During the bending process, the machine is subjected to a tension that causes a deformation of the structure and, consequently, also of the sheet metal; to compensate for this kind of stress, the crowning system comes into play. When we bend the sheet metal with a press brake, the upper crossbar always tends to curve upwards. The crowning system lifts the die to maintain a constant distance between punch and die. Without it, the result of the bending angle would be irregular. To put it in a nutshell, in a press brake with incorrect crowning or without crowning, the bending result will have a more open or closed bending angle. For this reason, it is of fundamental importance to choose the correct crowning system for your press brake. What are the main crowning systems? There are several crowning systems, some of which are exclusive patents of very few manufacturers such as VICLA. Today you will discover the three main systems and which, among them, really helps you to achieve perfect folds without having to waste material and money on tests and verifications of the part. If you want to read immediately what it is, you can go directly to the paragraph where it talks about active hydraulic crowning. Wedge-style crowning system The wedge-style crowning system is an adjustment that takes place beforehand and can be modified on the basis of the characteristics of the sheet metal. It consists of two rows of wedges across the length of the bed; one row is fixed and the other is movable; moreover, it involves a series of profiles with different inclinations, characterized by a stronger marking in the center and less on the sides. The wedge in the middle of the bed has a higher slope than the wedges under the pistons, and the angle of the slope decreases toward the ram from the middle of the bed. On one of the sides of the machine there is a gear motor: when activated, the movable wedge creates a curve with the high point at the center of the bed and the low points at either end of the bed below the pistons to create a spline curve in the table. The wedge bench always requires an intervention by the operator; In fact, the profiles, when viewed from the side, show an oblique contact plane that allows the expert bender to adjust the rib and make it localized. This system, while very useful, has one major drawback. With the wedge table, changes to the linearity of the bench cannot take place during bending, but must necessarily be made beforehand. In fact, this crowning system is also called pre-crowning, precisely because the adjustment takes place before starting to bend the sheet metal. Sheet metal bending and crowning: how much do you need to compensate? Compensation is one of the crimper's big pet peeves. While it is true that there are theoretical tables and formulas to calculate compensation, it is equally true that sheet metal is an unpredictable material. It happens very frequently that the theory clashes with the variable behavior of sheet metal. What can be done in these cases? Surely the first step to take is to know all the factors that determine the behavior of the sheet metal. It will help you understand how to compensate for them and not waste time and material on tests and verifications. Sometimes, however, even knowing the material is not enough and the company could run into many problems deriving from non-uniform parts: material cost, late deliveries, high waste. Getting the result right the first time becomes essential for companies that want to remain competitive in the market. Crowning systems: hydraulic crowning Hydraulic crowning is a system historically used by many manufacturers. Inside the bench, in the table that bears the stress and supports the dies, high-pressure and low-flow cylinders are inserted. Like real hydraulic jacks, they push the center of the bench upwards, thus compensating for the deformation of the stomp. The effect you get is the perfect parallelism between the punch line and the die line. With hydraulic crowning, you get a workpiece with a constant bend between the center and the sides. Even in this case, however, it may happen that, due to the variability factors of the sheet metal, the system returns a value that is not optimal. In fact, the numerical control calculates the compensation on the basis of the description of the piece to be produced and on the calculation calibrated to the structure of the sheet metal machine. Linear bends of sheet metal at the first attempt: active hydraulic crowning The only way to successfully manage crowning is to use technology that measures the actual deformation and corrects it in real-time. VICLA, for this reason, can guarantee active crowning, which, in fact, represents the evolution of the system and the ultimate in terms of repeatability and precision. With VICLA's Clever Crowning active crowning system, you can be sure that no matter how different the material is, you will always achieve a perfectly linear crease. How does the active crowning system work? VICLA's Clever Crowning active crowning is a sophisticated and extremely intelligent system that provides for a modification of the linearity of the bench, calculated exactly on the basis of the real need. The press brake, in fact, thanks to special sensors inserted at the strategic bending points, is able to understand exactly how many hundredths of a millimeter the extent of the crossbar bending is. It is no longer a parametric calculation, but a real value that establishes the exact pressure that the cylinders must use to compensate for the bench and achieve the perfect bends along the entire length of the profile. This solution does not require corrections because it is positioned completely automatically, always guaranteeing excellent results. In short, it is a real revolution in the bending process that improves work in the workshop in many ways: you get excellent results even with inexperienced staff, as