When we talk about tandem press brakes, we refer to a particular configuration that involves the connection of two machines into one, but there are also solutions that combine three bending machines (tridem) or 4 bending machines (quadrem). In this type of configuration, the machines can have the same length and the same nominal bending power or different lengths and nominal bending powers can be provided. What are the characteristics to consider when choosing a tandem configuration? Let's find out together in this complete guide. What are tandem press brakes? When two press brakes are used in tandem, a single CNC controls both machines. However, each machine can also be used independently for added flexibility What are tandem bending machines used for? To bend long profiles, it is not necessary to have a large bending machine. Sometimes it is enough - and much more beneficial - to choose a tandem configuration, because it allows for greater versatility and productivity. Specifically, tandem bending machines can be used in synchronised or single mode. In the first case, both machines can be programmed by the numerical control of the master machine, which sends the signals to the secondary machine, allowing synchronized management with a single CNC. It is crucial that both machines are perfectly calibrated, as any problem on one machine will affect the operation of both. In any case, machine builders already prepare the optimal configuration of the machines during assembly, so if the operator follows all the instructions given during installation, it is very difficult for problems to arise in the future. In the case of separate use of the machines, each machine is independent, equipped with its own photocells and a safety guard. With this solution it is possible to carry out different processes in each machine, with the advantage of optimizing production in the best possible way. In fact, many metalwork fabrication, in addition to the bending of heavy and long profiles, supports the bending of shorter pieces. Moving a huge machine to bend smaller profiles would be costly in terms of time, energy and productivity. With a tandem setup, however, you can easily switch to single mode and operate each machine completely autonomously. So that's one of the great advantages of the tandem setup! We'll talk about the other benefits - and limitations - in a moment, but first we'll focus on some equally important aspects. What processes can be done? Most of the bending that requires a tandem configuration concerns long sheets that require high powers. The processed products belong to the most varied sectors, including: industrial bodywork, trailers, agricultural equipment, aircraft parts, modular spaces and storage solutions. Most tandem bending machines have deeper recess dimensions (e.g. around 1000 mm) in order to allow more agile bending of wide profiles. To enable this, machine tool manufacturers such as VICLA design a larger, thicker and more solid structure that can compensate for the increased stresses that result from having a larger groove. Another interesting aspect is that, compared to a large bending machine, tandem bending machines generally do not need a pit for the lower bench housing What are the characteristics to consider when choosing a tandem? When choosing a tandem configuration, it is important to consider the bending force: it is widely believed that using two bending machines in combination allows you to double the bending force at every point of the machine, but this is a mistake. The total force, given by the combination of the force of each machine, applies only in the case of bending along the entire length. Let's take a concrete example. Let's take two bending machines of 4 meters and 250 tons each. In a tandem configuration, the total force is equal to 500 tons, but only if you are working on a profile that requires the entire length. On the other hand, in the case of a shorter profile, for example less than 4 meters, the total power will be 250 tons! Another aspect to evaluate is the configuration: tandem bending machines allow you to have almost the same customizations as a single bending machine, with one caveat: while, for example, it is possible to have a different number of axes for each machine, the configuration of the stomp and the bench, for obvious reasons, will necessarily have to be identical in both machines. Here is a list of the customizations you can do: Oversized recess Increased stroke Larger opening Intermediate heights Clamps for all types of tools Sheet metal escorts Motorized front supports What are the advantages of tandem compared to using a single machine with the same length and power? When choosing whether to have a tandem, it is important to consider the following advantages: Flexibility: we have repeatedly specified the great versatility of a tandem, but it is worth repeating it once again. Such a configuration allows two machines to be used together or separately, with the great advantage that a workshop does not need to equip itself with additional machines. It also allows you to adapt to business changes effectively, always ensuring future business options. Last, but not least, is the speed of execution: thanks to the reduced size, the bending machines configured in tandem are more streamlined in movements than a larger bending machine and this allows to obtain a fast work cycle. Lower risks: buying a tandem allows you to halve the risks compared to buying a large bending machine, which will be more exposed to the risk of production stoppages. In a tandem, on the other hand, it will still be possible to produce parts on the working machine. Lower ancillary costs: Before purchasing, it is always important to evaluate all the costs related to the new project. How do transportation costs differ for one large machine compared to two smaller machines? Will special permits be required? Will additional foundation preparation