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.