the system calculates everything automatically; reduce material waste, as the system applies the exact compensation in real time; reduce production times because you no longer need pre-crowning and part checks. All the systems currently offered on the market, hydraulic or mechanical wedge, require corrective intervention by the operator. They are therefore semi-automatic systems, in which the positioning is theoretically determined by the NC but is subsequently corrected by the operator. With VICLA's Clever Crowning active crowning system, on the other hand, the NC measures the changes to be made in real time without you having to intervene with subsequent adjustments. This option is available on the hybrid press brake. SUPERIOR and allows you to achieve exceptional performance. Now that you know how to achieve perfect folds without wasting time and material, discover the other benefits of VICLA press brakes.
During the last 10 years, industries across all sectors have actively participated in a significant shift towards automation, with solutions for every aspect of production, from automated warehouse management lines to robotic bending cells. Robot integration revolutionized the sheet metal bending process on press brakes. Automated press brakes 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, press brake bending cell 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. Automated press brake: how does it work? The sheet metal processing sector is experiencing remarkable technological evolution, especially in the field of press bending. Traditionally, the bending phase has always been considered the bottleneck of the entire process because it is where the most significant waste occurs, both in terms of material and time. Automated solutions act on two fronts: speeding up the bending cycle and reducing human error. The automated bending cell relieves operators from strenuous, repetitive, and unstimulating work, allowing them to focus on other tasks. VICLA automatic tool changer allows machine setup without operator intervention. Programmable remotely or on the machine, it accelerates the bending cycle. Advantages of Robotic Bending In the new smart factory, the programming phase of different processing stages is managed by the technical office, which becomes the true operational center of the workshop. With everything controlled from a single location, the bad habit of having programs in the machine more accurate than the technical drawings or relying solely on the notes of the benders ceases. Reduces Costs By reducing the discretion of the human factor, costs can be reduced. Positive impacts include a reduction in material waste and a decrease in the production cycle (operators can focus on optimizing other production cycles). Additionally, the work of people involved in other areas is expedited. Lifts operators from repetitive, strenuous, and risky activities Another aspect not to be overlooked is the safeguarding of the health of operators who, freed from taxing and dangerous activities, can engage in other tasks. Operators can cease manual handling of large sheets, eliminate the risk of finger crushing during the bending phase, especially for very small pieces, and reduce risks and fatigue from manual tool changes. Improves Job Estimation Automation allows precise measurement of the time, material, and energy required to produce a piece. This enables more accurate quotations and eliminates the discretion of the human factor. How often does one base the price on skilled operators who are not always the same ones producing the piece? Additionally, knowing in advance the timing, energy, and material, the company can make accurate forecasts of costs and revenues for the current year, improving the overall management of cash flows. Robotic Bending vs. Manual Work It is a common misconception to believe that automated bending will lead to the end of thousands of jobs. The same was said of the advent of the PC, but facts have shown that the introduction of new technology tends to have more positive than negative effects. Bending automation will drive the development of human skills. New skills will range from machine maintenance to programming. Thanks to the time saved, versatile figures capable of performing multiple tasks could emerge— for example, a laser cutter or a welder could learn to manage a robotic bending station much more quickly than a manual machine. So, will benders lose their jobs? Absolutely not! A robot can never replace the work of a highly skilled bender, also because not everything can be automated. There are indeed processes so complex that they must necessarily be carried out by the human hand. Control Systems in Robotic Bending: Optimization and Precision As advanced as bending robots may be, they cannot understand if they are working correctly and if the piece is successful. To avoid unpleasant situations where the system worked all night and one ends up with a series of pieces that have errors and inconsistencies, it is necessary to equip oneself with sensors and bending control systems. The first is angle control. It consists of a system of laser readers running parallel to the bending bench. This solution guarantees the set angle without any additional correction. Another useful precaution that ensures the correct positioning of components is the rear register sensor system. Other very useful devices are inserted inside the bending bench and serve to detect and compensate for natural flexions due to the bending effort. Adaptive bending device (VICLA Clever Crowning) Ensures excellent results and requires no in-depth technical knowledge; adjusts compensation without any need for operator intervention; guarantees a perfectly linear bend even on non-uniform materials (e.g., mixed perforated/solid material). Device for controlling structural flexions of shoulders (VICLA Flex) allows maintaining the same