks to which it is possible to make the process more streamlined and solve many problems upstream of production. A highly skilled press brake operator or fabricator who possesses a deep understanding of both the practical and theoretical aspects of sheet metal working is an invaluable asset to any company. In fact, a qualified and adequately trained operator will play a key role in making the production cycle increasingly efficient, contributing to increasing the quality level in the repetitiveness of the processing processes. A second interesting aspect related to personnel training is its flexibility. Companies are increasingly aware that to improve the efficiency of the production chain, synergy is needed between the technical office and the production department. In fact, the technical office must have precise information on the characteristics and limits of press brakes in order to design and draw efficiently, avoiding errors and waste. It happens too often, in fact, that the technical office develops developments with tolerances that are too hard, if not impossible to achieve considering the equipment (press brake and tools) in the bending department. Knowing the theoretical bases behind the sheet metal forming process can help designers and draftsmen to have a complete overview of all the necessary elements in the design and drawing of parts. It is precisely to encourage the sharing of knowledge that at VICLA we have chosen to move in two directions: on the one hand, by organizing training days, full of detailed diagrams and valuable insights that stimulate lively debates; on the other hand, by creating a bending manual – as for now, available only in Italian - which summarizes the theoretical and operational bases of sheet metal working. The manual contains numerous tips and practical advice to take press bending to its maximum possible performance, as well as an in-depth overview of the evolution of press brakes and new technological solutions to improve the quality of finished products. For 10 years now, the machine tool industry has been witnessing an incredible revolution, says Marcello Ballacchino, owner of VICLA together with his partner Corrado Nucci. I am referring to the automation of processes, the advent of robotics and the development of machines with a high energy coefficient. And then we must not forget the great theme of the Digital Factory. This new way of conceiving production is projecting the entire sector into the future. Hence, VICLA's mission to continue to look ahead, to anticipate requests and meet the needs of customers. The Bending Day was a valuable opportunity to share our passion for sheet metal working and to forge stronger relationships with our customers We can't wait to replicate this experience!
Within a carpentry, sheet metal bending often represents the bottleneck of the entire production process, because sheet metal, which is a living material, can take on infinite shapes and sizes and this, sometimes, is the cause of little-known and complex problems to solve. It must be said that, sometimes, problems do not arise in front of the machine, but very often are caused by an upstream error in the technical office. It is for this reason that you should learn to identify sources of error early on and correct them upstream, when it is still possible to intervene in the entire bending process. What are the most common problems when bending sheet metal? Simplifying, we can distinguish between two categories: punctures and vent curls. For each, there are different approaches you can take to eliminate or limit the problem. Here's a summary of what we'll be talking about: Punctures near the bend line Partial punctures Pre-drilling with smaller diameter Vent Cuts Reducing the width of the matrix Changing the Folding Mode Using tangential bend dies Vent Curls Vent Cuts Bending Mode Changes Tangential bend dies A book would not be enough to describe in detail every single point and the possibilities of solution. Today we will limit ourselves to talking about sheet metal drilling and what are the first two solutions you can adopt. We'll be delving into the rest of the game in the coming weeks. Drilling near the bend line Punctures in the vicinity of the bend line are an extremely common problem. The presence of holes near the bend axis can create a deformation that changes the shape and position of the hole. The best solution would certainly be to avoid designing bent sheet metal elements with holes too close to the bend lines. However, if you do not have this possibility, there are several strategies that can be adopted both by the technical department of the company that physically makes the piece, and by the operators. Partial drilling Mainly used in heavy carpentry, partial drilling involves not completing the entire shape of the hole. This makes it possible to preserve a surface useful to be supported by the matrix during deformation with the consequent stability of the perforated shape. The hole will be completed by further processing, such as with a hand plasma. As you can imagine, this technique is best used in the presence of high thicknesses and small quantities of pieces. Pre-drilling with smaller diameter All in all, similar to partial drilling, pre-drilling with a smaller diameter involves a non-complete drilling of the template to be removed during cutting. In this case, a small hole is drilled and sufficient to avoid any deformation during bending. Unlike the partial drilling technique, pre-drilling with a smaller diameter is faster and suitable for even medium-thin thicknesses and medium-large batches. In the next article, we'll continue to dive deeper into the approaches you can use to handle holes near bend lines. If you haven't already done so, we recommend subscribing to the VICLA newsletter!
Two weeks ago we discussed how important it is to know the recurring problems of sheet metal bending and we saw what the first two cases are, i.e. partial drilling and pre-drilling with a smaller diameter. Today we are going to delve a little deeper into the theme of drilling, introducing vent cuts and we will end by talking about the use of tangential bend dies. Are you ready? Tagli di sfogo It consists of providing a cut at the bend line that allows the flap to be bent up to the apex of the notch. The cut can then be restored by welding or left open depending on the end use of the piece. This method, where permitted, also guarantees absolutely outstanding results. It consists of making cut strokes or real windows that interrupt the bend line at the holes. In the presence of a high thickness, simple cuts cause tears on the ends of the bend line break. This phenomenon may not be a problem, even more so if the external radius is restored through welding and grinding. However, in the presence of elements subject to fatigue and high loads, it is advisable to operate in a different way, for example as in this image, where, thanks to an H-shaped cut, tears and potential crack triggers are completely avoided. Die width reduction The reduction of the width of the matrix is a technique that finds its best application when it is already provided for in the technical office. At the drawing or planning stage, if there is the appropriate knowledge, it is already possible to understand whether the deformation of the holes can be avoided with this system and whether the workshop has the right tooling for the purpose. If so, the technical department will necessarily have to generate a development suitable for the new condition. This also means that it is a good rule of thumb to state on the drawing which is the die to be used in production to obtain the correct part. Reducing the width of a die, as already described, causes a smaller bending radius in the sheet metal with the consequence of obtaining a part with a smaller finished size than desired. Changing the bending mode As already discussed in this volume, there are three folding methods, each with its own peculiarities: air folding, matrix bottom and coining. Depending on which mode it is adopted, there is a different constancy in the shape of the holes during bending. Working in air, in fact, the sheet metal is totally free and suspended on the die and this approach is the least favorable condition to preserve the holes from deformation. For this reason, it is more suitable to use an 88° homologated matrix for hollow bottom mode. In this case, the internal faces of the die, coming into contact with the sheet metal, reaffirm the deformations bringing the holes back to their initial shape. If high precision is required, it is advisable to consider the use of this technique already when determining the development of a part. Using tangential bend dies For several years now, special dies have been offered on the market equipped with milled semi-rollers and housed on special seats. The position of these rollers is maintained by springs that allow them to move and return to their initial horizontal position. Tangential or oscillating bend dies have many advantages in the face of a rather high purchase cost and a wider width than traditional dies that makes it more complex to make closely spaced Z folds. In the next article we will complete the topic of the most common problems by talking about venting curls. If you haven't already done so, we recommend subscribing to the VICLA newsletter! Is this your first time reading this blog? Download our press bending manual and subscribe to the newsletter!
During the bending process, the machine is subjected to a tension that causes a deformation of the structure and, consequently, also of the sheet metal; to compensate for this kind of stress, the crowning system comes into play. When we bend the sheet metal with a press brake, the upper crossbar always tends to curve upwards. The crowning system lifts the die to maintain a constant distance between punch and die. Without it, the result of the bending angle would be irregular. To put it in a nutshell, in a press brake with incorrect crowning or without crowning, the bending result will have a more open or closed bending angle. For this reason, it is of fundamental importance to choose the correct crowning system for your press brake. What are the main crowning systems? There are several crowning systems, some of which are exclusive patents of very few manufacturers such as VICLA. Today you will discover the three main systems and which, among them, really helps you to achieve perfect folds without having to waste material and money on tests and verifications of the part. If you want to read immediately what it is, you can go directly to the paragraph where it talks about active hydraulic crowning. Wedge-style crowning system The wedge-style crowning system is an adjustment that takes place beforehand and can be modified on the basis of the characteristics of the sheet metal. It consists of two rows of wedges across the length of the bed; one row is fixed and the other is movable; moreover, it involves a series of profiles with different inclinations, characterized by a stronger marking in the center and less on the sides. The wedge in the middle of the bed has a higher slope than the wedges under the pistons, and the angle of the slope decreases toward the ram from the middle of the bed. On one of the sides of the machine there is a gear motor: when activated, the movable wedge creates a curve with the high point at the center of the bed and the low points at either end of the bed below the pistons to create a spline curve in the table. The wedge bench always requires an intervention by the operator; In fact, the profiles, when viewed from the side, show an oblique contact plane that allows the expert bender to adjust the rib and make it localized. This system, while very useful, has one major drawback. With the wedge table, changes to the linearity of the bench cannot take place during bending, but must necessarily be made beforehand. In fact, this crowning system is also called pre-crowning, precisely because the adjustment takes place before starting to bend the sheet metal. Sheet metal bending and crowning: how much do you need to compensate? Compensation is one of the crimper's big pet peeves. While it is true that there are theoretical tables and formulas to calculate compensation, it is equally true that sheet metal is an unpredictable material. It happens very frequently that the theory clashes with the variable behavior of sheet metal. What can be done in these cases? Surely the first step to take is to know all the factors that determine the behavior of the sheet metal. It will help you understand how to compensate for them and not waste time and material on tests and verifications. Sometimes, however, even knowing the material is not enough and the company could run into many problems deriving from non-uniform parts: material cost, late deliveries, high waste. Getting the result right the first time becomes essential for companies that want to remain competitive in the market. Crowning systems: hydraulic crowning Hydraulic crowning is a system historically used by many manufacturers. Inside the bench, in the table that bears the stress and supports the dies, high-pressure and low-flow cylinders are inserted. Like real hydraulic jacks, they push the center of the bench upwards, thus compensating for the deformation of the stomp. The effect you get is the perfect parallelism between the punch line and the die line. With hydraulic crowning, you get a workpiece with a constant bend between the center and the sides. Even in this case, however, it may happen that, due to the variability factors of the sheet metal, the system returns a value that is not optimal. In fact, the numerical control calculates the compensation on the basis of the description of the piece to be produced and on the calculation calibrated to the structure of the sheet metal machine. Linear bends of sheet metal at the first attempt: active hydraulic crowning The only way to successfully manage crowning is to use technology that measures the actual deformation and corrects it in real-time. VICLA, for this reason, can guarantee active crowning, which, in fact, represents the evolution of the system and the ultimate in terms of repeatability and precision. With VICLA's Clever Crowning active crowning system, you can be sure that no matter how different the material is, you will always achieve a perfectly linear crease. How does the active crowning system work? VICLA's Clever Crowning active crowning is a sophisticated and extremely intelligent system that provides for a modification of the linearity of the bench, calculated exactly on the basis of the real need. The press brake, in fact, thanks to special sensors inserted at the strategic bending points, is able to understand exactly how many hundredths of a millimeter the extent of the crossbar bending is. It is no longer a parametric calculation, but a real value that establishes the exact pressure that the cylinders must use to compensate for the bench and achieve the perfect bends along the entire length of the profile. This solution does not require corrections because it is positioned completely automatically, always guaranteeing excellent results. In short, it is a real revolution in the bending process that improves work in the workshop in many ways: you get excellent results even with inexperienced staff, as the system calculates everything automatically; reduce material waste, as the system applies the exact compensation in real time; reduce production times because you no longer need pre-crowning and part checks. All the systems currently offered on the market, hydraulic or mechanical wedge, require corrective intervention by the operator. They are therefore semi-automatic systems, in which the positioning is theoretically determined by the NC but is subsequently corrected by the operator. With VICLA's Clever Crowning active crowning system, on the other hand, the NC measures the changes to be made in real time without you having to intervene with subsequent adjustments. This option is available on the hybrid press brake. SUPERIOR and allows you to achieve exceptional performance. Now that you know how to achieve perfect folds without wasting time and material, discover the other benefits of VICLA press brakes.
During the last 10 years, industries across all sectors have actively participated in a significant shift towards automation, with solutions for every aspect of production, from automated warehouse management lines to robotic bending cells. Robot integration revolutionized the sheet metal bending process on press brakes. Bending cells represent for sure an advanced solution for industrial automation, increasing the quality and efficiency of work. Thanks to the advantages of state-of-the-art programming, this solution can work continuously, providing constant, repeatable and high-quality results, without the variability associated to human operators. How does a bending cell work? A robotic bending cell is an integrated system that combines a robot and a press brake. This solution allows to automate the entire bending cycle. In particular, automation includes: Part picking by the robot, which is equipped with suction cups or magnets Thickness control and centering plate Bending phase (includes performming of re-grips or turnovers) Palletizing Faster production cycles thanks to robotic bending The lack of qualified staff has developed an increased need of automated production. Without any doubt, the scarcity of qualified labor can be considered one of the main factors that has required this change in the workshop organization. Robotic bending cells are designed to perform a variety of operations. The use of automated solutions allow companies to make the production cycle more efficient, while keeping production costs low, without compromising quality. The robotic bending cell automates the entire bending cycle, from part picking to final palletization, ensuring high-quality and consistent results. Let's take a real example: the bending department of a company can organize the work on a continuous cycle. You might optimise effectively the work by using the robotic cell during the night to perform all the simplest and repetitive processes, while operators can focus exclusively on the most complex and challenging phases of processing, especially those in which a robot cannot compete with the creativity and added value of an experienced bender. The operator, released from doing repetitive tasks, can put its attention on other activities, such as preparing for the next processing phases, or can be trained on machine maintenance. With this kind of organization the company can fully exploit the potential of automation for the simplest working phases, where the human contribution is less appreciated. On the other hand, companies can employ human capital on more remunerative tasks, fostering the development of new skills and creating the conditions to retain the most valuable resources. MATRIX: robotized cells without limits To meet these needs, VICLA has designed MATRIX, the fully customizable robotic cell that perfectly meets the real needs of customers. It is a highly performing integrated system, easy to program and designed to meet the needs of the individual customer. VICLA stands out for the high level of customization of both the robot and the press brake, which can be configured in terms of power and length, while the integration with the robot is designed according to the customer's needs. The cell configuration is highly versatile and allows to easily switch from automatic to standalone mode when needed. The design is compact and can be configured according to the space available. The robot can pick a wide variety of sizes, even the smallest, thanks to different gripper options. It is possible to equip the robotic cell with a mobile or press brake-integrated (ATC) tool changer and obtain a fully automated bending system. The high-tech sensors ensure a consistently accurate bending angle. The angle control, the adaptive crowning system, and the Flex device ensure perfect linearity even on non-uniform materials. Matrix offers a suite that combines bending software and robot programming in a single environment, also allowing to import drawings, collect real-time data, monitoring production. These features make the Matrix bending cell particularly reliable and productive, thus helping to meet the shortage of skilled labor. Due to the fact that it is fully customizable, VICLA offers various custom-designed configurations. The customer can therefore choose a solution with a gantry robot, a rail robot or a fixed platform robot. Let's see together the advantages of each type. Robotized cell .Matrix Baseline Integrated robotic cell that combines a press brake and a floor-mounted robot. The robot can be configured to move on a rail, thus obtaining a seventh axis, or it can be positioned on a fixed support platform. A bending cell with a rail robot offers a lot of advantages; let's see some of them: Increased flexibility: if the robot is equipped with a seventh axis on a rail, it can serve multiple workstations, allowing for different operations without the need for operator supervision on the machine and the execution of tasks at different points in the production line. Downtime reduction: thanks to the ability to move along the rails, robots can reduce downtime associated with the movement of materials or components within the work area, improving overall production efficiency. Increased productivity: robots moving on rails can avoid the downtime typical of production, optimizing cycle times during the day and the night by serving production lines 24/7, saving time increasing productivity. Better use of space: thanks to their mobility, rail robots can be used more efficiently because they work in a larger space, allowing for better organization of the production area and a strong reduction in the footprint of the machines. First piece right: each process is first designed remotely and feasibility is checked using specific software. The robot checks and positions the part exactly where it needs to be bent, and specific devices are used to verify the position and material, which ensures the right first piece from the beginning. Matrix Skyline: for a more efficient use of space Integrated robotic solution that combines a press brake and a robot mounted on a gantry. This configuration is the best solution when it would not be possible to install a rail-mounted robot due to space limitations. Thanks to the use of an overhead gantry for the robot, the working area is free of obstacles, allowing for greater flexibility and versatility. Unlike the version with a floor-mounted robot, this system does not require to place the bending brake on lifting blocks, making it a more versatile solution even when used in standalone mode. Robotized bending with automatic tool changer Robotic bending can be integrated with an automatic tool changer that automatically performs even the most complex setups, handles dies up to 70 mm V width, round tools and also allows 180° rotation of the tool. VICLA ATC - Single or Twin - can reduce setup times by 4 or 5 times compared to manual operations. This system, combined with a bending robot, is the most suitable solution for saving time in the bending cycle, combined with flexibility and production speed. Robotised solutions from laser to bending Matrix Tailor is an innovative system that enables the complete automation of laser cutting and metal bending. Its uniqueness lies in the use of two or more 8-axis gantry robots, where the eighth axis is dedicated to bending. This solution allows the robots to be used not only for bending, but also for sorting and palletizing the laser cut parts. The automation covers several aspects, including: automatic sorting, part transportation from laser machine to bending machine using by AGV (Automated guided vehicles) robots and bending phase. The flexibility and versatility of this solution become even more evident when considering that the system can be designed for 24/7 production. During the day, production can be managed by operators and/or robots, while at night the system can operate automatically. In this way, robots can work with or without human intervention, even carrying out entire shifts fully automatically.
