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.