bending depth regardless of the sheet metal's length. The CNC receives data from the pressure sensors of the cylinders, which are then interpolated to establish the correction to be made. Limits of Robotic Bending As with any other machinery, it would be wrong to think that a robotic bending cell can do anything. These are application limits that must be known and explored before proceeding with the machinery purchase, so as not to end up dissatisfied with the investment made. Looking at the issue from another perspective, the question to ask is: what factors should be considered when choosing an automatic bending system? What kind of work do you do? The essential prerequisite is that the work is repeatable, so it cannot include prototyping. This is because it makes no sense to invest time in programming a product that will be made only once and never again. If a workshop regularly produces different parts for customers, however, the program can be easily recalled, and it might make sense to invest in a robotic bending cell. Furthermore, to get the maximum benefit from an automated system, it is crucial to ensure maximizing the variety of operations that can be performed on it. What are the best jobs for a robotic bender? Surprisingly, it covers a fairly wide range of applications: repeated high-volume jobs; low-volume jobs that are repeated; heavy jobs can all make sense. Evaluate all costs The cost of an automated system is certainly important, and it is undeniable that, for the same price, one could purchase one or more independent bending machines. However, the significant limitation of this reasoning is that, for each bending machine, an operator is needed. Are we sure the game is worth the candle? When introducing an automated bending system, it is possible to optimize human resources as well. An experienced operator can manage an independent bending machine while monitoring a robotic cell. Organize work and space In addition to choosing the right-sized tooling, a workshop must also consider how the parts will be removed from the cell. Will they be assembled into kits, placed on a conveyor belt, removed via a chute, or stacked on pallets? Decisions like these will influence the length and width requirements of the cell. Always Monitor Production It is a misconception to believe that merely programming in the technical office, hitting start, and waiting for the system to do all the work is sufficient. This oversimplification disregards the variables involved in sheet metal processing. With a traditional bending machine, the operator can manually intervene to manipulate the piece and avoid potential collisions. In the case of a robotic system, the automated bending machine will only perform what it is programmed for, so the tool configuration must be precise. A tool out of place could cause significant damage. It is crucial for the operator of the bending machine to ensure that every part is in its proper position because the robot cannot reposition the part to accommodate a misplaced tool. In conclusion, working with a robotic bending machine requires meticulous attention to detail. 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In sheet metal working, batches are increasingly small, complex and non-homogeneous. More and more efficient technologies are needed, while also trying to maintain compatibility with existing machines and services. This is why Nuova Inox decided to focus on VICLA'S ATC automatic tool changer combined with two .SUPERIOR press brakes. Nuova Inox Srl, based in Rovato (near Brescia, North Italy), is a metal carpentry company for medium-light components. Founded in 1989, the company began with the management of small metal products and immediately stood out for its excellent ability to machine stainless steel, becoming a reference point in this field in just a few years. Nuova Inox has always believed in technological innovation, investing in facilities and auto-mation, it has also implemented a next generation management system which, combined with 4.0 technologies, makes the service qualitatively better with useful information for the customer. The strengths of the Lombardy-based company, which employs around 50 people, are its speed of response to requests, efficiency in the execution of orders, and timely deliveries. The work is based on customer projects which generally require the production of sub-as-semblies of machine carpentry in their vari ous sectors, especially packaging, food and medical, given the Lombardy-based company's specialisation in stainless steel and construction steel. A comprehensive service The entire activity is based on various stag es, starting from engineering, which is the stage where the design of a manufactured article is received in preparation for its real-isation, as Fabiano Fieni, General Manager of Nuova inox, pointed out: The intervention of the engineering department serves to make any corrections to the incoming design with the intention of improving its characteristics, implementing better technical solutions to minimise the time needed for realisation. We are well organised to offer a complete service: after the technical department, there is the sheet metal and tube laser cutting department with different working ranges and thicknesses, able to meet most requirements. Then we have the bending division, in which we have recent ly concentrated our resources. More and more often we are producing small batches. these are not even prototypes for large or ders, they are really components of special machines custom-built by our customer, completely different automatic machines, true unique pieces which are very unlikely to be replicated except in very few examples Nuova Inox's services are completed by the punching, welding, assembly and finishing departments, when necessary, not forgetting deburring, which is also useful for company safety. Compatibility first and foremost