A robotic bending cell is a system that integrates a robot and a bending press, designed to perform operations of picking, bending, and depositing metal sheet profiles. It is a solution born out of the need for companies to make the production cycle more efficient while keeping production costs low without compromising quality. The modern era of mechanical processes is characterized by a common thread: an increase in the level of quality in the repeatability of machining processes. In the field of sheet metal processing, continually improving productivity is one of the current major challenges, especially considering the growing variability in shapes, sizes, and quantities of pieces demanded by the market. What are the possible solutions? As always, there is no one-size-fits-all formula, but there are options that better suit each individual company. Today, we will talk about robotic bending and how it can enhance corporate productivity. Robots and Innovations in Industrial Bending: Latest Developments Bending automation has made significant strides compared to a few years ago, considering collaborative robots (cobots) or automated tool changer. Before the advent of cobots and anthropomorphic robots, a Cartesian robot was used. This is a robotic arm that moves along a large steel frame positioned in front of the bending press. Technological evolution in recent years has allowed freeing the robot from the elevated horizontal sliding beam, giving rise to the anthropomorphic bending robot. Automation of Bending The sheet metal processing sector is experiencing remarkable technological evolution, especially in the field of press bending. Traditionally, the bending phase has always been considered the bottleneck of the entire process because it is where the most significant waste occurs, both in terms of material and time. Automated solutions act on two fronts: speeding up the bending cycle and reducing human error. The automated bending cell relieves operators from strenuous, repetitive, and unstimulating work, allowing them to focus on other tasks. VICLA automatic tool changer allows machine setup without operator intervention. Programmable remotely or on the machine, it accelerates the bending cycle. Advantages of Robotic Bending In the new smart factory, the programming phase of different processing stages is managed by the technical office, which becomes the true operational center of the workshop. With everything controlled from a single location, the bad habit of having programs in the machine more accurate than the technical drawings or relying solely on the notes of the benders ceases. Reduces Costs By reducing the discretion of the human factor, costs can be reduced. Positive impacts include a reduction in material waste and a decrease in the production cycle (operators can focus on optimizing other production cycles). Additionally, the work of people involved in other areas is expedited. Lifts operators from repetitive, strenuous, and risky activities Another aspect not to be overlooked is the safeguarding of the health of operators who, freed from taxing and dangerous activities, can engage in other tasks. Operators can cease manual handling of large sheets, eliminate the risk of finger crushing during the bending phase, especially for very small pieces, and reduce risks and fatigue from manual tool changes. Improves Job Estimation Automation allows precise measurement of the time, material, and energy required to produce a piece. This enables more accurate quotations and eliminates the discretion of the human factor. How often does one base the price on skilled operators who are not always the same ones producing the piece? Additionally, knowing in advance the timing, energy, and material, the company can make accurate forecasts of costs and revenues for the current year, improving the overall management of cash flows. Robotic Bending vs. Manual Work It is a common misconception to believe that automated bending will lead to the end of thousands of jobs. The same was said of the advent of the PC, but facts have shown that the introduction of new technology tends to have more positive than negative effects. Bending automation will drive the development of human skills. New skills will range from machine maintenance to programming. Thanks to the time saved, versatile figures capable of performing multiple tasks could emerge— for example, a laser cutter or a welder could learn to manage a robotic bending station much more quickly than a manual machine. So, will benders lose their jobs? Absolutely not! A robot can never replace the work of a highly skilled bender, also because not everything can be automated. There are indeed processes so complex that they must necessarily be carried out by the human hand. Control Systems in Robotic Bending: Optimization and Precision As advanced as bending robots may be, they cannot understand if they are working correctly and if the piece is successful. To avoid unpleasant situations where the system worked all night and one ends up with a series of pieces that have errors and inconsistencies, it is necessary to equip oneself with sensors and bending control systems. The first is angle control. It consists of a system of laser readers running parallel to the bending bench. This solution guarantees the set angle without any additional correction. Another useful precaution that ensures the correct positioning of components is the rear register sensor system. Other very useful devices are inserted inside the bending bench and serve to detect and compensate for natural flexions due to the bending effort. Adaptive bending device (VICLA Clever Crowning) Ensures excellent results and requires no in-depth technical knowledge; adjusts compensation without any need for operator intervention; guarantees a perfectly linear bend even on non-uniform materials (e.g., mixed perforated/solid material). Device for controlling structural flexions of shoulders (VICLA Flex) allows maintaining the same bending depth regardless of the sheet metal's length. The CNC receives data from the pressure sensors of the cylinders, which are then interpolated to establish the correction to be made. Limits of Robotic Bending As with any other machinery, it would be wrong to think that a robotic bending cell can do anything. These are application limits that must be known and explored before proceeding with the machinery purchase, so as not to end up dissatisfied with the investment made. Looking at the issue from another perspective, the question to ask is: what factors should be considered when choosing an automatic bending system? What kind of work do you do? The essential prerequisite is that the work is repeatable, so it cannot include prototyping. This is because it makes no sense to invest time in programming a product that will be made only once and never again. If a workshop regularly produces different parts for customers, however, the program can be easily recalled, and it might make sense to invest in a robotic bending cell. Furthermore, to get the maximum benefit from an automated system, it is crucial to ensure maximizing the variety of operations that can be performed on it. What are the best jobs for a robotic bender? Surprisingly, it covers a fairly wide range of applications: repeated high-volume jobs; low-volume jobs that are repeated; heavy jobs can all make sense. Evaluate all costs The cost of an automated system is certainly important, and it is undeniable that, for the same price, one could purchase one or more independent bending machines. However, the significant limitation of this reasoning is that, for each bending machine, an operator is needed. Are we sure the game is worth the candle? When introducing an automated bending system, it is possible to optimize human resources as well. An experienced operator can manage an independent bending machine while monitoring a robotic cell. Organize work and space In addition to choosing the right-sized tooling, a workshop must also consider how the parts will be removed from the cell. Will they be assembled into kits, placed on a conveyor belt, removed via a chute, or stacked on pallets? Decisions like these will influence the length and width requirements of the cell. Always Monitor Production It is a misconception to believe that merely programming in the technical office, hitting start, and waiting for the system to do all the work is sufficient. This oversimplification disregards the variables involved in sheet metal processing. With a traditional bending machine, the operator can manually intervene to manipulate the piece and avoid potential collisions. In the case of a robotic system, the automated bending machine will only perform what it is programmed for, so the tool configuration must be precise. A tool out of place could cause significant damage. It is crucial for the operator of the bending machine to ensure that every part is in its proper position because the robot cannot reposition the part to accommodate a misplaced tool. In conclusion, working with a robotic bending machine requires meticulous attention to detail. 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In sheet metal working, batches are increasingly small, complex and non-homogeneous. More and more efficient technologies are needed, while also trying to maintain compatibility with existing machines and services. This is why Nuova Inox decided to focus on VICLA'S ATC automatic tool changer combined with two .SUPERIOR press brakes. Nuova Inox Srl, based in Rovato (near Brescia, North Italy), is a metal carpentry company for medium-light components. Founded in 1989, the company began with the management of small metal products and immediately stood out for its excellent ability to machine stainless steel, becoming a reference point in this field in just a few years. Nuova Inox has always believed in technological innovation, investing in facilities and auto-mation, it has also implemented a next generation management system which, combined with 4.0 technologies, makes the service qualitatively better with useful information for the customer. The strengths of the Lombardy-based company, which employs around 50 people, are its speed of response to requests, efficiency in the execution of orders, and timely deliveries. The work is based on customer projects which generally require the production of sub-as-semblies of machine carpentry in their vari ous sectors, especially packaging, food and medical, given the Lombardy-based company's specialisation in stainless steel and construction steel. A comprehensive service The entire activity is based on various stag es, starting from engineering, which is the stage where the design of a manufactured article is received in preparation for its real-isation, as Fabiano Fieni, General Manager of Nuova inox, pointed out: The intervention of the engineering department serves to make any corrections to the incoming design with the intention of improving its characteristics, implementing better technical solutions to minimise the time needed for realisation. We are well organised to offer a complete service: after the technical department, there is the sheet metal and tube laser cutting department with different working ranges and thicknesses, able to meet most requirements. Then we have the bending division, in which we have recent ly concentrated our resources. More and more often we are producing small batches. these are not even prototypes for large or ders, they are really components of special machines custom-built by our customer, completely different automatic machines, true unique pieces which are very unlikely to be replicated except in very few examples Nuova Inox's services are completed by the punching, welding, assembly and finishing departments, when necessary, not forgetting deburring, which is also useful for company safety. Compatibility first and foremost The specialisation and care put into production have brought Nuova Inox great success in the market, but have also required careful optimisation of work, especially in the bending phase. The lat ter is particularly affected by both set-up times and the management of a vast number of unique codes associated with each job, including non-repeatable ones. There was a need to reduce the time as much as possible on these components of different lengths and thicknesses: the bending set becomes laborious and par ticularly difficult to manage, due to several consecutive settings and a different bending logic from the standard. With a view to reinforcing the department by purchasing more press brakes, this phase had to be made smoother: We examined the mar ket proposals. The first machines with automatic tool changers had already appeared, but we had requirements which could not be overlooked: interchangeability with our existing dies ( matrices and punches already present in the workshop), the fact of having a single magazine serving two machines and a bending CAM program which could manage the entire fleet of machines in the bending department and, finally, having machines equipped with the angle control device. At the time, our needs were met by VICLA, a company specialising in designing and building press brakes, shears and robotic cells in Italy. We therefore purchased two VICLA SUPERIOR 170 and 250 ton press brakes (3 and 4 metres respec-tively, both equipped with an automatic sheet metal loader and angle control de-vice) and a VICLA ATC tool change system to service both machines Speed and precision VICLA'S ATC automatic tool changer is designed precisely to minimise set-ups when these operations follow one after the oth-er; the system can reduce them by 4 or 5 times compared to manual operations. It also eliminates downtime between one phase and the next, allowing you to go di rectly from cutting to bending the part with out having to wait for traditional set-up times. In the new cell, office programming is now managed, a non-trivial operation in this new operational strategy, which begins with 3D 'solid mathematics and ends with bent products. The VICLA SUPERIOR hybrid press brake represents the top of the range from VICLA: brushless engines with a high energy coefficient, active crowning, flex system, angle control and double guided ram. This family of machines is available in difierent configurations (lengths, pressure forces and controls); all are characterised by an extremely solid structure made of high quality steel, capable of absorbing and eliminating mechanical stress and guaranteeing excellent bending precision. For example, the double guide preserves the stability and perpendicularity of the upper crossbar with respect to the work surface: this allows bending precision to be maintained with different tools and intermedi-ates, guaranteeing that the centring carried out at the test is maintained over time. A value not to be forgotten At Nuova inox we have seen that an operator's decades of bending experience is really an added value: we have seen, General Manager Fabiano Fieni concluded, that not infrequently these professionals are capable of inventing' a equivalent or better bending strategy than the one suggested by the soft. ware itself. But not evervone is such an ex-pert, and so cam programming combined with automation is very useful in routine op-erations, through which even beginners can become productive, indeed, they can take advantage of CAM to build on the results and therefore learn! We have put in place a system consisting of press brakes, stor age, ergonomics, set-up time reduction and safety, without neglecting the 4.0 approach and the tracking of the various steps. We are confident that this set-up in the company will allow us to consolidate our carpentry business through improvement of production capacity. As for the future, we look for ward to automation for welding and finish-ing, always ready to innovate”.
Let’s further discuss the fundamental aspects that need to be analysed before choosing a press brake. Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends... Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based. So what are the key elements to examine before signing a contract for press brake supply? #1: the Structure The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product. Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles. The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy. #2: the Double Guide The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing. This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced. #3: the Cylinders Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part. VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left. #4: the Hybrid System If in the past there were few types of bending machines, nowadays the market offers different choices: hydraulic press brakes; electrical press brakes; hybrid press brakes. These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system. Be careful, though! It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines. The results in numbers of this technological innovation are significant, as seen on the graph. #5: the Clever Crowning The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well-processed part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length. What are the advantages of this intelligent system? Mainly three: it ensures great results even in the presence of an inexperienced operator; it uniforms the bending angle without any need for operator intervention; it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material). #6: the Flex Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet. Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon yawn and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out. #7: the Back The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities: Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance; Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence; New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength; Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference. Ultimately We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of: reducing operating costs; maximising productivity; achieving the most in terms of processing quality. By doing so, even the end client can count on a standardised and reliable supply.
The press brake is an extremely versatile machine, yet at the same time complex. The technology on which operation is based is only trivial in appearance, however it hides remarkable developments in the mechanical and technological field. In fact, if we compare a modern press brake to one from fifty years ago, on the outside it seems that little has changed. However, the truth is that they are two completely different machines; the external elements may also have remained stationary with the typical design that we all know, but mechanics and electronics have evolved in a silent and inexorable way. Conceptually, between a bending machine from the past and a modern one, there are no changes in the process; both, in fact, share the same purpose: to bring a punch to a matrix up to a certain altitude in the most precise and repeatable way possible. Yet, the modern press brake is the result of constant evolution. Just as happened with cars, which from a simple and almost rudimentary means of transport have become truly high-tech machines, the bending machine is also now a concentration of technological and mechanical innovation. However, both in the case of the car and the press brake, the basic mechanical components have remained the same, but over time they have been improved and refined. To understand the fundamental stages of sheet metal bending and know the best technology that combines efficiency, effectiveness, operating costs and versatility, you need to take a trip back in time and know a little history of press brakes. Among the pioneering countries, there is undoubtedly Italy. In an area surrounding Brianza, businesses have flourished that have enhanced Italian products and continue to do so to this day, within the bending press brake sector. Our country is renowned worldwide for great tradition and quality in the construction of press brakes. Big names like Mariani and many others have literally invented this technology Let’s now take a short journey through the systems that have followed one another, focusing on today’s non plus ultra: the hybrid hydraulic press brake. Press brakes: types and characteristics 1) Mechanical press brakes Mechanical press brakes are still used in many workshops to do marginal work, even if they are now considered to be illegal machines from a safety point of view and, therefore, cannot be used by employees. In the past, the best known mechanical press brakes were Mariani or Omag branded; they were characterised by extremely fast movement and great pressure strength. 2) Promecam RG hydraulic press brakes Originated in France thanks to the intuition of the Italian-French Roger Giordano, RG Promecam hydraulic press brake machines are compact and low. Their most obvious feature is movement of the bench, different from all other press brakes. In fact, if it is usually the upper part - called the beam- that lowers, in this case the bench goes up. Movement is obtained by pushing a central hydraulic system. Simple and very reliable, they have practically made the history of Italian press bending and more besides.To date, they no longer comply with safety regulations as they do not have a speed change point and are not equipped with modern safety systems. They can, therefore, only work if they are adapted with specific kits. They were widespread for quite some time and it is not rare to still find them in many workshops and still operational; in the post-war period they represented a real revolution, as the bench contrasted the natural bending of the beam. The latter, being rather low and compact, allowed large, closed profiles to be obtained, which could embrace the upper part of the machine. 3) Hydraulic press brakes with torsion bar They are the forerunners of the synchronised ones that look very similar in appearance. Movement is via the beam that descends through a pair of hydraulic pistons. They usually have two or three axes: X for the rear carriage; Z for the height of the rear carriage; Y for the descent of the beam. The characteristic of these machines is that the two cylinders are mechanically connected through a bar that couples movement up to the lower dead centre. The latter is regulated through movement of two nuts that lower or lift to adjust the height of the end of stroke of the cylinders and the beam. The machine is controlled by a simple positioner, often without internal memory. 4) Synchronised hydraulic press brakes To date, the synchronised hydraulic press brake is the most widespread modern machine. It includes movement of the upper beam by means of two independent hydraulic cylinders and regulated by appropriate proportional valves. By doing so, the machine is more versatile and allows the operator to work on both cylinders independently to change the descent of the beam and counteract any irregularities of the sheet. It can happen frequently, in fact, that a piece bends more on one side than the other because of the aforementioned variables of the raw material. The numerical control of a synchronised hydraulic press brake is much more advanced than the positioner of the torsion bar press brake. The CNC allows the operator to make many adjustments: from the parking time to the lower dead centre, from the bending speed to decompression. Fig. 4.4 5) Electrical press brakes They represent the latest evolution of press brakes and continue today to be considered a border line solution for some specific needs. They guarantee speed and repeatability, combined with low consumption, however they are less versatile and have much higher costs than synchronised hydraulic press brakes. There are basically two techniques to operate an electrical press brake: with ball screws or by means of special belts. The future of press brakes: the hybrid press brake Synchronised hydraulic press brakes are the breeding ground for technological innovations and improvements with very important results. VICLA has grasped the occasion with much commitment, specialising in hybrid technology. This solution allows the best to be got from the system, combining it and making it into an advanced solution, which is distinguished for: precision; repeatability; energy consumption; quality-price ratio. Millesimal precision VICLA hybrid presses guarantee millesimal positioning of the beam, always ensuring precise and constant bends: all possible irregularities should be exclusively attributed to natural factors due to the variability of the raw material. This surgical precision is possible thanks to use of less oil compared to traditional hydraulic press brakes. Simply think, for example, that a 110-ton VICLA .SUPERIOR hybrid synchronised hydraulic press has a double tank with just 50 litres per chamber (compared to 200 litres used by a hydraulic press brake). Less oil means fewer ducts, smaller tubing, less heat and expansion and reduced clearance and wear. Two powerful electric motors work exclusively and directly on the minimum quantity of oil necessary. Precise repeatability Repeatability is a direct result of the lesser quantity of oil used. Heating litres of oil that flow within metres of tubing causes considerable side effects, first and foremost, loss of precision. This becomes more and more obvious as the machine is used after numerous work cycles and the inconsistency becomes more visible with each bend. Thanks too to a smaller tank, a compact circuit that allows you to have little oil that changes its volume as the temperature changes, VICLA press brakes maintain bending precision on each work cycle. Repeatability is also guaranteed by precision and the constructive sturdiness par excellence. Without these basic qualities, no electronics or new technology could express its real potential. Energy savings up to 78% If we compare the performance of a hybrid bending machine to a conventional synchronised hydraulic press brake, the results are really impressive: energy savings, in standard conditions, are equal to 55%. But even better limits can be achieved: if the standard hybrid technology achieves 55% energy savings, with the Hybrid Plus option, a sophisticated exclusive hydraulic component, energy savings up to as much as 78% are achieved! This is possible thanks to a simple and effective use philosophy: consume only when the press brake is bending. In a traditional synchronised hydraulic press brake. there is always a large three-phase motor that is never switched off, even while the operator equips the machine, programs the numerical control, organises the pieces near the workstation or, simply, looks at the drawing of the item to work. Instead, the highly coefficient motor of a VICLA hybrid press brake only switches on when the operator activates the machine by pressing the descent pedal. It is a huge advantage in financial terms, even in the short term. In terms of cost, the benefit of hybrid technology is even more obvious. This is because, on comparing the VICLA hybrid system with an electrical press brake that however allows energy savings, the purchase cost is still favourable to hybrid technology. But there’s more: electric hydraulic press brakes, especially if they use a belt system, have a very different structure that makes them generally less versatile. In fact, it is impossible to bend particular parts such as hoppers, tanks of a certain depth or chutes, because their closed structure on the sides and the widespread use of casings creates numerous occasions for collision between the parts and the machine. On the other hand, the hybrid hydraulic press brake allows, like any hydraulics, to work even leaving the machine sideways, with greater use versatility.