work be required for one type of configuration over another? Understanding all the associated costs is the only way to accurately calculate your return on investment. What are the limitations of a tandem? We often talk about the benefits, but little about the limitations. Let's look at some factors that can influence the decision to buy a tandem: We have already said that the versatility of tandems consists in being able to bend long pieces without having to equip themselves with imposing machines that require more space and additional bending at the foundations. However, it's worth noting that a tandem setup still has limitations. One of them is related to the recess: although it is possible to increase the depth, it could still interfere with the bending of certain parts. Another consideration is the cost of the machine. Depending on the case, buying a large car can prove to be more expensive than choosing a tandem, however, the opposite is also true. In fact, a tandem consists of two machines and therefore each component is doubled (two CNCs, 4 cylinders, etc.). This does not mean that a tandem is less convenient than a single car, but it is certainly one of the many aspects to consider when buying. Now let's see what the other criteria are to consider before buying a machine. What criteria should be adopted when purchasing a new machine? Before proceeding with the purchase of a tandem or a large bending machine, it is essential to consider all the variables at play, first and foremost your production needs. What are the processes you need to do? How much do they cost you? What is the level of sustainability in continuing to process the parts through the current production process? These are fundamental questions to pay close attention to. How to achieve higher productivity and save costs? What are the markets that offer the latest products? What are the changes in the production field in recent years? Buying tandems seems like a serious financial solution. Start with a clear estimate of the status of your work and get the answers to questions about how to increase the productivity of your operations and get the most profit possible. Our consultants at your disposal Would you like personalized advice to find the right machine for you? Contact us now.
Let’s further discuss the fundamental aspects that need to be analysed before choosing a press brake. Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends... Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based. So what are the key elements to examine before signing a contract for press brake supply? #1: the Structure The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product. Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles. The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy. #2: the Double Guide The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing. This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced. #3: the Cylinders Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part. VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left. #4: the Hybrid System If in the past there were few types of bending machines, nowadays the market offers different choices: hydraulic press brakes; electrical press brakes; hybrid press brakes. These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system. Be careful, though! It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines. The results in numbers of this technological innovation are significant, as seen on the graph. #5: the Clever Crowning The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well-processed part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length. What are the advantages of this intelligent system? Mainly three: it ensures great results even in the presence of an inexperienced operator; it uniforms the bending angle without any need for operator intervention; it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material). #6: the Flex Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet. Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon yawn and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out. #7: the Back The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities: Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance; Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence; New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength; Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference. Ultimately We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of: reducing operating costs; maximising productivity; achieving the most in terms of processing quality. By doing so, even the end client can count on a standardised and reliable supply.
The press brake is an extremely versatile machine, yet at the same time complex. The technology on which operation is based is only trivial in appearance, however it hides remarkable developments in the mechanical and technological field. In fact, if we compare a modern press brake to one from fifty years ago, on the outside it seems that little has changed. However, the truth is that they are two completely different machines; the external elements may also have remained stationary with the typical design that we all know, but mechanics and electronics have evolved in a silent and inexorable way. Conceptually, between a bending machine from the past and a modern one, there are no changes in the process; both, in fact, share the same purpose: to bring a punch to a matrix up to a certain altitude in the most precise and repeatable way possible. Yet, the modern press brake is the result of constant evolution. Just as happened with cars, which from a simple and almost rudimentary means of transport have become truly high-tech machines, the bending machine is also now a concentration of technological and mechanical innovation. However, both in the case of the car and the press brake, the basic mechanical components have remained