The specialisation and care put into production have brought Nuova Inox great success in the market, but have also required careful optimisation of work, especially in the bending phase. The lat ter is particularly affected by both set-up times and the management of a vast number of unique codes associated with each job, including non-repeatable ones. There was a need to reduce the time as much as possible on these components of different lengths and thicknesses: the bending set becomes laborious and par ticularly difficult to manage, due to several consecutive settings and a different bending logic from the standard. With a view to reinforcing the department by purchasing more press brakes, this phase had to be made smoother: We examined the mar ket proposals. The first machines with automatic tool changers had already appeared, but we had requirements which could not be overlooked: interchangeability with our existing dies ( matrices and punches already present in the workshop), the fact of having a single magazine serving two machines and a bending CAM program which could manage the entire fleet of machines in the bending department and, finally, having machines equipped with the angle control device. At the time, our needs were met by VICLA, a company specialising in designing and building press brakes, shears and robotic cells in Italy. We therefore purchased two VICLA SUPERIOR 170 and 250 ton press brakes (3 and 4 metres respec-tively, both equipped with an automatic sheet metal loader and angle control de-vice) and a VICLA ATC tool change system to service both machines Speed and precision VICLA'S ATC automatic tool changer is designed precisely to minimise set-ups when these operations follow one after the oth-er; the system can reduce them by 4 or 5 times compared to manual operations. It also eliminates downtime between one phase and the next, allowing you to go di rectly from cutting to bending the part with out having to wait for traditional set-up times. In the new cell, office programming is now managed, a non-trivial operation in this new operational strategy, which begins with 3D 'solid mathematics and ends with bent products. The VICLA SUPERIOR hybrid press brake represents the top of the range from VICLA: brushless engines with a high energy coefficient, active crowning, flex system, angle control and double guided ram. This family of machines is available in difierent configurations (lengths, pressure forces and controls); all are characterised by an extremely solid structure made of high quality steel, capable of absorbing and eliminating mechanical stress and guaranteeing excellent bending precision. For example, the double guide preserves the stability and perpendicularity of the upper crossbar with respect to the work surface: this allows bending precision to be maintained with different tools and intermedi-ates, guaranteeing that the centring carried out at the test is maintained over time. A value not to be forgotten At Nuova inox we have seen that an operator's decades of bending experience is really an added value: we have seen, General Manager Fabiano Fieni concluded, that not infrequently these professionals are capable of inventing' a equivalent or better bending strategy than the one suggested by the soft. ware itself. But not evervone is such an ex-pert, and so cam programming combined with automation is very useful in routine op-erations, through which even beginners can become productive, indeed, they can take advantage of CAM to build on the results and therefore learn! We have put in place a system consisting of press brakes, stor age, ergonomics, set-up time reduction and safety, without neglecting the 4.0 approach and the tracking of the various steps. We are confident that this set-up in the company will allow us to consolidate our carpentry business through improvement of production capacity. As for the future, we look for ward to automation for welding and finish-ing, always ready to innovate”.
Let’s further discuss the fundamental aspects that need to be analysed before choosing a press brake. Due to the complex nature of the machinery, it is often difficult to precisely pinpoint the elements that can guarantee reliability, robustness, safety, predictability of processing over time, complexity of the achievable bends... Many of these elements are substantially hidden, and this is the most important decision risk factor, because it is precisely on these details that the soundness of the investment is based. So what are the key elements to examine before signing a contract for press brake supply? #1: the Structure The frames are the part of the machine that is assigned to withstand stresses when the bending action is carried out: a weak structure will tend to deform, compromising the quality of the end product. Research carried out over the years on bending of the structure have allowed us to design and build a press brake that appropriately responds to mechanical stress. The frames are cut after rolling the plate: this apparently secondary measure ensures that deformation evenly takes place on both sides, with the benefit of obtaining bends with consistent angles. The parallelism of the frames is guaranteed by processing with centesimal tolerances and allows greater accuracy, repeatability and speed of the back gauge to be obtained. This technical-structural peculiarity eliminates vibrations and stresses, allowing the gauge to move at high speeds, without neglecting positioning accuracy. #2: the Double Guide The guides have the function of maintaining the stability and the perpendicularity of the upper beam with respect to the work surface. This allows bending precision to be maintained with different tools and intermediaries, ensuring centrings is maintained over time as carried out on testing. This is a particularly important detail, because in the absence of this measure, the operating time