A CNC press brake is a modern machine for sheet metal deformation. There are different types on the market: Hydraulic press brakes, hybrid press brakes and electrical press brakes. Modern press brakes are operated and controlled by a computer that helps quickly set the specifications of a job and perform production cycles according to different needs, both short and long term. What is a CNC controller? All mechanical components of the press brakes are integrated with numerical control, which is responsible for setting the bending parameters. The most important parameters in the bending process are: thickness of the sheet; dimensions of the sheet; bending angle; One of the many advantages of numerical control lies in the possibility of implementing bend simulations, during which the machine verifies if there are any collisions or overloads. What are the benefits of using a press brake with numerical control? There are many benefits obtained from numerical control programming on CNC press brakes: Speed Precision Repeatability Adaptation Flexibility Agility The main technologies of ESA numerical control ESA 650 and 660 numerical control This version, with colour graphics and multilingual function, allows the automatic calculation of the PMI according to the type of tool and the required angle, and the automatic calculation of the bending force. Optimisation options include optimal bending sequence, and display of any collisions in the sequence proposed by the operator, also carrying out anti-collision checks between the axes and the matrix in the automatic phase. ESA 675 numerical control It is equipped with an ultra-large 21” LCD HD Multi-touch colour screen and integrated Windows PC, which allows drawings to be opened in PDF format or in another format directly on the machine. Furthermore, it allows optimal management of all Cad-Cam 3D. It is equipped with RAM 8 Gb, 4 USB ports 2.0 + 4 USB ports 3.0. Delem numerical control It is a simple and intuitive Numerical Touch Screen control, with a high level of functionality and a user-friendly and modern graphic environment. It is available with screens of different sizes and features customised to your needs. Press brake programming: management of 3D projects Our modern press brakes can be equipped with programming software for the preparation and processing of 3D projects that guarantees multiple advantages. The programming software available on VICLA machines for sheet metal, for example, guarantee maximum efficiency in tool selection, based on bend radius, maximum force of the press brake, collision control, and the availability of different types of tools and splits. It is also able to recognise and automatically manage the flattened bend thanks to definition of the angles of the pre-bend and the inner counter-bends, calculating the best bending sequence, avoiding collisions and taking into account the availability of splits and skids. Although automatic management almost always finds a solution, the operator also has the possibility to intervene manually and change the data set by the software. For positioning of the stops, the software available on VICLA press brakes provides automatic and manual control options for the back gauge, thanks to the 3D simulation that allows you to view all the moving elements, including the tools, the part to bend and the machine structure. Finally, the software provides the complete tooling report, from the 3D bending sequence, including detailed information bend by bend. The report can be printed or displayed directly on the numerical control.
The press brake is a simple machine, while at the same time complex because it is linked to the variability of the sheet metal, which requires each machine to be equipped for different sheet metal customisations. This is why it is important to know the characteristics and the elements to consider when configuring a press brake. We discover the fundamental points to consider: Length The length of the press brake depends on the maximum length of the part to work. Furthermore, if bent per stations, it is useful to consider the purchase of a longer press brake, which allows multiple stations to be implemented. For example, for a sheet measuring 1100 x 700 mm, you are advised to choose a press brake measuring 2000 mm long. Tonnage It is intended as the bending force of the machine. In other words, it refers to the capacity to bend of the press brake. Tonnage depends on various factors, first of all the material: a ductile part requires less bending force; on the contrary, a more resistant material such as stainless steel or high strength steel requires greater force. The other factors to consider are: thickness, length and type of work. It is always worth over-dimensioning the press brake by 20%/30% of the theoretical data, thereby avoiding working at the limit of machine capacity. One of the most common misjudgements is to confuse the total force needed to bend a given sheet metal part with the tons per metre for the specific thickness, material and die. Find out more in this guide. Clearance and stroke Clearance is simply the front opening of the press brake A press brake with a larger stroke is a machine equipped with greater intermediates that allow easier extraction of the bent parts. Locks and intermediates Intermediates are adaptors to insert between the beam and the punches and are very useful because they allow deep box structures to be easily made. The tool locking systems are sub-divided into: manual locks; semi-automatic locks: pneumatic blocks; hydraulic locks; The choice of correct locking is fundamental to reduce the work times and correctly manage the work zone. Semi-automatic locks It is a manual semi-automatic lock with rapid front locking-unlocking system of the punch. Operation is very simple and, compared to the traditional manual solution, allows faster and easier re-equipment of the machine. In fact, by moving the locking lever, the punch is released to remove it from the front; while, on closure, the punch is automatically brought to stop and perfectly aligned. Automatic locks The automatic tool locking systems allow equipping of the press brake in complete safety. The tools are automatically aligned, positioned and fastened. This solution drastically reduces the equipping time and considerably increases production. Automatic tool change for press brakes Today, a modern and innovative solution exist that allows automated change of the punches and matrixes. For example, VICLA hybrid press brakes can be connected to an automatic tools warehouse that allows equipping, even on multiple stations, of higher and lower tools. This system is customisable and designed to measure according to client requirements; it reduces setup by 4 or 5 times compared to manual tasks and automatically performs even the most complex equipping, managing 70 mm wide V matrices, rod holding tools and allowing the tool to rotate 180°. Automation covers everything, including upstream operations. One of the more interesting aspects is programming by the technical office: the CAD/CAM system processes the three-dimensional file, creates the best bending cycle and sends the program to the machine that is automatically equipped, referencing the bending sequence directly on the numerical control. All tooling and machining data are automatically saved at the end of the work and exported to management for a 4.0 key data analysis. Back gauge The rear gauge is a motorised structure on which the references are set and can be moved and positioned to allow a variety of complex bends. Movement of the back gauge along the depth of the machine is called axis X. Vertical lifting is called axis R. References It consists of very important and useful tools to support thin sheets. They are equipped with pneumatic operation and a Teflon coating that prevents marks on the material. They can also be activated by numerical control. There are 2 references and they are usually manual, but they can be automated and controlled directly by the CNC; the positioning of the stops is along the Z axis. Independent tower gauge All towers are equipped on VICLA press brakes with a visual LED stop. Switch on of the LED ensures contact of the sheet with the reference. In more accessorised versions, the towers are: Motorised (axes z1- z2) Independent (axes x2 - x3) Anthropomorphic (axes r1 - r2) Bending compensation The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well worked part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. Thanks to special sensors in the beams, crowning enables measurement and compensates deformations in real time. There is no need to set any data; the system actively reacts to changes in characteristics. Each press brake, despite its robustness, is subject to structural bending, during the bending phase, and obviously the deformations are much bigger the greater the effort the machine has to make. The main deformation is crowning, which corresponds to bending of the beam which is pushed into position by the side cylinders; the other (and for many reasons semi-unknown), is called in jargon “yawn” and is the tendency of the frames to open in the throat zone. Thanks to the Flex system the sheet metal press brake dynamically compensates any deformations based on the effort required: the CNC receives the data from the pressure sensors of the cylinders, which are interpolated in real time to establish the correction to implement. Energy saving systems It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. The results in numbers of this technological innovation are significant, as seen on the graph. Angle control systems L.A.C. VICLA angle control L.A.C. angle control consists of two laser sensors mounted on linear guides that slide to the rear and front of the press brake bench taking the measurement in one or three points depending on the length of the piece. Located on the sides of the matrixes, they have the purpose of reading, through a system of lasers and cameras, the inclination of the edges of the bends during deformation. It is the most complete and performing solution for automatic angle measurement and control. Angle reading takes place in 3 phases: A laser beam is projected on the sheet metal surface The camera detects the elastic recovery of the material The CNC automatically sets the correction suitable to obtain the system desired angle that we use on our VICLA press brakes and is the best you can find on the market. The guaranteed precision is very high and in the order of fractions of a degree. The system is also able to historicize the elastic recovery of the sheets, ensuring a constant and specific self-learning of the press based on the real situation of the company. Obviously the angle control system guarantees the best performance if it is supported by solid and precise mechanics and perfect integration with numerical control. With the latter, there is a continuous data exchange dialogue that allows perfect application with each item being processed. If, for example, for volume issues, a specific bend cannot be measured by the angle control system, it can be linked to the previous reading made on another flap of the same piece. Vicla optical angle control is a safe investment and surprisingly quick return as it makes continuous measurement operations by the operator completely unnecessary with an exponential increase in productivity and quality. Probe angle control There are essentially three types: inserts in the punch, hosted in the matrixes or applied to parallel sliding trolleys the exact same as those of the optical systems and placed on the sides of the bench. On first examination, it could appear a definitive solution, however these are also not without limitations which, in practice, only appear during their real use. The first is without doubt the installation difficulty. This is the typical limit of the controls inserted in the tools that include use of special punches and matrixes equipped with sophisticated, sensor-based strips. Such angle control systems have very poor versatility when you consider they are not usable by changing tool set-ups. Another limitation is their characteristic fragility. Being small and very sophisticated mechanical elements, they are easily subject to failure caused by accidental impacts or malfunctions due to the accumulation of dust and dirt. O.A.C. (Optical Angle Control) Optical control is directly assembled on photocells to capture images of the profile detecting, calculating and correcting the bending angle. One of the most sophisticated optical controls is the IRIS PLUS system. Although it is part of the optical angle control unit, IRIS plus is an alternative solution because it can perform an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. This eliminates any interference between the parts and the angle control devices and achieves totally versatile use. The system, in fact, allows very interesting accuracy and reliability if the emitter and the receiver are not beyond a certain distance. After approximately 2.5 metres, in fact, there is a natural increase in the phenomenon of refraction of light rays that reach the control system which are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not ensuring the same accuracy in the reading of the bend. Optionals and accessories on the press brakes Bending flattening table The bottom bed has a bending/flattening table in order to perform flat hem bends without the need for a dedicated die. Its versatility makes it the ideal solution for companies that carry out many flat hem bends. The option is built directly into the die holder, and therefore can be used in conjunction with any other die that has a standard connection without the need to disassemble the table. Front sheet metal supports These front supports have a linear guide that extends beyond the bottom beam. Their height can be adjusted and they also slide sideways and rotate. A practical clamp-release system makes them very easy to mount and remove quickly. Metal sheet bending followers They can lift weights up to 380kg. Use of the metal sheet bending followers offers an important advantage to reduce risks for the operator and increase the quality of the bent parts: it was designed to avoid counter-bend effects and reduce the need for other operators. It can also be easily removed from the front and placed on another bending machine. Side parking An extension of the linear guides, extending beyond the bench. This solution is used to park the sheet metal supports when not in use. Wireless 2-pedal foot switch It is powered by an integrated solar panel that allows you to get up to 20% more autonomy from battery life; it does not require connection, nor cable laying. The ultrasonic sensors are located on either side of the lower bench to transmit and receive data wirelessly. Tool locator The system indicates via the incorporated LED the right locking position of the equipment during tool configuration and indicates the position of the active tool in production mode. It is a real and proper visual aid immediately available to the operator who, by doing so, does not waste time measuring and understanding where to position the tool and can dedicate his time to other operations.
The VICLA is not just synonymous with efficiency and accuracy in the sheet metal processing world. Another real strength is our ability to design ergonomic machines with a simple, user-friendly interface. We have studied these features to make them easier to use. Discover our video tutorial to learn how to power a VICLA machine up and
VICLA has been working on systems to help fabricators reduce setup time and minimize production time through stage bending. VICLA Automatic Tool Changer provides the ability to produce multiple bending stations that require various tooling types with only one setup. The demand for smaller, more complex and heterogeneous batches requires finding solutions to shorten production times and lower costs. The smaller the batch, the more the setup times impact on the productivity of the machine and on the production cost. VICLA ATC system - Single or Twin – is designed to automate and speed-up the setups for efficiently producing small batch sizes. The system combines one or two hybrid press brakes with an automatic tool changer, allowing for multiple tooling setups, reducing setup times by 4 or 5 times compared to the ordinary manual operation. The main element of the system is a compact shuttle that serves as robotic tool changer that places the tool sets, up to 1-3/4” V opening, in the clamping systems of the upper and lower beams. This shuttle retrieves and replaces tools in the tool magazine, which can store up to 197 ft. of dies and punches. The tooling can be used in manual or robotic setups. The upper tools can also be rotated 180 degrees. A modular and custom-made solution One of the many other advantages of the VICLA automatic tool changer is the offline programming capability. The CAD / CAM system processes the three-dimensional file, creates the best bending sequence and sends the program to the machine, which is automatically equipped, and calls-up the bending sequence directly on the numerical control screen. All tooling and processing data are automatically saved at the end of the job and exported to the management system for data analysis. About VICLA Sheet Metal Machineries VICLA is an Italian manufacturer specialized in the design and engineering of high performance and customizable bending press brakes, shears and robotic cells. Each machine is tailored to the needs of the individual customer and designed based on its specific production needs. As a result, there is no VICLA machine equal to the other and each of its products excel in terms of production performance and productivity. Thanks to detailed attention, continuous research of high quality, and cutting edge technologies, VICLA has what it takes to provide its customers with the most innovative, robust and reliable technology on the market. This is the company mission since 2008 which has brought VICLA to steadily grow as a machine manufacturer and increase its market shares in Italy, Europe and North America. VICLA official USA Dealer: Comeq Inc., +1 410-933-8500, vicla.eu VICLA Headquarters (Italy): +39 031-622-065, vicla.eu
Sheet metal fabrication is the process of cutting, bending, punching, and assembling flat sheets of various types of metal into desired structures or products. Sheet metal fabrication is now widely used in industries such as agricultural, aircraft, automotive, energy, robotics, and more to manufacture industrial and consumer equipment. Fabrication shops are businesses that specialize in sheet metal fabrication and employ a variety of personnel to handle the difficult process. Design, cutting, punching, bending, assembly, quality check, and packing are the main steps. The creation of a design for the final product is the first step in the sheet metal production process. CAD engineering is the starting point for the route from sheet metal to metal products. The procedure comprises specific data, including dimensions, material qualities, and tolerances that thoroughly outline how to turn a bespoke design into a tangible product. Engineers, architects, designers, and many other experts came up with concepts using schematics and blueprints before the widespread adoption of CAD models in many industries. However, all of that changed thanks to computer-aided design (CAD) models. Modern metal fabricators may use CAD software to create bespoke designs that are accurate and repeatable and can then be scaled up to mass manufacturing. If you're interested in learning about the many ways CAD aids in sheet metal fabrication, here are five of them. 1. Streamlined design process When working with CAD, a designer can take advantage of the software's ability to smooth out bumps in the sheet metal design process. CAD software aids designers in the process of synthesizing, analyzing, and documenting their designs. These factors contribute to the designer's productivity, which translates into faster design, lower design costs, and shorter project completion times. Furthermore, the amount of effort required to design the various models has been significantly reduced because the software automates the majority of the task. Designers can experiment with concepts and save draughts digitally thanks to computer software. You'll be pleased with the results of having your designers work in CAD. Furthermore, because the designer is using CAD, every step of the design process will be documented, allowing everyone to synthesize and analyze the process. 2. Better quality design CAD systems are extremely accurate, allowing error figures to drop dramatically and, as a result, improving design quality. Traditionally, if a design did not work as expected, the team would have to start over. CAD design teams, on the other hand, are better equipped to control the quality of the final engineered product. With CAD software, designers have access to a plethora of tools that aid in conducting a thorough engineering analysis of the proposed design. The low-risk virtual investigation, for example, enables organizations to improve manufacturing speeds and reduce resource waste caused by flawed designs. For starters, CAD reduces the possibility of human error significantly, allowing machinery to craft an item seamlessly while avoiding resource waste. Furthermore, the CAD design process results in fewer draught productions and wastes, resulting in a cheaper and faster production process. 3. Simplified information sharing Creating design documentation is one of the most important aspects of designing when using CAD software. In fact, CAD software aids in better design documentation. Next, all design data can be easily saved and used for future reference, reducing the need for excessive communication. These documents and files can be easily shared among partners and reviewed by teams to ensure that all details are correct. This allows for a more thorough internal understanding of the vision and the work that must be done. CAD software, especially if you're part of a large team, makes it simple to collaborate with team members. Furthermore, due to the integrity of these documents, team members on the ground can be directly allotted information about critical design features, allowing for faster development while reducing assembly errors. 4. Better visualization Visualization is an important tool in Computer-Aided Design because it allows you to effectively and efficiently design, debug, validate, market, maintain, repair, update, and recycle products. The unrivaled visualization capability of CAD software is due to higher levels of sophistication achieved with graphics and visualization techniques, which allow for the creation of images of stunning quality and realism. This is how CAD enables you to create and visualize 2D or 3D objects, as well as make as many changes as you need with less effort than drawing them on paper with a pencil. Architects, engineers, and designers can now use CAD visualizations to create 3D versions of their plans to test how well the design works before spending any money. Furthermore, a completed design will boost their confidence when selling their work to clients. 5. Speed and versatility Speed and versatility are two important aspects of CAD systems that have helped them become an important part of sheet metal fabrication and encourage us to come up with new ways to build things. Designers can use CAD software to visualize their designs and test them against real-world variables. They can easily change the same file if something needs to be changed. Before CAD, people had to do things the old-fashioned way, with paper, pencils, and rulers. They would have to redo the entire design if they wanted to change it. However, CAD eliminates the need for physical prototyping by allowing the designer to simulate all necessary testing in the program virtually. Furthermore, CAD software allows users to use various effects, typography, shapes, and backgrounds to help with artwork and creativity. Final words CAD may be the most significant innovation for metal fabrication and other industrial needs. CAD modeling enables the development of a specification for a custom metal part that is easily understood and actionable by all parties involved in the design and manufacture of the part. When you embrace the benefits of CAD, your designers, prototyping team, and project managers will all be pleased. Furthermore, increased productivity will result from improved quality and reduced waste.
Manual and robotic measurement, control and bending systems made by VICLA. VICLA is committed to adopting reliable and efficient technical solutions in its press brake designs. In the wake of Industry 4.0 innovations, VICLA of Albavilla in the province of Como and on the market for over 10 years, is committed on a daily basis to adopting technical solutions at the highest levels of reliability and efficiency. This results in press brake designs that can be operated in complete safety, either manually by operators or robotically. The press brakes use software and technologies to ensure the highest finished product quality, minimise downtime and guarantee a long service life. Adoption of hybrid systems such as the VICLA Hybrid System and Hybrid System Plus reduces costs and ensures the lowest consumption on the market. This improves the productivity of companies and artisans using VICLA press brakes, which can benefit from great flexibility and quick processing times. To demonstrate its full and consolidated membership of the Industry 4.0 system, VICLA offers latest generation technologies that ensure its machines are in high demand in both national and foreign markets. Innovative VICLA Matrix robotic cells, for example, make it possible to pick up, bend and place even very thick sheet metal profiles, up to 400 kg. With the standard configuration of three main stages: Handling with an anthropomorphic robot and press brake; Management using off-line programming software (able to program up to four cells); Completion with a loader, load platform, thickness gauge, tilting unit and gripper. Another technical feature of VICLA Matrix robotic cells is axis linearity, which simplifies management. In fact, this means that the cell arm can always be positioned consistently with respect to the pallets and bending stations. The raised position (from 2300 mm to 2950 mm) of the horizontal sliding beam also allows medium-load forklift trucks to pass in order to load raw materials and unload semi-finished products. The 3D PROV software is an important key to access Industry 4.0. It is a package designed for processing 3D products, and can manage the entire process from design to finished product quickly and efficiently. The option of remote programming greatly reduces downtime and prevents bending collisions. The waste reduction that this software brings is also very significant. 3D PROV also offers significant features to control backguages manually and automatically. Recent updates to 3D PROV add new software features such as Data Rec (providing very precise information for process programming and production) and Track Prod (providing real-time information, analysis and reports to optimise machine use) to complete the framework of great innovation and efficiency to which the company in the province of Como is committed. Regarding process control, VICLA press brakes feature significant technologies such as the Flex system, a device that can control structural flexing without affecting the bend depth. All regardless of the sheet metal profile length. Uniformity of the bend angle is also guaranteed by CNC-controlled hydraulic or mechanical crowing systems. Finally, the Clever Crowning option ensures linearity over the entire bend profile without the need for operator intervention.