the same, but over time they have been improved and refined. To understand the fundamental stages of sheet metal bending and know the best technology that combines efficiency, effectiveness, operating costs and versatility, you need to take a trip back in time and know a little history of press brakes. Among the pioneering countries, there is undoubtedly Italy. In an area surrounding Brianza, businesses have flourished that have enhanced Italian products and continue to do so to this day, within the bending press brake sector. Our country is renowned worldwide for great tradition and quality in the construction of press brakes. Big names like Mariani and many others have literally invented this technology Let’s now take a short journey through the systems that have followed one another, focusing on today’s non plus ultra: the hybrid hydraulic press brake. Press brakes: types and characteristics 1) Mechanical press brakes Mechanical press brakes are still used in many workshops to do marginal work, even if they are now considered to be illegal machines from a safety point of view and, therefore, cannot be used by employees. In the past, the best known mechanical press brakes were Mariani or Omag branded; they were characterised by extremely fast movement and great pressure strength. 2) Promecam RG hydraulic press brakes Originated in France thanks to the intuition of the Italian-French Roger Giordano, RG Promecam hydraulic press brake machines are compact and low. Their most obvious feature is movement of the bench, different from all other press brakes. In fact, if it is usually the upper part - called the beam- that lowers, in this case the bench goes up. Movement is obtained by pushing a central hydraulic system. Simple and very reliable, they have practically made the history of Italian press bending and more besides.To date, they no longer comply with safety regulations as they do not have a speed change point and are not equipped with modern safety systems. They can, therefore, only work if they are adapted with specific kits. They were widespread for quite some time and it is not rare to still find them in many workshops and still operational; in the post-war period they represented a real revolution, as the bench contrasted the natural bending of the beam. The latter, being rather low and compact, allowed large, closed profiles to be obtained, which could embrace the upper part of the machine. 3) Hydraulic press brakes with torsion bar They are the forerunners of the synchronised ones that look very similar in appearance. Movement is via the beam that descends through a pair of hydraulic pistons. They usually have two or three axes: X for the rear carriage; Z for the height of the rear carriage; Y for the descent of the beam. The characteristic of these machines is that the two cylinders are mechanically connected through a bar that couples movement up to the lower dead centre. The latter is regulated through movement of two nuts that lower or lift to adjust the height of the end of stroke of the cylinders and the beam. The machine is controlled by a simple positioner, often without internal memory. 4) Synchronised hydraulic press brakes To date, the synchronised hydraulic press brake is the most widespread modern machine. It includes movement of the upper beam by means of two independent hydraulic cylinders and regulated by appropriate proportional valves. By doing so, the machine is more versatile and allows the operator to work on both cylinders independently to change the descent of the beam and counteract any irregularities of the sheet. It can happen frequently, in fact, that a piece bends more on one side than the other because of the aforementioned variables of the raw material. The numerical control of a synchronised hydraulic press brake is much more advanced than the positioner of the torsion bar press brake. The CNC allows the operator to make many adjustments: from the parking time to the lower dead centre, from the bending speed to decompression. Fig. 4.4 5) Electrical press brakes They represent the latest evolution of press brakes and continue today to be considered a border line solution for some specific needs. They guarantee speed and repeatability, combined with low consumption, however they are less versatile and have much higher costs than synchronised hydraulic press brakes. There are basically two techniques to operate an electrical press brake: with ball screws or by means of special belts. The future of press brakes: the hybrid press brake Synchronised hydraulic press brakes are the breeding ground for technological innovations and improvements with very important results. VICLA has grasped the occasion with much commitment, specialising in hybrid technology. This solution allows the best to be got from the system, combining it and making it into an advanced solution, which is distinguished for: precision; repeatability; energy consumption; quality-price ratio. Millesimal precision VICLA hybrid presses guarantee millesimal positioning of the beam, always ensuring precise and constant bends: all possible irregularities should be exclusively attributed to natural factors due to the variability of the raw material. This surgical precision is possible thanks to use of less oil compared to traditional hydraulic press brakes. Simply think, for example, that a 110-ton VICLA .SUPERIOR hybrid synchronised hydraulic press has a double tank with just 50 litres per chamber (compared to 200 litres used by a hydraulic press brake). Less oil means fewer ducts, smaller tubing, less heat and expansion and reduced clearance and wear. Two powerful electric motors work exclusively and directly on the minimum quantity of oil necessary. Precise repeatability Repeatability is a direct result of the lesser quantity of oil used. Heating litres of oil that flow within metres of tubing causes considerable side effects, first and foremost, loss of precision. This