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 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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