Nowadays it’s possible to have both speed and accuracy when bending sheet metal, you just have to know how to choose: in fact, to create this apparently impossible marriage, you need a press brake that provides real added value to the production chain. Today we will find out what are the most important – and often overlooked – things to consider to finally have speed and accuracy in your company at the same time. Sheet meal bending brings with it physiological issues, first of all from a number of environmental and material variability factors. The production line of a sheet metal workpiece is similar to a chain, which begins with an idea developed in a technical office, which is subsequently roughed during the cutting phase, to then be “brought to life” and given form by the press brake. If every link in the chain is not high quality and well lubricated, your company's movement risks jamming or working badly, resulting in unacceptable speed and efficiency losses. That is why it’s counter-productive to invest inconsistently in the technologies you need. For example: it’s unreasonable to think of reducing waste sufficiently by purchasing a laser cutting machine of the latest generation, a champion of speed, if you then accompany it with an obsolete or low-cost press brake. So here are some tips to avoid having to choose between speed and accuracy. 1) Choose a robust, well-built machine Being able to count on machines designed specifically and manufactured with care and quality is a key factor in ensuring speed and accuracy at the same time. In this sense, made in Italy is in itself a great business card, especially considering experience, professionalism, capability and general quality. Contrary to any false stereotypes, Italy is one of the top five countries in machine tool production, and it’s no coincidence that the sector worldwide has always recognized Italian manufacturing as offering great added value. 2) Choose a manufacturer that listens to you This is a much undervalued issue, but several sources confirm that choosing a good machine without having the same good support can turn out to be completely counter-productive. For example, relying on a manufacturer that is smaller in size but large in service gives a huge competitive advantage that is hard to quantify. What you need is a partner that is willing to let you visit its site, talk to its owners and employees and, of course, directly to its service department for any need. Because speed and accuracy must also go together in support. 3) Choose a manufacturer that focuses on your needs If you need a particular component or accessory in order to work with speed and accuracy, it's good if the manufacturer has it in its catalogue and, above all, that it can advise which one is best for you with transparency and expertise. Sheet metal bending supports, hybrid technology, multi-axis backguages, quick tool connections, etc. All devices that should never be considered a running cost, but a real investment to improve process quality and effectiveness. Therefore, bending speed and accuracy can only coexist if you have a high-quality machine made by a professional manufacturer that is willing to listen to your needs. These have become essential conditions in order to ensure that your work provides added value. None of your customers will ever be willing to pay a premium for waste because your machine is slow and inaccurate, especially in an extremely competitive market like ours.
The art of press brake bending is sometimes unjustifiably underestimated. Companies, sometimes unconsciously, tend to concentrate their economic commitments in other parts of the production chain. For example, technical offices are often state-of-the-art and equipped with the latest tools, while the press brakes used are old and hyper-economical. Sheet metal is a living material that presents a range of objective difficulties during the bending process: underestimating it is an own goal for the company and can become very expensive in the long term. Fortunately, technology has made huge strides, allowing some manufacturers to make the best use of it and develop efficient equipment. If press brakes can now be considered mature machines from an operational and structural perspective, we cannot say the same of the equipment used to enhance them and increase their performance. So, what equipment is essential in a press brake? A hybrid system that makes it accurate and green For most processing, a hybrid system of the latest generation guarantees an indisputable energy saving and can position the top beam with an accuracy in the order of thousandths of a millimetre. These are all benefits that bring great economic savings for the company. Active crowning As is known, press brakes are subject to natural structural deformation during processing. Bending of the top beam is the most obvious. An automatic system with special sensors located in strategic areas of the press to ensure that the punches and dies are the right distance apart along the whole length of the working area is undoubtedly an invaluable benefit. This ensures that a bent workpiece will have the same desired angle in the middle as at the ends. A multi-axis backgauge Having backgauges that can be positioned quickly and accurately almost anywhere has become a must. In fact, the market increasingly demands production of high-quality complex workpieces in small batches: tapered bends, edges that are not parallel to the deformation line, processing stations and so on. With multi-axis backgauges, these and many other complex processes can be carried out more easily. Off-line programming On other words: standardisation. Being strictly linked to the human factor, bending efficiency depends on the skill and experience of the operator, as well as the quality of the machine used. Where the company has a high personnel turn-over or a growth in volumes that must also be supported by an increase in personnel, the use of CAM can be extremely useful in bending. In fact, in this case the know-how and experience of an expert can be “spread” over the new recruits in a short time, bringing great benefits to production. User-friendly numerical control In any case, even if there is no off-line programming, numerical control is the main tool that allows even unskilled press brake operators to interface effectively with their machines in a short time through a clear, simple and complete interface. When the start-up time of a new machine is longer than expected, the problem is often due to difficulty in understanding and controlling an unclear system, which can create problems for operators, regardless of whether they are expert or inexperienced.
A press built to the highest standards, with numerous process parameter checks and alarms to warn when any of them drifts is able to maintain a consistent level of bend quality, but there is much more to be considered. The spring back variable Let’s look at sheet metal bending: it’s a material with many variables: bending response to laser cutting, plasma cutting, size tolerances and so on. Whenever you have to tackle a different workpiece, you also have to think about aesthetics if you are dealing with materials such as pre-painted sheets and steel. For those working with the press brake, everything has to do with the ever-present forming variable: spring back. This is a variable that occurs when the material attempts to return angularly to its original shape after being bent. Tensile strength, material thickness, tool and press brake type naturally all affect spring back. It is essential to predict and evaluate spring back effectively, especially when working with tight bends, as well as with thick, high-strength materials. Laying out workpieces for bending The material normally deforms during bending. The length of the workpiece to be bent is naturally not the same as that of the axis of the bent workpiece. The axis that retains its original line (known as the neutral axis) shifts towards the inside of the bend, and its position depends on various factors such as the sheet metal thickness, bend radius and material quality. These are the factors that can be used to establish the layout of the workpiece to be bent. The tools Many types of press brake tools are available, such as radial, gooseneck and bending/flattening tools, for which the load limit becomes a decisive factor. There are two limits to consider: the limit that the tool itself can withstand, and the load limit at the centre line of the press brake. When it comes to tools, take great care to choose the correct tool and consider the load that the tool can withstand. Work is often carried out at the tool load limit, which risks damaging the punch and die. To avoid damaging tools or even worse the press brake, always observe the load limits. Cleaning Dirt particles can enter the hydraulic circuit if it's not sealed properly, so make sure that the tank cover and breather seals are in good condition. The breathers are fitted on the tank cover, and allow air to flow into the tank to avoid creating a vacuum inside when oil is pumped into the cylinders. Dirt in the oil can result in malfunctions and faults in the pump and valves. Most hydraulic circuit problems are related to contaminated oil, which can cause the valves to stick in the “on or off” position. This means that tool cleaning is very important: dust, oil, debris, chips and other material that builds up over time can scratch the workpiece surfaces.
Industry 4.0, the fourth industrial revolution. You hear about it often, but what does it actually mean? It is a change to the production parameters used up until now or, better still, an inevitable and necessary evolution in the way we manufacture in order to improve quality and working conditions. The fourth major change in the industrial age – known as “revolution” for good reason – is taking place through computerisation and system digitisation. In fact, Industry 4.0 refers to a new way of conceiving today's industrial systems, a transformation that affects the structure of the industry as a whole. To be 4.0 involves not only individual machines, but the entire factory system. Innovation, integration, efficiency Transforming a company into 4.0 involves first of all an in-depth analysis of all aspects of its structures, and of its own needs and goals. Every business is first and foremost called upon to understand where actions are needed and feasible and, most importantly, how to structure the change towards the digital world internally. There are three elements in this new way of viewing industry: technological innovation, based in particular on a drive towards computerisation that allows close collaboration between all the elements involved in the production process; integration between systems, between different parts of the company and between the various components of the entire supply chain; efficient energy use, in which consumption reduction is a major consideration. The data above all But where to start? Based on the digitisation process, Industry 4.0 requires knowledge and systematic collection of the data produced; all of the data! This means not just the data from the actual production process, but also data, for example, from handling incoming and outgoing goods, or even from management of resources and relationships throughout the supply chain. In essence, any aspect of company life. When properly managed and shared, this massive amount of information – the so-called Big Data – can be used to optimise resources and reduce waste. All of this results in a decrease in material and time losses for the company. It streamlines processes and work flows, making the business more efficient, with cost savings and therefore a financial benefit. The evolution toward Industry 4.0 also brings new job opportunities. From a professional perspective, over the coming years digitising industries will require specialist professionals with digital skills, figures that did not exist until recently, and greater attention to continual personnel training.
Maintenance is a key aspect of keeping a sheet metal press brake in good working condition, but is often overlooked. Bear in mind that regular press brake maintenance will allow you to identify possible damage and faults that could affect its long-term efficiency. You are well aware that detecting serious press brake operation issues early will allow you to avoid costly maintenance work. Cleaning the machine and carrying out scheduled maintenance is easy, but also requires special care and attention. This guide will show you the daily, weekly and monthly procedures we recommend. In addition, there is a list of procedures to be carried out at least once a year in order to keep your press brake in perfect working condition at all times. Always bear in mind that these are routine procedures; for more serious problems, always rely on our VICLA qualified technicians. Press brake maintenance: preparing the press brake Before cleaning, you must prepare the machine to ensure your safety and that of your colleagues. We recommend the following procedure: At the start of the work shift, inspect the machine and check that the table and die area are free of residues from the previous shift. Delimit the area with barriers and signs. Lower the mobile beam until the tip of the top tool touches the bottom tool. Keep the tools closed until all maintenance work is complete. Switch off the power supply and padlock the main disconnector switch on the electrical cabinet door. Turn the mains switch to the 0 position. The five precautions to take during press brake maintenance. When combined with correct press brake use, scheduled maintenance makes a significant difference to its performance and efficiency. When carrying out maintenance or repair work, always follow the instructions in your press brake maintenance manual carefully. Here is a generic list of precautions you should observe: Do not use solvents and flammable materials Take care not to disperse cooling lubricants in the environment Use suitable equipment to access the highest parts of the machine Do not climb on parts of the machine as they have not been designed to support people When the work is complete, reinstate and secure all safety devices and guards removed, opened or disabled previously Scheduling press brake maintenance Daily maintenance Carry out the following checks at the end of the shift or working day: Check that the safety devices are working. For example, our VICLA press brakes are equipped with Lazersafe devices. They are optical safety devices fitted with lenses that focus laser beams to monitor the danger zone under the beam. The front lenses of the transmitter and receiver must be cleaned whenever you notice any traces of dust, grease, fingerprints, oil, stains or dirt. Remember to check that the three-position down pedal is working. Use a dry cloth to remove all processing residues. NEVER use compressed air and always protect your hands with neoprene or PVC gloves. Clean the tools, bed, supports and backgauge carefully. Do not forget to check any accessories installed on the machine. Weekly maintenance Make sure that the emergency stop button is working correctly. Check that the rear guard is working. Check the side guards. Check the filter clogging indicator. Replace the filter element if the vacuum switch pointer is on yellow. Monthly maintenance Clean the hydraulic pipes and components. Clean the outside of the hydraulic system (manifolds, valves, motor/pump unit, pipes, etc.) at least once a month. This cleaning serves to identify possible leakage areas and reduce the risk of contaminants entering the system when replacing components. It also prevents a reduction in heat exchange between the system and environment. Visually inspect the fittings to ensure that they are sealed, and tighten them if necessary. Remember to check that the hydraulic circuit connections are tight after the first 160 hours of press brake operation. Monthly maintenance of the rigid pipes, especially near fittings, pump and cylinders is important to identify leaks. Consider also the hoses connecting the pump to the system; replace them if there are any bulges. Oil level: remember to check this after any maintenance work on the hydraulic system. Clean the air filter on the compressed air tank. Annual maintenance Clean and lubricate the guides of the mobile beam with a clean cloth every year. Air filter unit with condensate separators. Replace the oil separator micro-filter once a year or when the pressure drop reaches 1 bar. Change the oil in the hydraulic circuit. Clean the tank and replace the filter element in the oil filter. In this guide we have seen how to keep your press brake in good working condition. In fact, a clean machine is also a monitored machine, because damage or small oil leaks can appear at any point. Now that you know what to do every day, every week and every year, you can create a complete maintenance schedule for your press brake.
The importance of knowing how to assess your perfect press supplier. In an extremely competitive sector such as that of sheet metal machines, it's very easy to come across false legends, old beliefs and complete speculation. It is said that: “all that glisters is not gold”, and nothing is more true. Very often, the market is influenced by misleading news and messages that can lead potential buyers to make sub-optimal or even bad choices. Large renowned brands or those that have simply been on the market for a long time are often chosen “blindly” for the aura of “sacredness” surrounding them. But can we be sure that a significant investment, such as that of a press brake, a long-lasting and demanding asset, does not deserve a more in-depth analysis? The characteristics of the perfect manufacturer A manufacturer that can fully meet the needs of a modern company facing today’s stormy market head-on must be: technological. It must be able to manage, and therefore offer, the best applied technology currently available on the market. Simple and user-friendly numerical controls that allow total, interactive machine management, fast, accurate and green motion systems, as well as state-of-the-art safety systems. It is better to be wary of suppliers who only offer obsolete systems in their catalogues. reliable. Your perfect press supplier does not leave the customer alone under any circumstances. The perfect supplier provides support to clarify all the customer's doubts: support that is ready, available and provided by extremely competent personnel is among the most important ingredients to prevent unnecessary and harmful downtime. This is because even the best machine in the world can have problems, and they are not necessarily related to its quality. Sometimes external factors can also affect press brake operation. available. A manufacturer offering standard machines or machines with few customisation options are rarely able to meet customer needs: even more so in a context like today, in which almost all orders are for special parts, in small batches, of high-quality and with a quick turnaround. It is not acceptable to spend large sums on a standard machine and then realise that it's unable to perform many jobs. You need versatility and flexibility when choosing, designing, and then using. near. Or better: “close”. We do not mean physically close: the closeness of a supplier is measured in its willingness to open its doors and listen to potential customers, and to accompany them through all the stages of making the correct choice. Understanding customers’ core business together, knowing how to explain the solutions that are right for them and how they work: this is closeness, because the perfect supplier cannot take anything for granted. Potential customers, even the most expert, are not press brake manufactures, so they may not be aware of all the aspects to be assessed at the configuration stage. That is why the perfect supplier, besides being able to offer the most suitable technological machine, must also educate customers about it. In short, buying a seemingly banal machine like a press brake is not at all easy. The perfect supplier is one that lets customers make the right choice and offers the best solutions… and know how to explain them!
The k-factor is fundamental in the press-bending sector and is closely linked to the concept of spring back. It is also known as bend allowance and serves to calculate the sheet metal layout. Knowing the k-factor formula is essential in order to bend any kind of sheet metal correctly; in fact, it varies according to the type of material to be deformed. What is the k-factor? The k-factor indicates the behaviour of the material being bent and how it reacts to the applied tensile and compressive stresses. In essence, it's nothing more than the ratio of the sheet metal thickness to the neutral axis, i.e. between t (distance between the inside of the bend and the neutral plane) and T (the workpiece thickness). What is the neutral plane? The neutral plane is the ideal area that does not vary during bending, and neither shortens nor lengthens. Do you want to know more about the neutral plane? We have written an article that goes into this topic in more detail. Broadly speaking, we can say that in the vast majority of cases the neutral plane lies at about 1/3 of the thickness from the inside, so it is 0.33. E.g.: a thickness of 30/10 will have t = 1 mm, so 1/3 = 0.33 = k Nevertheless, there are cases in which the neutral radius tends to shift towards the centre, i.e. when the ratio r/T > 1 Where r is the inside bend radius and T is the thickness. K-factor formula for sheet metal The following formula is used to calculate the sheet metal layout: k = log(r/s)x0.5+0.65 In any case, this table provides a set of values that can be used once you have the right inside bend radius. Sheet metal k-factor table 0,65>r/t<=1 k=0.3 1 k=0.35 1.5 k=0.4 2.4 k=0.45 3.8 k=0.5 What affects the sheet metal layout? The sheet metal layout generally depends on factors such as: the material, thickness and dies used and, to a lesser extent, the punch radius. All of these components affect the inside radius to varying extents. The natural consequence is that, the larger the radius, the smaller the layout, and vice versa. Let’s now look at the main factors that affect the sheet metal layout: 1) The die width: a wider die creates a larger radius than a narrower one. 2) Bend type: another aspect that is often ignored is that the finished workpiece dimensions vary for the same die, material and thickness, depending on whether air bending or bottom bending is used. In fact, the latter creates a smaller radius and therefore requires longer layouts. Special consideration must be given to coining. It is the only method in which the inside radius is the same as the punch radius, so the layout depends on the punch radius alone. 3) Punch radius: as already seen, the punch radius in standard conditions (therefore not with special bends that require the use of tools with very large radii) should be about 2/3 of the inside bend radius. This is because, to a lesser extent, this component also tends to create differences in the dimensions of finished workpieces. Bending medium thicknesses with a punch radius that is too small (e.g. r of 0.8 on a thickness of 50/10) not only creates unsightly grooves on the inside, but also causes more material stress and an unnatural curvature. Sheet metal k-factor: how to lay out a metal sheet Workshops use various techniques to find the layout. There is now a tendency to rely on the many software packages on the market, but the corrections made may still be based on empirical methods developed within companies. Now let us look at some of the methods used by operators. Experience-based tables: these are obtained by noting the compensation added to layouts in practical trials. Compensation values: this involves adding compensation values corresponding to a percentage of the thickness to the inside bend measurements. DIN tables: these are tables that provide values to be subtracted from the outside dimensions of the bent workpieces. Geometric calculations: by applying the k-factors obtained from the formula seen above or by using the example grid values based on r/t. Forcing the radius and changing the k-factor: this is an approach used by designers and draughtsmen who use 3D modelling software. Percentage method: this is a widely used system. It involves initially simplifying the inside radius of the alloy based on the die and material, and then entering the k-factor from the table. Now that you know what the k-factor is in detail and how to calculate it, you can accurately determine the layout of the sheet metal to be bent.