becomes more and more obvious as the machine is used after numerous work cycles and the inconsistency becomes more visible with each bend. Thanks too to a smaller tank, a compact circuit that allows you to have little oil that changes its volume as the temperature changes, VICLA press brakes maintain bending precision on each work cycle. Repeatability is also guaranteed by precision and the constructive sturdiness par excellence. Without these basic qualities, no electronics or new technology could express its real potential. Energy savings up to 78% If we compare the performance of a hybrid bending machine to a conventional synchronised hydraulic press brake, the results are really impressive: energy savings, in standard conditions, are equal to 55%. But even better limits can be achieved: if the standard hybrid technology achieves 55% energy savings, with the Hybrid Plus option, a sophisticated exclusive hydraulic component, energy savings up to as much as 78% are achieved! This is possible thanks to a simple and effective use philosophy: consume only when the press brake is bending. In a traditional synchronised hydraulic press brake. there is always a large three-phase motor that is never switched off, even while the operator equips the machine, programs the numerical control, organises the pieces near the workstation or, simply, looks at the drawing of the item to work. Instead, the highly coefficient motor of a VICLA hybrid press brake only switches on when the operator activates the machine by pressing the descent pedal. It is a huge advantage in financial terms, even in the short term. In terms of cost, the benefit of hybrid technology is even more obvious. This is because, on comparing the VICLA hybrid system with an electrical press brake that however allows energy savings, the purchase cost is still favourable to hybrid technology. But there’s more: electric hydraulic press brakes, especially if they use a belt system, have a very different structure that makes them generally less versatile. In fact, it is impossible to bend particular parts such as hoppers, tanks of a certain depth or chutes, because their closed structure on the sides and the widespread use of casings creates numerous occasions for collision between the parts and the machine. On the other hand, the hybrid hydraulic press brake allows, like any hydraulics, to work even leaving the machine sideways, with greater use versatility.
A CNC press brake is a modern machine for sheet metal deformation. There are different types on the market: Hydraulic press brakes, hybrid press brakes and electrical press brakes. Modern press brakes are operated and controlled by a computer that helps quickly set the specifications of a job and perform production cycles according to different needs, both short and long term. What is a CNC controller? All mechanical components of the press brakes are integrated with numerical control, which is responsible for setting the bending parameters. The most important parameters in the bending process are: thickness of the sheet; dimensions of the sheet; bending angle; One of the many advantages of numerical control lies in the possibility of implementing bend simulations, during which the machine verifies if there are any collisions or overloads. What are the benefits of using a press brake with numerical control? There are many benefits obtained from numerical control programming on CNC press brakes: Speed Precision Repeatability Adaptation Flexibility Agility The main technologies of ESA numerical control ESA 650 and 660 numerical control This version, with colour graphics and multilingual function, allows the automatic calculation of the PMI according to the type of tool and the required angle, and the automatic calculation of the bending force. Optimisation options include optimal bending sequence, and display of any collisions in the sequence proposed by the operator, also carrying out anti-collision checks between the axes and the matrix in the automatic phase. ESA 675 numerical control It is equipped with an ultra-large 21” LCD HD Multi-touch colour screen and integrated Windows PC, which allows drawings to be opened in PDF format or in another format directly on the machine. Furthermore, it allows optimal management of all Cad-Cam 3D. It is equipped with RAM 8 Gb, 4 USB ports 2.0 + 4 USB ports 3.0. Delem numerical control It is a simple and intuitive Numerical Touch Screen control, with a high level of functionality and a user-friendly and modern graphic environment. It is available with screens of different sizes and features customised to your needs. Press brake programming: management of 3D projects Our modern press brakes can be equipped with programming software for the preparation and processing of 3D projects that guarantees multiple advantages. The programming software available on VICLA machines for sheet metal, for example, guarantee maximum efficiency in tool selection, based on bend radius, maximum force of the press brake, collision control, and the availability of different types of tools and splits. It is also able to recognise and automatically manage the flattened bend thanks to definition of the angles of the pre-bend and the inner counter-bends, calculating the best bending sequence, avoiding collisions and taking into account the availability of splits and skids. Although automatic management almost always finds a solution, the operator also has the possibility to intervene manually and change the data set by the software. For positioning of the stops, the software available on VICLA press brakes provides automatic and manual control options for the back gauge, thanks to the 3D simulation that allows you to view all the moving elements, including the tools, the part to bend and the machine structure. Finally, the software provides the complete tooling report, from the 3D bending sequence, including detailed information bend by bend. The report can be printed or displayed directly on the numerical control.