Just saying 4.0 is not enough to have “the” press Some manufacturers try to anticipate the changes, exploiting the fact that press brakes already have certain characteristics that take them in the direction of Industry 4.0 parameters, but they clash with the discordant opinions of others who say that “Speaking of Industry 4.0 in this sector is undoubtedly more difficult if we compare it with laser cutting, punching and panelling.” So let’s look at what characteristics make a 4.0 press: CNC directly connected to the company network with programming from the office; high level of safety equipment; remote support; direct connection with the company ERP. Press brake and tools When it comes to bending sheet metal to give it a custom finished shape for the specific application, the accuracy of the finished bend is essential: if the bends are not made accurately, then the final product will simply not be correct to the drawing. This is a particularly relevant scenario for users that bend complex parts, in which even small inconsistencies during the bending process can ruin a whole batch of parts. When it comes to tools, it's very important to choose the correct punch and die combination, and to assess the bending radii and capacity of the tools. However, numerical control can check the choices made and warn if they are inappropriate, as it's already configured with the specifications of the main tool manufacturers. The force of sheet metal An excellent bending result without wasting material, however, does not depend on the press alone. Industry 4.0 standards or not, it's necessary to consider that steel is a living material, which bends in a specific direction but requires special attention to its spring back and, consequently, to the force used during bending. For those using the press, spring back is a variable that occurs when the material attempts to return angularly to its original shape after bending. However, spring back can increase very significantly as the inside bend radius increases in relation to the material thickness. New high-strength steels, for example, exhibit greater spring back than basic mild steels, some stainless steels and many types of aluminium. Cutting costs and increasing accuracy of the press brake In addition to the ecological and energy-saving aspects, the most obvious benefit of using 4.0 press brakes is that they can be integrated into factory IT systems in order to manage the entire production process in a modern and increasingly automated way. Electric press brakes eliminate the need for hydraulic oil and can reduce energy costs. Greater efficiency has helped to stimulate manufacturers’ interest in electrical and hybrid designs. For many of them, peace of mind comes from knowing that their press brakes will produce bends to precise specifications without the need to adjust for changes in oil temperature, which is more than enough reason to switch to an electric or hybrid system. For others, the frustrations they have endured due to imprecise bends, such as unnecessary costs and stress, are a reason for pushing toward Industry 4.0. In simpler terms, hybrid and electric bending presses can help manufacturers dramatically simplify downstream operations, saving time and money while increasing customer satisfaction. Accuracy and energy savings are therefore driving manufacturers to invest in hybrid press brakes, which require much less maintenance because they use significantly fewer valves and less oil, or electrical press brakes, which are completely oil-free. Choose your next press carefully: rely on the experts!
There is one thing in VICLA that nothing could break or bend. It is our system of values based on the principles of maximum efficiency and utmost attention to detail. Each machine leaving the factory is in fact manufactured by merging all the creative capacity and typical innovation of Made in Italy with top sector professionals and engineering skills. This results in extremely strong, stable, ergonomic and precise products. Starting with the VICLA flagship product and technological and innovative gem, the hybrid press brake .SUPERIOR or .FIRST compact bending press for small and medium-sized bends, up to the .DIAMOND guillotine shears manufactured to guarantee extremely precise cuts. Use of the best Italian and European parts completes the circle of our inspirational philosophy to obtain maximum quality and efficiency. This is why our company has a long-standing collaboration with the Swiss Hoerbiger Group, a world leader in the production of parts for sheet metal machining and in the sectors of compression and drive technologies, production of hydraulic systems and numerous mechanical engineering applications. A partnership for our clients that guarantees utmost levels of reliability and state-of-the-art technical equipment. State-of-the-art technology used by VICLA Hybrid System as standard on the .SUPERIOR press brake: this technology is offered without additional costs compared to traditional machinery, and ensures considerable energy savings (55%), and a significant reduction in oil consumption, risk of leaks (70%) and pollutants. Qualities that make the entire production system highly efficient and increases productivity by 20%. This is just one of many examples of the style and philosophy behind the VICLA brand, a way of working that has proudly brought us satisfaction and recognition. Last but not least is the great commercial and marketing acclaim received at the prestigious Euroblech 2016 international fair in Hanover: the world's number one event in the field of sheet metal processing, where we were the protagonists. In terms of turn-out, image and gratification. Find out how to choose your next press: rely on the experts!
Software 4.0 integrated into VICLA press brakes can increase company performance by at least 20%. The world of press brake bending is moving increasingly towards interconnected and automated production processes, and Industry 4.0 is certainly changing the way we work. That is why VICLA press brakes come with software to help collect, analyse and improve the performance of your company. We have always focussed on innovation, and this led us to integrate advanced solutions for the smart factory when developing our range of press brakes. Let's look at the solutions. Why choose a 4.0 press brake Press brakes have undergone an incredible evolution in recent years, transforming them from simple bending machines into truly technologically advanced and complex systems. And, while this has allowed the most modern companies to equip themselves with efficient, high-performance press brakes that improve production, more traditional entrepreneurs, accustomed to old press brakes that are no longer fully functional, continue to mistrust and fear innovation 4.0. Let’s take a brief look at how a 4.0 press brake can significantly improve production in your company and why: A 4.0 press brake is a smart machine: it can store and use huge amounts of data to continuously improve production. The CNC is connected directly to the company network and programmed by the technical office: the benefit of remote programming is that it considerably reduces downtime and guarantees full control of bending collisions. The high level of safety equipment: a 4.0 press brake is equipped with technologies and devices that reduce variability and dependence on the human factor, as well as the risk of accidents. The devices installed on our press brakes protect operators without limiting the working speed. Later we will see how our press brakes combined with software 4.0 can help you increase your industrial production by at least 20%. Data Rec and Track Prod software: software 4.0 for VICLA sheet metal press brakes Our press brakes all come with software 4.0. Already mechanically robust and tested, all VICLA machines come with our software 4.0 to communicate with the company management software in order to provide data that can be used to optimise the entire production process. We have already seen what a 4.0 press brake is; now we will see how our software increases company performance by at least 20%. The first of the two tools is Software Data Rec It features functions to: acquire data from the machine and enter it into an SQL or Access database; provide detailed information for job scheduling: e.g. workpiece production times with manual, semi-automatic or automatic processing; access time data related to programming, tooling, testing the first workpiece, workpiece processing. The second is Software Track Prod This software can: Monitor, display and trace data in the company management software and enhance the entire production cycle. Acquire information, analyses and reports in order to optimise machine use Identify critical conditions: an Alarm History provides a report of the messages sent by the machine. These two programs can then analyse the production flow in real time and detect any critical conditions so that you can act in real time to correct, reduce and eliminate errors. The great benefit of this software is that it promotes an approach based on data analysis by operators and the company organisation, which can lead to significant production performance improvements. In fact, our customers can testify that their company performance has been improved significantly by optimising production processes and reducing waste.
If there is a versatile machine in the workshop, it's the press brake. There are hundreds of variants with different performance capabilities, but all have a recognisable architecture. It might seem to be a simple machine made up of relatively few parts, which performs a simple, even trivial, process. Nothing could be further from the truth! A good press brake in the hands of a great operator can create real works of art. In the hands of an inexpert operator, on the other hand, it risks becoming the root of big problems. However, it should be noted that experience alone will not prevent mistakes. Often, even experienced operators can have bad habits or insufficient awareness, or can underestimate risks, resulting in damage of various kinds. In practice, here are five mistakes to avoid with your press brake: 1) Neglecting cleaning What many consider to be a mere waste of time is actually one of the primary procedures to be carried out as standard practice. A clean machine is also a monitored machine, because damage or small oil leaks can appear at any point. 2) Not carrying out maintenance Operators must not only be able to bend, but also to take care of those aspects of their machines for which they are responsible. No company expects press brake operators to know how to disassemble and reassemble a press brake. However, operators should be responsible for all aspects of normal lubrication, proper cleaning of moving parts, and reporting any anomalies, even the smallest. 3) Attempting to bypass safety systems A rather burning topic, also because those who violate the minimum safety rules usually have a wide range of excuses to justify their actions. In reality, today's safety systems, such as the widely used multi-beam photocells, can be considered quite mature. There are no longer any excuses: the systems anchored to the machine beam no longer impede the process, unless they are not set up correctly. What’s more, nowadays modern systems are difficult to bypass. If an operator must raise a photocell because of some workpiece with a complex shape that cannot be made in any other way, they must be aware that the working speed cannot exceed 10 mm/s by law. 4) Concentrating forces in small areas One of the most common misjudgements is to confuse the total force needed to bend a given workpiece with the tons per meter for the specific thickness, material and die. When, for example, bending a 15 mm stainless steel bracket that is 100 mm wide using a die with V = 100 mm, the total force required would be about 26 tons. However, even though the machine has a much higher capacity, a similar force concentrated in a small area can not only ruin the tools, but even deform the machine structure. That is why the force to be assessed in order to establish whether the processing is feasible must always be expressed in Tons/m! 5) Using the machine improperly It will seem obvious to most, but the press brake is made for bending. In addition to the problems already mentioned, which can result from underestimating the tonnage per metre, there are those that arise when operators use the press brake improperly. For example, using the bed as if it were an anvil for fixing badly-made workpieces or for processing other than bending that involves excessive stresses, such as straightening, drawing with home-made dies, etc. Problems can arise even when urethane dies are used brutally, expecting them to perform a 90° bend in one stroke, dangerously stressing the proportional valves as they rise and wearing the tools out quickly. To these we could add many other misuses that, besides damaging the machine, can also cause serious injuries to the operators. So, press brakes are among the machine tools that are most subject to interpretation during use, leaving room for the imagination. It is up to operators to respect them and take care of them in order to extend their life and efficiency.
The importance of having the right equipment to achieve great results is often mentioned. In this case, it is not just the quality of what you have that is important, but how you use and look after it is also essential. In fact, improper use and poor maintenance are factors that will demolish even the best equipment over time. That is why, when it comes to press brake bending, you have to remember that a machine is to the operator what a winning horse is to the jockey. Looking after your press brake is a duty that, however, makes it a pleasure to work with! But what are the best practices for looking after your machine properly? 1) Know your machine technically Managing your press brake properly and taking care of it is undoubtedly the first step in making it last a long time. 2) Lubricate the machine correctly and consistently The press brake is an orchestra of moving mechanical parts conducted by electrical and electronic systems. It is extremely important to follow the manufacturer's specifications carefully regarding lubrication frequency and the location of the lubrication points. Proper lubrication also means using high-quality greases and oils, chosen exclusively on the basis of the manufacturer's specifications. The points that require lubrication include: the beam sliding points, the rear carriage and any bending supports. If there is a centralised lubrication system, check it methodically. 3) Clean the machine A clean press brake is not just beautiful to look at, but is also efficient! Usually, you can only see oil leaks if the machine is perfectly clean, even small ones such as seepage from the cylinders, or abnormal drips in the backgauge area or on the floor inside the machine. Proper cleaning means following the manufacturer’s specifications and not using aggressive detergents or other unsuitable products. In addition to this, take great care to avoid cleaning the optical scales improperly! If in doubt, contact the manufacturer. 4) Generally check correct operation and settings A press brake is composed of many moving parts, including some large ones. These large masses are actuated repeatedly for millions of cycles in a year, with extremely tight tolerances. Just think of a beam that weighs thousands of kilograms: during each cycle it is “dropped” and then braked to slow it down in just a few tenths of a millimetre. It is taken to bottom dead centre (BDC) with an accuracy in the order of hundredths of a millimetre, and is then raised for the next bend. Inertia, vibration and continuous stress can wear out some susceptible components over time. Operators who work diligently must also be diligent in relation to their machines, and immediately report any kind of anomaly, even the smallest. Only they can recognise the signs of potentially much larger problems that will harm the machine and production. For example, small gaps in the backgauge or poor positioning accuracy. Obviously, the first step is to choose a manufacturer that is able to make high-quality press brakes in order to eliminate almost all of these kinds of problem. 5) Keep the tools and bed clean Keep the mating surfaces between the dies, punches and machine clean. In fact, when bending materials such as carbon steel, or when stainless steel has small slag balls in the corners of the holes and edges caused by an imperfect laser cut, these residues often end up on the press bed. If they are not removed, they can score the supporting bases, which may compromise optimal bending over the years.
VICLA press brakes are made based on strong features: frame sturdiness, maximum efficiency, and outstanding bending accuracy. For top quality that is also expressed through the most advanced and innovative technical solutions. An example of such a solution is 3D PROV, programming software for preparing and processing 3D products that offers multiple benefits. Such as the use of automated systems that can speed up the management times of the entire process (from design to finished product), minimum downtimes thanks to the offline programming feature, fewer discarded pieces thanks to collision control during bending sequence, tool library compatibility that allows for checking the availability of the tools required for production. Some of the main features of the 3D PROV are: Direct import from SolidWorks, Solid Edge and Inventor; Import and development of 3D parts in IGES and STEP formats; Automated and manual setup based on the type of material, machine and tool properties; Automated and manual bending sequence with collision control; Automated and manual calculation of retainer position and ledge with interactive graphical control on all axes; Automated calculation of retainer retraction; 3D simulation of the bending process with collision control; Detailed report on machine setup stations, also including bending sequences, used tools, graphical information, and bending specifications. The 3D PROV programming software ensures maximum efficiency in tool selection, based on bend radius, maximum press brake force, collision control, and the availability of different tool types and splits. To make the machine even more efficient, you can have full control over the hemming process, because the software allows you to set the default tools for automatic recognition as well as the pre-bending angle (default and editable value). 3D PROV can also calculate the bending parameters automatically to avoid any collisions, taking account of the availability of tool splits, horn tools and inward back-bending. Full manual control with split of complete bends into partial bends and the option to set the pre-bending angle and interactive change of the bending sequence order. For retainer positioning, 3D PROV offers automatic and manual backgauge control options with automatic 3D simulation (retainers, tools, piece to bend, machine frame) and collision control with all parts in motion. The software also provides a full setup report, from bending sequence instructions to charts containing detailed information for each bend.
A modern CNC press brake can cut down on maintenance costs while improving the production performances. Over the years, manufacturers have been developing different solutions to improve the performance of their products. Through tools, functionalities and technological innovations sheet metal press brakes have evolved starting from mechanical presses to hybrid cnc press brakes. Recently we have produced two hybrid cnc press brakes to a Russian company specialized in metal and alloy processing for the design and furniture sectors. The need to reduce production costs, create many product prototypes and complete orders in a short time, were the reasons that convinced the company to buy our cnc hybrid press brakes. Scroll at the bottom to read the technical specs of these two industrial press brakes. Let's now have a closer look at the real benefits of a hybrid sheet metal press brake. Hybrid cnc press brake: less consumption and environmental impact In a traditional hydraulic press, a big pump is constantly active, whether the machine is working or not. In this way there is high and useless energy and heat dissipation. VICLA's hybrid system allows the machine to consume energy only when the pedal is activated. This means that the consumption of the press brake is minimum when tools are changed and, in general, during those steps in which the crosspiece is not involved. Low oil consumption is another key point. The quantity of oil used in our bending machines is dramatically low compared to traditional hydraulic press. Small oil tanks translate into many advantages, such as: more savings less environmental impact less maintenance costs A quicker production The brushless engines are directly connected to two small oil tanks. The advantage is that the cnc press brake is more precise and is not affected by temperature variation, as opposed to traditional machines. Moreover, such as in the case of hybrid press brakes that we have recently sent to Russia, the addition of high-tech devices to perfectly control both the bending precision and the structural flexions of frames, allow to achieve unrivaled performances. CNC press brakes: special configuration We recently produced two hybrid sheet metal press brakes for a client based in Russia and specialized in the processing of high-end furnitures. The company requirements in terms of adds-on and personalization included the choice of adding two special devices that control the bending precision and the structural flexions of the frames. See below the detailed configuration of each hybrid cnc press brake. Hybrid CNC sheet metal press brake VICLA .SUPERIOR 50/20 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Hydraulic crowning system managed by CNC Optical scales and high speed photocellls IRIS LazerSafe Tooling set for punches and dies Main power 5,5kW Oil capacity 80l Hybrid CNC sheet metal press brake VICLA .SUPERIOR 110/31 Backgauge with axis X-R managed by CNC Two backgauge fingers CNC ESA 650 Dynamic hydraulic crowning system managed by CNC (Clever Crowning) Management of the structural flexions of the frames (Flex System) Optical scales photocells with double optical path Lazersafe Manual quick system clamping of the punches Tooling set for punches and dies Main power: 11kW Oil capacity 50l + 50l Call us or contact us for more information Now that you now exactly how a hybrid cnc press brake can improve your production, you may want to receive a personalized quotation. Use our online configurator or contact us by filling out this form. Our international team will be more than happy to provide you with all the necessary information you need.
Superior in every aspect, even in terms of power saving, low consumption and environment protection. .SUPERIOR is a sheet metal press brake made by VICLA, able to bend and cut the costs of the entire manufacturing cycle, reducing them to a minimum, while speeding up the production times to maximum velocity. Hybrid System The standard version is equipped with an innovative hybrid system and comes at the same price as a traditional machine, ensuring exceptional power savings and a massive reduction in oil consumption thanks to the use of the double tank. The results in numbers of this technological innovation are: power savings of up to 55%, significant oil consumption reduction (e.g.: 2X40 litres – press of 110 t), output increased by 20%, 20% decrease in fast-up limit, 50% decrease in oil temperature, risk of leakages reduced by 70%, tank volume reduced by 50%, and 50% faster and easier installation. With VICLA Hybrid System, the piping system is reduced by up to 60%. Hybrid System Plus All these advantages translate into greater performance of the manufacturing system and perfect finished products. In one word: quality. Not only in terms of stability of the frame and the bending precision, but also with regard to power saving and environment protection. The Hybrid System is a standard feature included in the standard version of the .SUPERIOR press brake, but the system is however extremely versatile: optional features and accessories or custom-made solutions are also available, depending on every production requirement. Hybrid System Plus: the system that cuts down consumption to 78% compared to traditional machines and to 23% compared to the standard Hybrid System. This is VICLA’s pursuit to ensure absolute quality. Daily investments in research and development, entrusted to highly skilled engineers and staff with top qualification and skills in metal working. Ongoing efforts that show the first evidence of achievement of new and important goals. First of all, an innovative system for automated die change will be shortly completed.