The press brake is a simple machine, while at the same time complex because it is linked to the variability of the sheet metal, which requires each machine to be equipped for different sheet metal customisations. This is why it is important to know the characteristics and the elements to consider when configuring a press brake. We discover the fundamental points to consider: Length The length of the press brake depends on the maximum length of the part to work. Furthermore, if bent per stations, it is useful to consider the purchase of a longer press brake, which allows multiple stations to be implemented. For example, for a sheet measuring 1100 x 700 mm, you are advised to choose a press brake measuring 2000 mm long. Tonnage It is intended as the bending force of the machine. In other words, it refers to the capacity to bend of the press brake. Tonnage depends on various factors, first of all the material: a ductile part requires less bending force; on the contrary, a more resistant material such as stainless steel or high strength steel requires greater force. The other factors to consider are: thickness, length and type of work. It is always worth over-dimensioning the press brake by 20%/30% of the theoretical data, thereby avoiding working at the limit of machine capacity. One of the most common misjudgements is to confuse the total force needed to bend a given sheet metal part with the tons per metre for the specific thickness, material and die. Find out more in this guide. Clearance and stroke Clearance is simply the front opening of the press brake A press brake with a larger stroke is a machine equipped with greater intermediates that allow easier extraction of the bent parts. Locks and intermediates Intermediates are adaptors to insert between the beam and the punches and are very useful because they allow deep box structures to be easily made. The tool locking systems are sub-divided into: manual locks; semi-automatic locks: pneumatic blocks; hydraulic locks; The choice of correct locking is fundamental to reduce the work times and correctly manage the work zone. Semi-automatic locks It is a manual semi-automatic lock with rapid front locking-unlocking system of the punch. Operation is very simple and, compared to the traditional manual solution, allows faster and easier re-equipment of the machine. In fact, by moving the locking lever, the punch is released to remove it from the front; while, on closure, the punch is automatically brought to stop and perfectly aligned. Automatic locks The automatic tool locking systems allow equipping of the press brake in complete safety. The tools are automatically aligned, positioned and fastened. This solution drastically reduces the equipping time and considerably increases production. Automatic tool change for press brakes Today, a modern and innovative solution exist that allows automated change of the punches and matrixes. For example, VICLA hybrid press brakes can be connected to an automatic tools warehouse that allows equipping, even on multiple stations, of higher and lower tools. This system is customisable and designed to measure according to client requirements; it reduces setup by 4 or 5 times compared to manual tasks and automatically performs even the most complex equipping, managing 70 mm wide V matrices, rod holding tools and allowing the tool to rotate 180°. Automation covers everything, including upstream operations. One of the more interesting aspects is programming by the technical office: the CAD/CAM system processes the three-dimensional file, creates the best bending cycle and sends the program to the machine that is automatically equipped, referencing the bending sequence directly on the numerical control. All tooling and machining data are automatically saved at the end of the work and exported to management for a 4.0 key data analysis. Back gauge The rear gauge is a motorised structure on which the references are set and can be moved and positioned to allow a variety of complex bends. Movement of the back gauge along the depth of the machine is called axis X. Vertical lifting is called axis R. References It consists of very important and useful tools to support thin sheets. They are equipped with pneumatic operation and a Teflon coating that prevents marks on the material. They can also be activated by numerical control. There are 2 references and they are usually manual, but they can be automated and controlled directly by the CNC; the positioning of the stops is along the Z axis. Independent tower gauge All towers are equipped on VICLA press brakes with a visual LED stop. Switch on of the LED ensures contact of the sheet with the reference. In more accessorised versions, the towers are: Motorised (axes z1- z2) Independent (axes x2 - x3) Anthropomorphic (axes r1 - r2) Bending compensation The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well worked part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. Thanks to special sensors in the beams, crowning enables measurement and compensates deformations in real time. There is no need to set any data; the system actively reacts to changes in characteristics. Each press brake, despite its robustness, is subject to structural bending, during the bending phase, and obviously the deformations are much bigger the greater the effort the machine has to make. The main deformation is crowning, which corresponds to bending of the beam which is pushed into position by the side cylinders; the other (and for many reasons semi-unknown), is called in jargon “yawn” and is the tendency of the frames to open in the throat zone. Thanks to the Flex system the sheet metal press brake dynamically compensates any deformations based on the effort required: the CNC receives the data from the pressure sensors of the cylinders, which are interpolated in real time to establish the correction to implement. Energy saving systems It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. The results in numbers of this technological innovation are significant, as seen on the graph. Angle control systems L.A.C. VICLA angle control L.A.C. angle control consists of two laser sensors mounted on linear guides that slide to the rear and front of the press brake bench taking the measurement in one or three points depending on the length of the piece. Located on the sides of the matrixes, they have the purpose of reading, through a system of lasers and cameras, the inclination of the edges of the bends during deformation. It is the most complete and performing solution for automatic angle measurement and control. Angle reading takes place in 3 phases: A laser beam is projected on the sheet metal surface The camera detects the elastic recovery of the material The CNC automatically sets the correction suitable to obtain the system desired angle that we use on our VICLA press brakes and is the best you can find on the market. The guaranteed precision is very high and in the order of fractions of a degree. The system is also able to historicize the elastic recovery of the sheets, ensuring a constant and specific self-learning of the press based on the real situation of the company. Obviously the angle control system guarantees the best performance if it is supported by solid and precise mechanics and perfect integration with numerical control. With the latter, there is a continuous data exchange dialogue that allows perfect application with each item being processed. If, for example, for volume issues, a specific bend cannot be measured by the angle control system, it can be linked to the previous reading made on another flap of the same piece. Vicla optical angle control is a safe investment and surprisingly quick return as it makes continuous measurement operations by the operator completely unnecessary with an exponential increase in productivity and quality. Probe angle control There are essentially three types: inserts in the punch, hosted in the matrixes or applied to parallel sliding trolleys the exact same as those of the optical systems and placed on the sides of the bench. On first examination, it could appear a definitive solution, however these are also not without limitations which, in practice, only appear during their real use. The first is without doubt the installation difficulty. This is the typical limit of the controls inserted in the tools that include use of special punches and matrixes equipped with sophisticated, sensor-based strips. Such angle control systems have very poor versatility when you consider they are not usable by changing tool set-ups. Another limitation is their characteristic fragility. Being small and very sophisticated mechanical elements, they are easily subject to failure caused by accidental impacts or malfunctions due to the accumulation of dust and dirt. O.A.C. (Optical Angle Control) Optical control is directly assembled on photocells to capture images of the profile detecting, calculating and correcting the bending angle. One of the most sophisticated optical controls is the IRIS PLUS system. Although it is part of the optical angle control unit, IRIS plus is an alternative solution because it can perform an extremely accurate reading during the bending phase while remaining at a safe distance from the work area. This eliminates any interference between the parts and the angle control devices and achieves totally versatile use. The system, in fact, allows very interesting accuracy and reliability if the emitter and the receiver are not beyond a certain distance. After approximately 2.5 metres, in fact, there is a natural increase in the phenomenon of refraction of light rays that reach the control system which are not sufficiently clear. The noise can be reduced by decreasing the sensitivity of the system but with the consequence of not ensuring the same accuracy in the reading of the bend. Optionals and accessories on the press brakes Bending flattening table The bottom bed has a bending/flattening table in order to perform flat hem bends without the need for a dedicated die. Its versatility makes it the ideal solution for companies that carry out many flat hem bends. The option is built directly into the die holder, and therefore can be used in conjunction with any other die that has a standard connection without the need to disassemble the table. Front sheet metal supports These front supports have a linear guide that extends beyond the bottom beam. Their height can be adjusted and they also slide sideways and rotate. A practical clamp-release system makes them very easy to mount and remove quickly. Metal sheet bending followers They can lift weights up to 380kg. Use of the metal sheet bending followers offers an important advantage to reduce risks for the operator and increase the quality of the bent parts: it was designed to avoid counter-bend effects and reduce the need for other operators. It can also be easily removed from the front and placed on another bending machine. Side parking An extension of the linear guides, extending beyond the bench. This solution is used to park the sheet metal supports when not in use. Wireless 2-pedal foot switch It is powered by an integrated solar panel that allows you to get up to 20% more autonomy from battery life; it does not require connection, nor cable laying. The ultrasonic sensors are located on either side of the lower bench to transmit and receive data wirelessly. Tool locator The system indicates via the incorporated LED the right locking position of the equipment during tool configuration and indicates the position of the active tool in production mode. It is a real and proper visual aid immediately available to the operator who, by doing so, does not waste time measuring and understanding where to position the tool and can dedicate his time to other operations.