The word “efficiency” is mostly associated to “saving”. Even if the link between the two is real, because a saving - be it a material, energy, time or fatigue saving – is very often the result of being efficient, they are two very distinct factors. Making a system, a production line, a process or just a single machine efficient means being able to make the most of what is available, its features and resources, elements that must work together to give the best possible result on the basis of the goals to be achieved. All this, paying attention to reduce waste. The heart of machine: the work area The possibility to customize a machine based on the specific operative needs of the company that will use it becomes an important thing to improve its production efficiency and, thus, it's competitive ability. Talking specifically of metal sheet working machines, such as industrial presses, the work area is an important element. From this station, machine operations are managed and production flow is set: for this, it is essential trying to ensure the best man-machine interaction, from which a relevant part of the final quality of what is produced depends. Comfort during the working stages and ergonomics of the station are the first two elements one thinks to: they are surely important, but not the only ones to be considered; the following factors are determinant as well: the adaptability of the work area, that allows to safely manage all the processing stages and to smartly pass to different tasks, ensuring in this way the production of different lots - also small ones - minimizing times; the custom setting of the station for an ideal access to tools; machine layout, so as to adapt it to the space in which it will be placed; safety, strictly respecting the relative current legislation. The cornerstones of efficiency In general, in the search for efficiency both generic elements, that is common measures that can be applied to any working condition, and specific factors based on the specificity of any single production or production exigency intervene; so they can differ depending on the situation, even when they interests the same type of machine. In this way, the search for efficiency becomes a real company strategic process that pivots on some fundamental factors (besides what has just been considered): collaboration supplier-user. Being able to understand and interpret a company necessity becomes the pass for new market shares. Starting from the design stage - just think of what has been already said about work area - the comparison with the customer allows to realize custom solutions, able to make a unique product from a standard one and to indulge the user company needs. the ability to look at the market, to understand its trends and, if possible, to anticipate them paying attention to innovation. Projecting solutions that can ensure high performances, energy and resources saving and a reduced environmental impact is part of this ability. relying on expert and certified suppliers. Choosing the right partner determines the final quality of the machine, in terms of material quality, speed in the answer and respect of delivery times, that need to be quicker and quicker. providing structured pre and after-sales able to respond to its customer needs, possibly by offering custom solutions. From planning consultancy to supply of spare parts, from assistance to maintenance, the service offered - on the ground or remote - needs to be professional, precise and prompt. investing in a continuous R&D (Research and Development) that focuses on the most innovative materials, components and technologies. Facts show that this approach is a valid one: the company that could develop flexibility in the management and realization of their machines have been able not only to keep, but also to increase their market shares, even during the long years of economical crisis. Basically, becoming efficient to ensure in turn solutions that make efficient the production process of customer companies.
When we talk about problems in engineering production and, more specifically, of a press brake, we are tackling an issue that represents a huge source of waste. In fact, a given problem can affect several parts of a machine tool and generate others within the entire production flow. In the field of press brakes, we can make two major distinctions, between: problems when purchasing problems arising over time The former are mainly linked to a lack of attention when it comes to its design and construction. In particular, the aspects that inevitably turn into problems are: Lack of structural precision There is no denying that machines offered at cheap prices and which come from countries where quantity is preferred over production quality, cannot boast an acceptable constructive attention. So, among the issues we can immediately encounter on a press brake, there are the poor alignment of the beam and the bed, and the perfect parallelism between the frames. But there’s more: also the perpendicularity of the assembled elements and their respect for dimensional tolerances. All this translates into lack of bending precision. Quality of the moving parts and their management We refer to cylinders and optical lines, but also and above all about the backgauge. In particular, in the latter element you can immediately see the construction quality of the press brake, the speed of the movements, their precision and the speed with which the matching parts are positioned, as well as how they stop. Robustness. It might seem self-evident, but it’s not. Always be wary of press brakes with structures that are too thin. Regardless of whether our core business is focused on making thin gauge parts, it is not acceptable for a single different process to irreparably damage our press brake. Deflections must be compensated for by special systems, such as camber, but they must not be excessive due to an undersized structure. The distortions of the machine, in fact, do not affect only the beam, but also the frames with the opening, the so-called “yawn. Instead, the problems encountered over time are often linked to poor build quality, which comes in the form of: Irreversible distortion of the machine or components It is not acceptable that the structure of a bending press undergoes irreversible distortions, nor that fundamental accessories such as, for example, intermediaries undergo it. When the structures are thin sheets or of unsuitable material, they can yield under not too excessive tensions. Overall unreliability A press brake is only apparently a simple machine. In reality it is an orchestra of components that must be chosen and manufactured to perfection, and which must also last over time. Cylinders, fittings, recirculating ball rails, motors, bearings, encoders: every single part, even the smallest, if it stops working creates a much bigger problem. Scarce availability of spare parts subject to wear or failures The reliability of the components, as well as the availability of spare parts are closely linked to the price of the press brake. What is the point of spending a low sum if the press brake not only breaks down continuously, but is also difficult to repair? The problems of a press brake, even if we refer strictly to the machine and not the supplier or after-sales service, turn out to be the biggest causes of all the waste of money that a company is forced to face. A press brake that does not function correctly could still manufacture parts, but the time spent in constant adjustments and fine-tuning is a bleed of money that no business can afford. Choose your next press carefully: find out what you need to know in the bending manual, which you can find for free below.
The ease of use of the Vicla CNC also for inserting a matrix in the library. The efficiency and reliability of a press brake is also measured by the machine's ability to allow simple and accurate programming of each type of processing. Vicla® presses are designed to offer the best in terms of operator control. This video tutorial shows metalworking enthusiasts how to quickly and easily insert a matrix into the library through programming on the Vicla CNC. First of all, you must select the icon of the matrix list and choose between new designated or default matrix. Let’s say we want to insert a matrix through the second option. Now all we have to do is set the following data: the height, the angle of the slot, the measure of the V, the distance between the center of the V and the side of the matrix, the height of the base, the radius that is detected from the data of the matrix, and finally the load. Now all you have to do is save the entered data and name our matrix. Once back in the library, it will be possible at any time to recall the saved matrix with all its stored data.
SET UP A WORK STATION FOR IMMEDIATE CALCULATION OF Z AND BENDS. A few simple steps to create a CNC workstation on a VICLA® press brake. In this short video tutorial we’ll show you how the operator can quickly and easily create one or more workstations by programming on the CNC. First, access the Tools menu and enter the tool name and the tooling values of the punch and die (initial quantity and length). The position of the tools on the press brake is now established and work station n°1 is created. To set station n°2 just repeat the steps. At this point you can calculate the Z value and set, for example, bend n°1 on station n°1 and bend n°2 on station n°2. In this way you obtain 2 different values of Z.
From VICLA’s CNC it is possible to insert the punch in the list through a few simple and quick steps. Programming on VICLA CNC is simple and intuitive. It is in fact designed to optimize processing times, minimize machine downtime, and increase press brake productivity. In this video tutorial we’ll show you how easy it is to insert a punch in the tools library. First you need to access the punches menu and choose the type of punch you want to insert in the library. From the standard and gooseneck punch, to the acute punch up to the reverse clamp one. For example, if you wish to create a new classic punch, all you have to do is just enter all the punch data, available from the catalogs of the manufacturers, such as height, bend angle and all parameters. Then simply save the recorded data with a name, to add the punch in the library list.
CNC graphics program: VICLA PRESSES ARE EQUIPPED WITH TECHNOLOGIES ABLE TO PROVIDE QUICK AND PRECISE SOLUTIONS.
The scenario is typical of today's market: huge workload, unmatched pieces, very high level of quality required and strict deadlines Everything seems to be going smoothly. The machine bought at a terrific price is turning out to be a real bargain: it folds everything and seems to be having no issues. The operator has finally adapted to the new press brake and his hands run as fast as the wind on the buttons of the CNC. Suddenly the unexpected happens: the operator presses the pedal, the press emits an unusual sound, as if it were unable to stand the pressure. The beam lowers, first aligned, then it goes down on one side. At the same time, a yellowish trickle pours down from the crankcase of one of the two cylinders. The situation is clear: the press brake is broken. The moment in which the damage occurs, you start counting your losses, an activity that bears the name of calculation of lost earnings from lost profit. It is difficult to quantify the waste of money, only after careful analysis is it possible to have a plausible estimate of its extent. It must be said that, unfortunately, collecting data costs time and effort. However, if we do not rely on precise and reliable numbers, we will not have an indication of which ones are the really convenient choices for our company. This is why it is very important to catalog the costs of a machine downtime. Some are intangible and difficult to estimate, but most are absolutely recognisable in a short time, by answering a few simple questions: 1) How much does your press brake operator cost? A bender is usually a skilled worker, so he is not the one with the lowest salary as he creates some type of added value. From the moment this element goes missing, the cost for the company immediately begins to have a certain weight. He could, perhaps, devote himself temporarily to other tasks, but the bending department will certainly travel at reduced speed due to machine downtime. 2) How much does the assistance cost? It depends on whether an agreement has been made with the manufacturer. Often, if the machine is not new, you can turn to the parent company service or to freelance technicians. In any case, there is an hourly cost to be incurred, which obviously increases in relation to the duration of the repair. 3) How much do the spare parts of our press brake cost? And let's add, how easy is it to find them? Their cost is what we immediately see, but the difficulty in finding them immediately extends the downtime, increasing the cost of the first point, and all the others that we will see later. Among the costs that cannot be quantified quickly, but that can have heavy implications, there are what we could define as risks, including: Stress of the adjacent units In other words, it means that the work that the faulty press brake does not do must be disposed of by the other machine(s) present in the company. Often this leads to an acceleration of processes which can increase the chance of error. Or, the need to increase the hours of employees, or add a shift for the entire downtime. All this has an obvious impact on the total cost of the breakdown. Manufacturing outsourcing. Contacting a workshop that carries out our same business could be a solution to temporarily solve the problem of halted deliveries. Obviously the cost of labor will be different, and is added to all other costs determined by the machine downtime. Delivery delays. This is the worst risk that a subcontractor can face, together with the non-conformity of the processed parts. Unfortunately, the consequences of this disservice can be different and depend on the type of relationship with your customers. With some, a late delivery can result in a penalty, which partially or totally affects your earnings. With others it can lead to the end of the business relationship, especially when it has just begun. So, you should always ask yourself how much does a downtime cost? whenever you’re choosing the supplier and the press to buy. It is necessary to look beyond appearances to see beyond the price! Choosing your next press is therefore a crucial choice that will determine your production. Choose the one that suits you best: trust the experts!
THE INNOVATION THAT CUTS DOWN COSTS, CONSUMPTION AND POLLUTION. Superior in every way, also in terms of energy saving, consumption reduction, and respect for the environment. .SUPERIOR is the press brake designed by VICLA, able to bend and cut the costs of the entire manufacturing cycle and to speed up production times. It is equipped with a standard innovative hybrid system, with no price difference compared to a traditional machine, guaranteeing exceptional energy savings and a significant reduction in oil consumption thanks to the use of the double tank. The results in numbers of this technological innovation are: energy saving of up to 78%, a significant oil consumption reduction (eg: 2X40 liters - press 110 t), an increase in productivity by 20%, decrease in fast-up limit by 20%, 50% decrease in oil temperature, 70% less risk of leakage, 50% reduction in tank volume, and 50% faster and easier installation process. With VICLA Hybrid System there is also a 60% reduction in the piping system. All these advantages translate into a greater manufacturing system efficiency and perfect finished products. In one word: quality. Not only in terms of frame stability and bending precision, but also energy saving and minimisation of pollutants. The Hybrid System is a standard feature present in the standard version of the .SUPERIOR sheet metal press brake which, depending on production needs, offers extreme flexibility even in terms of optional features and customised solutions. Such as the Hybrid System Plus: the system that cuts down consumption to 78% compared to traditional machines and to 23% more compared to the standard Hybrid System. Hence VICLA's commitment to endure absolute quality continues. Through daily investments in research and development activities entrusted to highly specialized staff and engineers, with top qualification and skills in metal working. Ongoing efforts that already demonstrate the achievement of new and important goals. First of all, the development of an innovative system for automated die change will be completed shortly. Now that you know about Hybrid System, find out what you need to know about your new press brake: Download the free press brake manual now.
The Hybrid Press Brake is the latest evolution of bending in the current market. Over the years, manufacturers have been looking for solutions to reduce the difficulties of standardization and manufacturing sheet metal parts but bending has many variables related to the material and the environment. Through tools, functionalities and technological innovations bending has evolved starting from mechanical presses, similar in terms of operation to eccentric presses for stamping. They are now completely unusable because they do not comply with current safety regulations and cannot be adapted. Promecam RG, French machines are no longer on the market, with a single central thrust point which raises the bench instead of lowering the crossbar. Hydraulic torsion bar presses, they are apparently similar to today's ones structurally but actually have the big limitation of not having independent cylinders. Synchronized hydraulic presses, evolution of the torsion bar machines, make bending easier and more effective, thanks to superior versatility and precision. Electric presses, in reality not widely used. Hybrid presses, represent the latest evolution of bending on the market. The latter contains the best of hydraulic technology combined with an excellent electronic management system. Hybrid bending machines This system upsets many of the set rules that the operators have firmly rooted in their experience. For example, a bad bending is almost always attributable to a piece of sheet metal with a thickness that is inconsistent and poor quality. But when you finally can rely on millesimal positioning of the crossbar, all the defects of the old technologies used up to that moment come up. The hybrid system allows three advantages that no company that wants quality and competitiveness can give up: Greater precision That translates into not only greater reliability on the single piece, but also into great repeatability. The punch always reaches the same low dead point (LDP) to the thousandth of a millimeter each time with consistency. This is also because the oil handled is much less than in traditional synchronized hydraulic presses. This means that the thermal range during operation does not affect the movement of the crossbar at all. Higher speed The hybrid system allows fast and precise crossbar movements. Even if the speed of execution is not only this, it is above all having to make fewer checks and adjustments on the parts produced in order to streamline the process infinitely, increasing productivity exponentially. Reduced consumption It is also under this aspect that the hybrid system gives the best of itself. When you turn on a traditional press you can easily understand that the energy absorption is huge and constant, because of the hydraulic pump that remains always running. All for an operation that takes place in only few seconds. The actual bending of a piece takes very little time compared to the set-up, handling and control phases. The hybrid system only absorbs the energy it needs when the operator activates the bending press. Although it may be an invisible cost, because it is not seen as a living cost, energy saving is absolutely important. So it is worth buying a bending press with a hybrid system, even if it means spending more than traditional systems. Why? Just read the three previous points and the conclusion is drawn! Find out everything you need to know about press bending. Download the free manual that will guide you on what to look for on your new bending press now.
VICLA announces the upgrade of the 3D PROV with two new, exciting features. The new 3D PROV Software Data Rec and Track Prod for an improvement in business performance. Since its launch in the world of metal working, VICLA has been operating with a future-oriented mindset. Bypassing the production of traditional machines and focusing on creating hybrid products. A choice that, together with the high-quality of the materials and components, has allowed the brand to establish itself as an ambassador of the Made in Italy style. This is just an example that proves VICLA's full adherence to every innovation capable of leading the company to ever higher levels of competitiveness. And to a growing processes automation. Through the implementation of interfaces and languages that promote interaction between operator and machine. Creating value with the use of data that enhance the computing ability of the machines. And again with the use of tools interconnected with physical and digital systems and real time adaptations (3D printing, robots, interaction between machines). All features that are at the basis of the definition of Industry 4.0 within which VICLA fully recognizes itself. In this regard, we are pleased to announce that we have taken a further step in this direction. With the upgrade of VICLA’s 3D PROV, designed for the preparation and processing of 3D products. This regards the ability to install two new features. Software that allow the machines, and the companies that use them for their productions, to operate according to Industry 4.0 standards. The first of the two new features is the Data Rec Software. A tool capable of acquiring machine data and inserting it into an sql or access database. It provides detailed information for job scheduling such as the production times of parts, processing in manual, semi-automatic or automatic mode. Basically, it allows access to the data relating to the programming, tooling, test execution on the first part, and running parts times. The second feature is the Software Track Prod. It offers the ability to monitor, view and track data on the company management program with a valorisation of the entire manufacturing cycle. In fact, it provides information, analysis and reports in order to guarantee optimal use of the machine and a remote control Alarm History. A very useful service for identifying critical issues by simply viewing the history of messages sent by the machine. The new functions of the Data Rec and Track Prod Software therefore offer the possibility of identifying any problem. In order to optimize and minimize them. With beneficial effects on business performance and the processe examination. And all while encouraging the development of approaches based on data analysis between operators and the company organization. A significant number of advantages that represent a revolution in the manufacturing systems of companies that choose VICLA brand for their production. Discover how to choose your next press brake: download the free press brake manual now.
The highly competitive market of our days brings companies to travel the road of increasing efficiency and reducing wastes simultaneously. It is really possible to get the two things? Without any doubt, if the card of technological innovation is played. Today, in press brake sector an extremely interesting system to produce more pieces, more quickly and with a special care to environment exists: it's hybrid system by Vicla. It represents the vanguard and the natural evolution of synchronized hydraulic press brakes that, thanks to hybrid technology, reach performances that were unimaginable until some time ago. It is useful to explain why we talk about hybrid technology: first of all because it puts together the best of hydraulic and electrotechnics, managed by exceptional electronics. Let's see its advantages. Producing more pieces Thanks to the presence of two powerful brushless engines, the movement of the cross piece is fluid and extremely precise. The upper tools distort the pieces with extreme precision and repeatability, and the movements reach incredible precision for a completely new bending experience. How many times, if the bending is not precise, the pin is on materials? Well, with hybrid system by Vicla all the limits of the machines we have always used emerge. Having available such a precise lower dead end makes everything simpler: in this way productivity increases. A quicker production Brushless engines, that are quick and precise, are directly connected to two small oil tanks. This means that the machine with the new hybrid system by Vicla has a simpler but more efficient hydraulics. The oil used to activate the crosspiece is much less than that used in traditional hydraulic press brakes. The result is more precision, since hybrid system by Vicla is not affected by temperature variation, as opposed to traditional machines. In this field, a precise machine is without any doubt the best way to increase the speed of pieces execution. Less consumption and environmental impact In a traditional hydraulic press, a big pump is constantly active, whether the machine is working or not. In this way there is high and useless energy and heat dissipation. Thanks to hybrid system by Vicla, the consumption is linked to the effective use of the machine (which consumes only when it is active). Brushless electrical engines move the crosspiece (consuming energy) only when the pedal is activated, otherwise they are off. This means that the consumption of the press brake is minimum when tools are changed and, in general, during those steps in which the crosspiece is not involved. Another aspect that makes hybrid system by Vicla really green is the low quantity of oil used compared to traditional hydraulic press. Replacement and disposal costs are drastically cut: in other words, more saving and less environmental impact. In the competition dictated by the market, innovating is not an option anymore, but an obligation. And Vicla proposed to innovate thanks to its hybrid system, by offering performances never seen before, new levels of productivity, precision and saving.
Everybody looks for speed at work, which translates into process efficiency. But what does speed mean? A quick press brake is not that which axels Y, X, R and possibly Z are quicker than the others. The speed of a press brake is compared only to the quality it offers to the whole production process. For this, it is important to know the evolution of technology and the limits that have been gradually overcome: this is useful to choose the quickest machine according to what we produce and what is offered by the market. Speed is, therefore, a partial component that can be reached only along with an evolved press brakes' builder and can be overcome thanks to most suitable suggestions for your needs. But first of all, it is necessary to know more about the obsolete technologies that in the past contributed to reach the current standards. If the three-points bending (see bending manual) is about a relatively simple notion, during the years many technologies have tried to get the same effect, that is the controlled approach of a stamp to a mold in the most precise and quick way. Mechanical press brakes It was the first bending press, now it is obsolete. Connected to a flywheel and with a movement similar to the one given by molding eccentric presses, they gave a focused and apparently rapid push. Indeed, with no precision nor adjustable gauges, the speed of axel Y is not enough to really improve the process. Moreover, they were really dangerous. RG Promecam One of the most historical machines, produced by the French company Promecam that doesn't exist anymore. Unconventionally, it worked the other way around (it went upside to fix stampings, rather that downside). Torsion Bar Hydraulic Press Brakes Apparently identical to synchronized hydraulic press brake still used today, they represent their forerunner. The descent of the two cylinders was synchronized by a system of levers connected to a torsion bar. The limits, instead, were often made by two pieces moved by universal joints that shifted the cylinders setbacks. Synchronized hydraulic press brakes They represent the majority of the machine used today. The two cylinders are independent and moved by the action of dedicated valves. They are a great compromise to reach the speed needed. Also, the technology used is established and reliable: since various tools can be added (multi-axels back gauges, graphic numerical controls and many more), it may represent the most suitable technology for you. Hybrid hydraulic press brakes Sometimes called electrical press brakes, they are the natural evolution of synchronized hydraulic machines. In this case there is a very high speed, thanks to the match between a great precision and the technologies just described. The secret is the presence of two brushless engines that directly move two separate small oil tanks. It follows that speed and precision go hand in hand with reduced consumptions. Electrical press brakes They represent a niche because they are suitable only for specific works. They can be moved by belts or by recirculation screws in traction or in pressure. Another aspect, that may not seem to be connected with speed, is its dimension: this is especially important if thinking in terms of workflow speed and not relying on a single machine. This could be the case of who produces the 80% of pieces or more which bending is under 1500-2000 mm. A valid alternative can be relying on a builder that has on the catalogue a very small and speed machine that does most of the work in terms of variety and tools.
The motor pool updating has become a real necessity for all those entrepreneurs who want to keep up with the market. When choosing the press brake, there are many features to consider since the machinery must be compliant with the company necessities and several requirements in terms of efficiency and performance. Press brakes by Vicla have cutting-edge features that, along with an open and settable software, ensure the possibility to answer all the company needs. .SUPERIOR PRESS BRAKE .Superior is Vicla high-end press brake. The study on the structure flexion allowed to design a press brake that properly responds to mechanical stress. One of the advantages of .Superior is the possibility to upgrade it and to add extras also at a later stage. Thanks to the Hybrid System included in the high-end .Superior press brake, the producer allows to use the hybrid system at the same price of the standard one: this translates into many advantages, especially the energy saving (up to 55% more than standard machines) and oil reduction, also thanks to its dual tanks. The parallel shoulders are a feature of this machine that ensure the precision and speed of back gauges. IRIS AND IRIS PLUS Iris and Iris Plus are two upgrades for .Superior press brake that ensure quicker work cycles thanks to the fact that its gear is at zero millimeters from the sheet and the speed is adjusted according to the pieces in working. Iris Plus ensures precision and speed thanks to this feature and the check of the angle ensures optimal results from the first bending. BEING .FIRST Besides the high working speed that ensures the maximum productivity, other remarkable features are the very quick axles movement, its ergonomic design that - along with its reduced dimensions - allows a perfect management of the machine, a led lighting of the work area, it's quietness, the possibility to customize the tool holders according to the customer's needs and many other features that make it safe and very precise. BE .SMART The little .Smart has been designed for a versatile, functional and flexible production. It has a non-active hydraulic convexity and 4 axels (that can be updated until a maximum of 6) and a 250 mm stroke. .Smart is a traditional machine with the technology of .Superior, completely assembled in Italy by using Italian and European components. An interesting feature is that it reduces flexions to the minimum thanks to the dimension of the blade holder. .Smart cylinders are made from high-resistance shaped bars lapped on the sliding part. VICLA SAFETY WORK Vicla is one of the youngest companies in press brake sector and in only ten years has become an important reference point for national and international markets, reaching Europe and Northern America, thanks to Research & Development and Safety investments, also redefining safety as safety work. Its press brake respects the strictest regulations in force, so as to respect all the standards, including legal ones.
There are several laws and safety certificates to be considered both in Europe and outside, because press brakes are a type of machine that involve many laws according to the safety disposal used on the machine itself. Let’s try to understand the importance and the application fields of such laws, but also legislative decrees of who is subjected to suc obligations and how this can help to choose the best in the field of press brakes. The importance of certifications Products manufacturer are the first to be involved in the field of laws and certifications: once identified the press brake, it is important trying to understand if it respects the standards required by rules or laws. In this regard, we consulted the Inail manual (ex Ispesl) for the safe use of press brakes (Caratteristiche di funzionalità e sicurezza dei dispositivi a protezione del fronte lavorativo delle presse piegatrici idrauliche, Features of functionality and safety of devices to protect the working front of hydraulic press brakes). Legislation is made of already operating State laws (in this case we refer to Presidential Decree of April 27th 1955 n. 547 Norme per la prevenzione degli infortuni sul lavoro, Rules for the prevention of accidents at work), as well as European directives that became laws and apply to machines where there is a significant number of cold working of metals machines. Regulations, laws and decrees in Italy The contents of the said Decree are applied to residential Decree 547/55 to press brakes, more in general to Title IV Norme particolari di protezione per determinate macchine (Special protection rules for specific machines) in chapter VI Presse e Cesoie (Presses and shears): 115 says that presses, shears and similar machines must be equipped with shelters or disposals in order to avoid that hands or other parts of the body are hurt by the stamp or by other mobile working organs; according to 117 a slow movement or other similar disposals or expedients to avoid possible dangers must exist; 78 involves the presence of a foot control; 77 involves set in motion controls; according to 76 every machine must have easy-to-recognize and clearly to access start and stop controls. Safety requirements Therefore, the manufacturer must produce machines that respond to essential safety requirements, but we highlight that the document of a technical rule is mandatory only if it is required by a law, otherwise the manufacturer can insert such rule only on a voluntary basis. Later we will see what are the systems and technologies for which Italy and the European Union get busy. Systems: pros and cons Different systems, different pros and cons. What we have just said about rules and decrees actually reverses on technology: as regards the photo-electric barrier, the limitations of use are those of pieces and boxed of small dimensions, the reflection possibility of infrared rays while using mirroring metal sheets or the danger for the operator if s/he fails to set the muting point; while the pros are the high performances, the possibility to operate with barrier both vertically and horizontally and with every type of tool. The advantage of laser systems that moves with the crossbeam is the possibility to work with little pieces and boxed, and the limitation of use regards a higher muting point and the respect of the safety distance only in particular working condition; the danger is in case of stamp replacement. Old inadequate technologies For the monitoring systems fixed to the press brake board there is laser monitoring that, like inconsistent light monitoring (we will see it later), is no longer representative of the state-of-the-art of these machines. The first one doesn’t ensure a complete protection of the dangerous area, it is obliged to frequent adjustments of the laser beam and, in case of uneven metal sheets, the adjustment is difficult to achieve. Instead, the infrared ray of the inconsistent light monitoring can be reflected by the metal sheet in progress and the ray divergence doesn’t ensure the proper Tx-Rx operation.
Previously, we focused on the law to deal with before buying a press brake. Today, we will try to understand the different features it must have to be considered safe by law. The importance of the various stages “During the design stage, the press brake already has to take into account the security integration principle that concerns not only the use of the press on duty, but also the regulation, maintenance, assembly and dismantling stages” the Inail Security Manual on press brakes quotes. So, the best moment to achieve the goals and secure press brakes is – as can be deduced – during the design stage, because during the metal sheet pressing nothing can be left to chance and to reach such goals we start from the premise that the mchine we want to buy and use must be safer than a spaceship. Factors to be considered Let’s start from this: muting and blanking. Muting is about the fact that press brakes are usually designed so that for a stretch of race, the stamp has a certain speed (e.g. 100 mm/s). Later, at a point called “muting” programmed when the CNC is on board, the stamp continues its race at low speed until it performs the fold (≤10 mm/s). This is possible only if the machine has a hold-to-run device and a system with a photocell system device. Blanking, instead, is a feature available for optical barriers: in some parts of the sensitive field they can be disabled. This means that one or more areas of the detection area of the optical barrier are made inactive to allow a part of the performing piece to enter a detection area without activating the protective device. Suppression can be incorporated into the optoelectronic protective device only as long as the safety distance is such as to guarantee that reaching the dangerous area is impossible. Other security points We know that a single post can’t explain all the topic, so here it is an hypothetical list to consider when buying a good press brake: for example, we need to consider the setting of the physical barriers (guards that can be of two types: fixed, at total segregation, that avoid the access to the dangerous area on all sides, solidly fixed to the machine, to another rigid structure or to the ground; and the one called “interlocked guard” associated to a micro-switch made for avoiding the access to the dangerous area during any dangerous movement, if used along with fixed guards) and intangible barriers (that is, safety photocells made of electro-sensitive protection devices that use opto-electronic protection devices active where the operator safety is given by the detection of that part of the human body that enters the dangerous zone and provokes the stop of dangerous movements). And then, in vertical or horizontal position, laser scanner systems, two-hand control, with other body areas to be protected, such as the front, side and back areas of who works with a press brake are just some of the factors to consider when talking about safety of machinery. Designers, manufacturers and safety Designers have to take all the practical measures to ensure that the devices inserted into the designing machines don’t become a danger for whoever assemble, install, keep or make fixings, while the designers, manufacturers and suppliers of press brakes and individual protection devices have legal duties that must satisfy also all the international laws. Indeed, the different control system such as the two-hand one and the three-position pedal and, more in general, all the press brake control systems and the associated safety components (laser, scanner, and so on) have a primary relevance for press brakes. Considering all the features just listed, a greater security will be achieved, even when buying a used product: wide and well stocked and, as we noticed, that every manufacturer has in the company.
Various factors influence fast and precise part manufacturing. With the possibility of remote programming and use of innovative systems for thickness detection, active crowning and angle control. VICLA has qualified, young engineers and technicians working for it. With an open mentality capable of designing fast and flexible solutions, designed for optimal operation of the entire bending presses machining process: from profile to manufacturing of the part. What you expect from an artisan is part precision, fast execution and the ability to group multiple processes in a single machine. VICLA bending presses, from the .SUPERIOR for large-sized bends to the .FIRST, a compact bending press for small and medium-sized formats, are equipped with systems for programming on the machine and from remote. Programming is guaranteed by the numerical control systems on board enabling enhanced quality of the parts, while at the same time reducing production costs and times. Programming from the office also enables the possibility of reducing operator intervention to a minimum, also in relation to difficulties of finding specialist staff. The first step to achieve part production involves drafting a 2D drawing (dxf or dwg) or 3D drawing (iges or Step). The cad/cam system on VICLA bending presses can host 2D and 3D files through a USB interface or a network card and recognises the bending lines and tools to use. This is how the software automatically calculates the profile, thickness and type of material, the development of the sheet metal as well as the bending sequence, force, positioning of the axes and crowning. Perfection of the part and rapid and error-free realisation also depends on other factors, such as detection systems for thickness, active crowning and angle control. Technical prerogatives finding ample use in VICLA bending presses.
Here is a quick tour of the dates and stop-offs in the world of trade shows. Where to find the best in sheet metal processing. In addition of course to the prerogatives of efficiency, stability and precision, in a rapidly growing, competitive market, as is the sector we work in, the quality of a sheet metal working machine is measured above all through the technological innovations with which it is equipped. Innovations which can gain maximum visibility at all the international fairs: excellent showcases and privileged meeting points for those who work in the world of sheet metal, and the industry's decision makers who are looking to discover the latest technological innovations to improve production efficiency. From those related to finished or semi-finished products to moulds, from CAD/CAM/CIM systems to the latest strategies in research and development. For these reasons, the success which comes from participating in a trade show for a brand such as VICLA® is a sign that the company is taking steps in the right direction, giving credence to their day-to-day efforts as they journey towards seamless perfection. Evidence of this can be seen from their last participation in the 2016 Euroblech trade show in Hannover, and that of Lamiera 2017 in Milan, important events that have enabled the VICLA® brand to become known and appreciated by a large number of interested and competent operators. With the view to providing a useful service to all those with a passion for the world of sheet metal processing, here below you will find information on the key stop-off points of the international trade show network. Starting with the most recent event, which took place just a short time ago in Poland from 6 to 9 June: the Mach-Tool Poznan annual trade show, which is one of the largest trade shows in Europe featuring the latest technologies in a wide variety of industrial sectors. Such as metallurgy, casting and welding, painting, hydraulics and pneumatics. The next upcoming European event in chronological order is in the Czech Republic with MSV, the 59th edition of the International Engineering Trade Fair, to be held in Brno from 9 to 13 October 2017. This is the most important event in the sector in Central and Eastern Europe which sees all the major sectors from the mechanical industry taking part and which traditionally enjoys the presence of a significant number of Italian companies from the sector. Event numbers are impressive: 1.500 exhibitors, and 75.000 visitors from 59 different countries. Once again in Europe, from 7 to 10 November 2017, operators in the sector will shift their attention to Stuttgart in Germany for the 13th Blechexpo, the international trade fair for sheet metal working: the only event in the world that deals with the complementary technologies of sheet metal processing and joining technology, an extensive trade fair with a focus on mechanical and thermal joining and connecting procedures, and thermal welding processes. Moving overseas to the USA, from 6 to 9 November 2017, the Fabtech Chicago trade show will be held, America's biggest metal forming, fabricating, tube & pipe and welding trade show, An event that can host over 35.000 visitors from all over the world with over 1.100 exhibitors. Meanwhile, on the other side of the world, in Shanghai in China, from 7 to 11 November 2017 the MWCS will take place, the major Asian trade show in the sheet metal processing industry, with a particular focus on intelligent production systems, digitalised technologies, and flexible, integrated systems. An event that has drawn audiences of over 120.000 trade visitors from all over Asia. We then head back to Europe, once again in Germany, from 23 to 26 October 2018 for the Euroblech Hannover: the World's no.1 for innovation in sheet metal working event, an eagerly awaited date for industry professionals, with a large trade show area devoted to the latest in technology and innovation. The last edition, held in October 2016, proudly saw our brand's participation with the launch of our SUPERIOR press brake, the flagship of VICLA products, on an international stage. It was an amazing success in terms of sales and marketing.
Equip the .SUPERIOR press brake with CNC controlled bending supports to optimise bending of large sheets such as panels or doors. This system increases productivity, halving operator’s intervention. Moreover, since the bending supports hold the sheet properly during processing, the deformation risks are zero. WATCH THE VIDEO
These are input we look for continue whit determination on the progressive innovation way. Today we ask an opinion about brand VICLA to Mr Danilo La Croce from company LMC, Pinerolo (TO), which produce on drawing for third parties, specialized in cutting and bending, going from thin sheet metal to the thicker one. “I found Vicla through the web site” he says, “and I bought a press brake .SUPERIOR 3 m 170 t, equipped whit clever crowning and with the possibility of frontal punch release. It’s a machine really fast. It allows me to go from a configuration to another one in rapid times. We learned to use the machine quite quickly.: a half-day briefing with Vicla technician was enough and then I didn’t have much difficulty. I have read the cnc manual and I learned all during a week, even if some details we will learn with time.” Mr Danilo Lacroce shows enthusiasm also about VICLA services: “it’s a machine built on my specific needs. During the pre-sales moment VICLA gave me all information I needed and I received the machine in the established times. Post-sales service and assistance is professional and complete too.” Thank to Mr Danilo Lacroce for the time you’ve been devoted to us: the opinion who, uses our machine all days is very precious for us.
The best business card for all potential customers of a company is the express satisfaction from who has already used its products or services. About this today we have asked an opinion to Mr Giordano Riva, the boss of CTL – CENTRO TAGLIO LAMIERE s.r.l., company at Stezzano (Bergamo), which is involved in the production of metallic materials for carpentry, plant, petrolchemical and whatever else field related to iron transformation through flat cutting or folding. “I met VICLA through Mr Vittorio Bestetti, great expert about press brake, and in 2016 I decided to buy a .SUPERIOR 4 m 320 t for my company: a versatile machine equipped with innovative technologies.” Says the boss of this north Italy company, who about this add some details: “…we uses this machine from a short time and it’s the first within the company. So to be honest, I haven’t all instrument to make accurate comparisons. I say just that on bases of my past experiences, when I was technical director of other companies, I can assert with certainty that press brake .SUPERIOR is up to a center of services like ours, where versatility and efficiency are indispensable prerogatives.” The businessman has got clear ideas also about technologies: “We chose a machine with base equipment and then we have strenghtened it according to our needs. We are very pleased with Clever Crowning or Hybrid System. We are able to bend all the thicknesses, even from 20 mm, getting the desired results each times.” “Excellent” CTL’s boss continues “is the turning off the engines during the moment of inactivity: this is an important feature because it allows us to obtain great saving energy”. Mr Giordano Riva also expresses his satisfaction about pre-post sales services offered by VICLA: “during the pre-sales period we have received complete and professional information, and then, the full machine knowledge will come with the use. I believe in the innovation and so we have been entrusted with versatility of a young company like VICLA, which is able to innovate.” About post-sales services, he says: “The machine has been delivered to us according to the scheduled time and installed in a couple of days. Some constructive anomalies have been overcome quickly and today the machine is doing its job well. And every time we need it, we can rely on VICLA technicians: rapid answers which allow us not to stop the working.” The use of the machine is easy and intuitive, says the businessman, with whom young, trained and dotated with great will to learn people work, also with the help of CNC ESA of machine, precise and interactive, which allows a good easy to use. Cited merits and benefits. But the superior also has some defect? “The machine is well done. Obviously something you could improve: some building solutions could be optimized in order to improve the exchange tools timing and production.” Thanks to Mr Giordano Riva, the boss of CTL – CENTRO TAGLIO LAMIERE, for the time devoted to us and for his cordiality. In order to know more details about this company which chose VICLA, you can go on the website ctltagliolamiere.it
VICLA offers effective and efficient solutions for press brakes automation thanks to new technologies and last innovation. There are many features of Industria 4.0 used in VICLA machines. And these elements guarantee: great fexibility and rapidity of production short set-up time reducing machine stops and errors in order to obtain productivity high quality. This solution increases the competitiveness of the created products. Other important features are the ability to personalize the warehouse capacity, only use Promecam Style upper and lower tools and the rotation for the inserting of the inverted tool. The Matrix Code also recognizes the features and size of the tool during loading in the warehouse. TOP SHIFT is also equipped by a software realized to manage the communications with different CNC about 4 axes, about warehouse stock, about the information of tools. The software manages the charger set up with total autonomy, charge and edit the programs. The APR robot, for complete automation of bending process through hydraulic press, is another innovation by VICLA, with instrument for pieces with a weight until 250 kg and with the possibility of a manual use. The APR robot follows the press brake linear structure thank to its 5 axes, of which 3 linear and 2 polar, which allow to do easily perform bending operations, overturning and tilting of the piece. The programming of the APR robot is more easy thank to the application on the transducer press directly connected to the robot. This characteristic allows to the operator not to perform any adjustments and to monitor in every moment the bending process through the warning of possible anomalies and preventing the production of faulty parts. There are two monitors for the operator to manage the Antil robot: the touch screen one and the joystick for movements. The software allows to do all picking operations of sheet in a comfort and easy way, with also the possibility to divide the area into little zone of work. VICLA offers Matrix bending cells for completely automatic procedures of picking operations: machines able to work on pieces until 400 kg thanks to laser cut. Among the main characteristics there are reliability of electronics, gear couplings with game recovery which allows the repeatability of placement, a controlled force of the thrust against back gauges, to the advantage of greater lifetime of the machine. The software out of line BendWizard is the brain that manage through a user-friendly, easy and intuitive interface, to certificate an important decrease of stops. The software allows the planning until 4 different cells with bending robot. To complete the range of VICLA’s product, Flexbender and Robot Studio with Virtual controller are the standard and flexible solution realized for press brakes. The Virtual Controller is the platform that shows the same control system used by robot and that allows to simulate robot’s behavior for its movement, working area accessibility, collision and stats.
A perfect sheet metal processing causes the systematic operation of several elements, all necessary to achieve whises performance. In addition to the options provided by the machine, the experience of operator is always important in order to coordinate the workings, but the progress achieved so far by VICLA brand machines enables more rapid and intuitive management. The technologies are really important in order to achieve high level of performance. About this, our main reference is press brake VICLA .SUPERIOR, a jewel of innovation which encloses all secrets to achieving performance at the highest levels of the market. Today we want to name some of the most important. Beginning with all those elements that are fundamental to produce extremely precise bending. At first, we would like to name the Flex System, the innovative system for the management of structural flexions, that ensures the same bending lenght of the sheet. This is a system of which are equipped only SUPERIOR machines: a revolution which underline the excellent relationship between quality/price of press brake .SUPERIOR, as well as a growning commercial success in the national and foreign markets. An other innovation that brings at VICLA’s brand is the availability to apply in upgrade the Clever Crowning Kit: the optional which offer the insurance to a perfect bend also in non uniform material (for example perforated/slotted mixed with full material) and to improve working in workshop. The Clever Crowning kit works in real time in order to avoid manual intervention. Finally for completing VICLA’s bending effectiveness, there’s the piping system reduction: a solution which brings a higher performance and high precision level. The sum of this prerogatives take our machines to a true reference model in the sheet metal working machine sector. The commercial numbers show the truth of this view.
Along with the continuous increase in power and length, the rear mechanisms must keep up the pace. In this case, the .SUPERIOR 6 m 250 ton comes with a Back5 back gauge characterised by a new larger and thicker rugged crossbeam that still preserves its high positioning speed. Rack and pinion system with linear guides mounted directly on the frame of the press, a feature common to all .SUPERIOR presses VICLA's strength points: rear retractable supports mounted to the sides of the back gauges that guide and support the sheet metal until it reaches the contact point, avoiding any positioning errors and eliminating downtimes thanks to their automatic CNC-controlled movement. They also feature a Teflon coating that facilitates material handling leaving no marks on the pieces. WATCH THE VIDEO
The attendance of Vicla at Lamiera 2017 successfully closed in an happyness, coordination and accomodation atmosphere. (that was held at the Fiera Milano Rho from 17 to 20 may). “When i founded this firm I didn’t expect to get here so early”. This is Marcello Ballacchino’s view about VICLA attendance at Fiera Lamiera. He also thinks that Fiera Lamiera was “One of the best professional experience tested till now”. It had been a success based since the early start on a futuristic view: building hybrid machines able to achieve an high energy saving. These machines are really well manufactured as well as they are easy using for the final user. “A bending press”, follows Ballachino, “should fully satisfy the needings of an artificier. This one is not a technician or an engineer but it’s a person which looks for easy and fast solutions for the most common troubles. For achieving the perfection we are hardly working and we’ll continue in this way”. The brand commitment in this direction reached lots of awards, first of all the access at full title in Industria 4.0, insurance of a continuous success market growth and a brand approach on the sheet metal world. VICLA stand space tripled compared to previous editions of Lamiera, signed lots of visits during the whole 4 days. In this show, it reached lots of contacts and requests coming 80 percent from Italy – in particular Lombardia, Veneto, Piemonte, Liguria and Emilia Romagna but also Sicilia, Puglia and Campania – and 20 percent from Foreign Market. VICLA Stand guest star was the best of Albavilla trademark: .SUPERIOR 3 meters / 170 Ton with a wide set of Technology add on – lots of this internally developed – and the littler one .FIRST 1,25 meters / 40 Ton really good for little and medium bendings. “At Fiera Lamiera we showed the best available technology in sheet metal working world”, word of CoFounder Corrado Nucci, “…one of the biggest attractive of the .SUPERIOR, for example, was the ’Hybrid System Plus: an hydraulic system which helps to achieve an energy saving up to 80% compared to traditional system. The .SUPERIOR allows to avoid lots of proportional valves and use few oil, only 9 litres per cilinder. The Machine equips also the angle control, clever crowning, Shoulder control with Flex system: these topics are more and more requested nowadays from the market and should give at our machines high fastness and precision”. The Same success was reached from the compact .FIRST, shown for the first time in an event like this: a really solid machine, compact, fast and accurate that allows to manage little pieces and be placed side by side with a traditional 3 or 4 meters bending press. Visits are also highly appreciated by tests carried out by VICLA technicians at the stand. Practical demostrations have allowed to touch with hand the precision and the efficiency of press brakes Vicla, from easier processing to the more complex ones. To conclude the great teamwork done for the praparation to this important event was the commitment in terms of investments and creativity for studying efficient marketing and communication strategies, “really important instruments for brand affirmation and, in our case, have contributed considerably to increasing a great perception of the brand from visitors” stresses Mr Corrado Nucci. This questioni s a must: What are VICLA’s projects for the next future? “doubling the company shed and so the production resulting with qualified staff recruitment” says enthusuastically Mr Marcello Ballacchino. He adds: “my dream is to guarantee the order evasion to 90 days”. Judging by the speed with which the VICLA brand is affirming in national and international markets, it is easy to keep and hold on to this promise.
The attendance of VICLA at Hanover exhibition in Germany from 25th to 29th October 2016 has had amazing feedback, both in term of sales and marketing both affluence. Euroblech 2016 has rapresented the ideal stage to lay the groundwork to internalization of brand from Albavilla, near Como, to achieve new customers and create relationship with important working people. 1.550 exhibitors from 40 States, 90.000 m2 of exhibition space and 60.000 visitors from all over the world. With these numbers Euroblech has demonstrated once again to represent in a excellent way the best showcase for experts of this sector who want exhibit their innovations about sheet metal working. So German, Indian, Argentine, Swedish, Finnish, Spanish, Russian people have had the opportunity to appreciate the quality and efficiency of machineries branded VICLA®at event number 1 for innovation in sheet metal working in the world. The absolute protagonist of our success has been the leading edge of VICLA: press brake .SUPERIOR. Guests of our stand could touch its quality of precision, solidity and reliability with demonstrative video and bending tests: test to check the perfection of our machinery, result of depth engineering studies which have allowed to ensure a great stability and a extreme precision of bend. In addition to solidity and to efficiency of .SUPERIOR, visitors have particularly appreciated the innovation of hydraulic crowning system – warranty of an excellent structural stability - the great variety of standard components of press brake and its versatility upgrading according to specific customer needs. The choose of an effective communication strategy has been a straordinary contribute for the success of this event. For a so prestigious occasion, it’s important make a good impression. This is the reason why the brand presentation, with demonstrative video and communication equipment for strong impact, has been studied taking care of every single detail. A strategy designed to leave a indelible mark on the memory of who for the first time came into contact with the brand VICLA. And after the success of this special international kermesse of sheet metal working, the VICLA’s thought already go with pride to the next event which will be at Hanover 2018: an event not to be missed to consolidate the brand’s presence and to show the exclusive potentiality of innovation in Europe and in the world. We would like to thank all the people who have helped in the preparation of this event or who, more simply, have showed interest for our products. Have you participated? Send us your comments! For this event we would like you send us a feedback with the aim to express your impressions about your visit: fill the form with your opinion, it will be a special suggestion in order to continue to improve the efficiency and the quality of our products.
25th - 29th October 2016 HANOVER PAV 11 – STAND A166 When there is something new in VICLA our first thought is to tell those, like you, who are passionate about real, state-of-the-art technology. Today, we are delighted to inform you that we will be among the 1,550 exhibitors from 40 countries participating in the International Sheet Metal Working Technology Exhibition which will take place in Hanover in Germany. We will be at the Euroblech Exhibition from the 25th to 29th October 2016 Pavilion 11, Stand A166 Euroblech, Euroblech, International Sheet Metal Working Technology Exhibition, is a leading international event in terms of innovative equipment and services. For the occasion, we are proud to present our .SUPERIOR press brake, the flagship of VICLA® products, a machine capable of guaranteeing extreme bending precision thanks to use of the CLEVER CROWNING hydraulic system, the FLEX device and the considerable stability of the structure; it also comes with the innovative hybrid system as standard. During the prestigious event, visitors will have the opportunity to know in advance the details of the latest VICLA® technology, such as the .DIAMOND shears, the perfect synthesis of creativity, design and innovation, all Made in Italy together with the compact VICLA .FIRST press brake, ideal for bending small and medium sized pieces. VICLA will attend the International Trade Fair for Sheet Metal Working Technology, Hannover!
THE VICLA ATELIER AND HOERBIGER FOR A SUCCESSFUL PARTNERSHIP When dealing with quality and excellence in VICLA we are extremely strict. This is why our management recently choose to sign an agreement in close collaboration with the company that is now the leader in the production of machinery parts for sheet metal machining: the German HOERBIGER Group, a world leader in the sectors of compression and drive technologies, production of hydraulic systems and numerous mechanical engineering applications. A company that has been in business since 1895, currently with 6,858 staff and turnover of 1.115 billion euro. A giant that is synonymous with continuous innovation and high performance parts. This partnership is wholly satisfying and sets the foundation for the production of sheet metal working machines manufactured by VICLA to ever-increasing perfection. Our clients are fully guaranteed maximum levels of quality and efficiency. VICLA and HOERBIGER, together guaranteeing innovation and quality Atelier means a laboratory, where a photographer, designer or artist in general works. In VICLA we offer our services in sheet metal, like a tailor in the fashion industry. Our flexibility enables us to create customised machines made to client specifications. Being more than just a company, VICLA® was set up and structured as an artisan's laboratory, a real and proper, all-Italian atelier for sheet metal machinery. In fact, every single project was developed through a continuous process of listening to our clients' needs, each different from the other. We are not just sheet metal machinery suppliers, but true partners capable of manufacturing products made to measure. With utmost attention to continuous research, quality and the most innovative technologies, in VICLA we have the resources to provide our clients which the most innovative, solid and reliable machinery the market has to offer. The crowning jewel in VICLA lies in its Research & Development department, a highly important strength to innovate and perfect our machinery and find state-of-the-art solutions in terms of the highest quality materials and parts. Our business is this, and much more. In fact, the difference in our sector lies in better structuring of the machinery, with masterful, meticulous and functional assembly of every single part. Today, more than ever, we are also committed to designing high performance products with huge energy savings while reducing waste and pollution. This takes place by reducing the quantity of hydraulic oil and maintenance intervention. Speed and precision are fundamental characteristics of machinery for sheet metal machining: obtain the best in the least time possible, group multiple machining processes on a single machine. In VICLA we work to optimise the entire production system. This is the philosophy which, from 2008 to present day, has led us to acquire a considerable share of the market. In Italy, Europe and North America. Requests are always different. Clients are increasingly asking for machinery to work small, long or complex parts. Following the insertion of two devices, CLEVER CROWNING and FLEX, machining at any level of difficulty is limitless with .SUPERIOR. Our machines are hybrids to better respond to market needs. In fact, we offer the innovative hybrid system at the same price as the traditional system, meaning multiple advantages. First of all, considerable energy savings (55% compared to a traditional machine) and a considerable reduction in oil, also thanks to the double tank.The research and development department designed the innovative HYBRID system, now standard on all .SUPERIOR machinery. Another intuition, the Flex, is an innovative control device for structural flection of frames to maintain the same bending depth independent of the length of the metal sheet. Such innovations have allowed us to offer our services on new markets which are increasingly attentive to consumption, speed and production cycles.The leading models are those in the .SUPERIOR range, starting with the 1250 mm 30 t, the fastest machine, followed by other models, which you can find in the catalogue. Our production is not 100% made-to-measure, since our standard models meet most of our clients' needs. For example, the openings and strokes on the standard models are bigger than those of competitors. Having designed and manufactured high quality machinery, all the machined parts are centesimal and built in a solid structure to guarantee excellent repetition over time and high precision of axis positioning. In VICLA we clearly known that selling a machine is not a conclusive act, but rather the start of a relationship based on loyalty. We want our machinery to always guarantee maximum performance and efficiency and, at the same time, minimise costs. This is why we design special, made-to-measure support packages capable of preventing faults or malfunctions and include a scheduled maintenance plan over time. VICLA is developing new machinery as we speak. We can announce in advance the release of our .SMART range to complete our press brakes and our latest shears called .DIAMOND, however you will have to wait a little longer for its release to appreciate its manufacturing and technical qualities. We promise you won't be disappointed. The most important invention is definitely the FLEX system. Marketing and communication activities aimed at positioning the leading market brand are fundamental elements to value products. We do it all the time, through institutional communications, aimed at B2B through various media: websites, technical catalogues, sector exhibitions, magazines and also through our ever-present sales network available to our clients. For over 2 years, VICLA market shares have been continuously expanding. In fact, we have clients in new markets such as Poland, Spain, Germany and France.Selection of the best suppliers in the sector is one of the main strategic factors to success. This is why, in VICLA, we only collaborate with certified companies, capable of guaranteeing the working times, quality materials and parts at the best market prices. Flexibility and reduced re-supply times are other decisive characteristics when choosing a partner. In VICLA the engine powering everything is passion. The same passion expressed each day and in every phase of every single project, while paying utmost attention to details and the clients' requests. In other words: aiming towards excellence. The framework of our system of values is completed by our attitude of continuous comparison through our work team, both internally and with clients and suppliers. This quality instils a relationship based on mutual satisfaction intended to last over time. We saw Hoerbiger as an ideal partner with whom we could share our vision. Our collaboration began in 2008, the year VICLA was established.We are convinced there is always room for improvement. In a continuously evolving market, the secret to expansion is anticipating where the innovation wind blows. In VICLA we are always open to change. This is what we expect from our partners. One should never stop being curious. Curiosity produces creativity. Creativity is the ability to generate new and useful ideas, solutions to everyday problems. In VICLA we support creativity by attending workshops, themed discussions and brainstorming on a weekly basis. In VICLA we plan our production to optimise work flow. Chez VICLA nous planifions la production afin d'optimiser le flux de travail. Marcello Ballacchino President and Co-Founder of VICLA Corrado Nucci Executive Director and Co-Founder of VICLA Highly trained and motivated staff, an important element for a successful company.
11-14 of May 2016 BOLOGNA PAD 30 - STAND A14 Even this year, VICLA - Sheet metal machinery will attend to “Lamiera”, the most important national exhibition in the field of equipment for processing of sheet metal, which it will be from 11 to 14 May in Bologna. For years it is landmark in this field, more than 18.000 visitors and 350 exhibiting companies in the last edition. Regular visitors are highly qualified and get directly involved in purchase decisions, in the fields mostly involved: steel structures, sheet metal working, automotive, subcontract working, food and packaging, stainless steel processing, aerospace.VICLA staff will be available to increase strengths about the last technologies implemented on the most important press brakes .SUPERIOR Press brakes Superior will be set up with new systems aimed to a market more and more demanding. Eco-saved hydraulic system, the latest generation angle control, Clever crowning and Flex System are some of the innovations which will be possible view at the fair. Stay connected on our social networks.
The innovative Flex system is a dynamic control device to management the structural flexions during the bending and it allows to keep the same depth of fold whatever the length of the sheet metal. The operation is based on the interpolation of data received from two pressure transducers places on cylinders and the deformation read by optical lines. During the testing phase it produces a table where pressure and deformation data are revealed. In this way, without operator support, the CNC receives the data from cylinders pressure sensors, which are interpolated to define the correction to be made in order to ensuring so the same result both bending a long sheet and a short one, speeding up greatly the production cycle.
22 - 24 of March 2016 Stand n° 1121 Toronto Congress Centre Goes on the VICLA Sheet metal machinery exhibition time table, after the great success obtained the last November at Fabtech in Chicago, Vicla will be at north American Trade Show in Toronto with the most important VICLA® press brakes: .SUPERIOR. It will be again the protagonist of the event where experts of this field could increase their knowledge about the machinery obtained by the research, specific attention on details and on the international market. In VICLA® passion moves everything, so Fabtech is the ideal place in order to have a productive comparison with new proposals from all over the world. At VICLA’s stand it will be possible to view Superior Press brakes 170/31 with CNC ESA S660, quick pneumatic clamps system for the punches, Lazersafe Iris system, two retractile arms and tool kit.
9 - 12 November 2015 Hall North – Stand 4150 Chicago McCormick Place 2301 S. Martin Luther King Dr Vicla is going to present the new press brake .SUPERIOR at FABTECH 2015 in Chicago, the space dedicated to sheet metal sector with its 40.000 visitors and 1.500 exhibitors from all over the world. The ideal place to meet importers and exporters, to send products or buy instruments in order to improve the productivity. The North American Trade Show is characterized by the variety of solutions, innovative and with an high technological content, offers by exhibitors. During the four days of fair in McCormick Place, an area of over 51.000 m2, it will be possible appreciate not only the present but also the future of this sector. There are over 100 appointments on the calendar including training sessions, workshop, conferences and special events where important experts will show market trends of the sheet. These appointments are also good networking opportunities both online and off line.
3 - 6 November 2015 Hall 3 - Stand 3103 Stoccarda New Stuttgart Trade Fair Centre Landesmesse Stuttgart GmbH Messepiazza 1 70629 - StuttgartWith pride we are pleased to communicate VICLA is going to be at 12th edition of Blechexpo/ Schweisstec: the international fair dedicated to sheet metal working and to joining technologies, to the thermal and mechanical connection and to thermal welding processes. Here we’re going to present the flagship of press brakes by VICLA: .SUPERIOR. This year the primary German fair will make record numbers. Exhibitors, spread on an area of 90.000 m2, will be 1.200 from 36 countries ( +14% than the last edition) and they will present high-tech services and products also in world preview. More than 40.000 visitors will come from over 96 countries in the world. It isn’t a coincidence if BLECHEXPO is the leader European fair and second in the world among those in the sheet metal sector.