of the press translates into a progressive loss of perpendicularity, initially inadvertent but gradually more invalidating of the centrings, until it has to be serviced. #3: the Cylinders Cylinders are a fundamental component of a press brake. They can be made from a tubular or rectangular part. VICLA chose to make them starting with a block of forged C-45 material. The upper part of the sleeve has a removable hydraulic block mounted to facilitate routine maintenance operations; the shafts are tempered and ground. The cylinders are connected to the upper cross beam by means of a semi-sphere that allows you to carry out any type of processing, even the most particular such as those requiring different angles between right and left. #4: the Hybrid System If in the past there were few types of bending machines, nowadays the market offers different choices: hydraulic press brakes; electrical press brakes; hybrid press brakes. These machines differ from one another in technology and construction methodology. In VICLA, we have always believed in the potential of hybrid technology. To ensure optimal performance by increasing productivity without compromising consumption, our choice was to design press brakes equipped with an innovative hybrid system. Be careful, though! It is not enough to just add an inverter to call a press brake hybrid; in fact, technological innovation revolves around a specific hydraulic system, which in the case of the standard hybrid model, includes a completely independent dual hydraulic circuit, each equipped with its own tank, motor, pump and inverter. The functional separation of the two cylinders allows optimised control according to the load required for each cylinder; moreover, it allows efficiency to be achieved in terms of energy. It is a system able to minimise wear of the machine by concentrating all its efficiency and automatically balancing the working pressure exclusively on the side that is used during bending of that specific part. A further level of performance is provided by the Hybrid Plus model: the system consists of a brushless motor for each cylinder, capable of providing high forces and high movement speeds. It is an even more compact system consisting of a direct drive motor and pump, installed directly on the cylinders. with significantly reduced piping. It is not wrong to say that the hybrid model is an evolution of the hydraulic press brake. In fact, it is an enhanced and improved bending machine thanks to the latest generation of electro-hydraulic components: This hybrid bending machine combines the best of electric presses and hydraulic bending machines. The results in numbers of this technological innovation are significant, as seen on the graph. #5: the Clever Crowning The greater the length of a bending machine, the more the problems relating to the structural failure of the bench, making it more difficult to get a well-processed part. Over the years, technological evolution has taken giant steps, passing from manual systems (such as using paper shims under the matrix) to automatic, mechanical or hydraulic systems, where a pre-load of the assumed deformation was determined. The limit of these systems is based on a theoretical calculation set by numerical control. VICLA has developed an intelligent system that improves the work in the workshop: the active Clever Crowning system. The active crowning system automatically calculates the thrust force of the bench cylinders, based on the specific sensors detected on the upper and lower beam. By doing so, the necessary corrections are calculated in real time for each bend made, obtaining linear bending over the entire length. What are the advantages of this intelligent system? Mainly three: it ensures great results even in the presence of an inexperienced operator; it uniforms the bending angle without any need for operator intervention; it guarantees a perfectly linear bend even on uneven materials (e.g. perforated/slotted mixed with solid material). #6: the Flex Flex is the innovative control device of structural bending of frames to maintain the same depth of bending regardless of the length of the metal sheet. Each press brake, however robust, undergoes structural flection during the bending phase, and obviously the deformations are greater the more force the machine must use. The main deformation is crowning, which corresponds to bending the beam that is pushed into position by the side cylinders; the other (and in many ways semi-unknown), is what is called in Italian jargon yawn and it is the tendency of the frames to open in the recess area. Thanks to the Flex system, the machine dynamically compensates for any deformation according to the effort required: the CNC receives data from the cylinder pressure sensors, which are interpolated in real time in order to establish the correction to carry out. #7: the Back The rear references are another hidden yet very important element. In VICLA, we have chosen to install references with particular structural technical peculiarities: Mechanics mounted directly on the frames machined with centesimal tolerances and equipped with brushless motors with integrated electronics managed in CANopen for high performance; Transmission on ground racks that guarantee high axis speed (560 mm/s) and positioning accuracy (+/- 0.02 mm): this allows high production cycles, high quality standards, high precision and silence; New gauge composed of a 10 mm structural beam thickness with an innovative parallel adjustment system for maximum flexibility of composition and customisation and extreme rigidity and strength; Sliding towers on 2 opposing linear guides adjustable from the front of the machine with pneumatic release. The basic BACK has 2 axes (X, R). It is also possible here to make a further upgrade up to a maximum of 6 axes (X, R, Z1, Z2, X2, X3). All towers are equipped with a LED visual stop. Lighting of the LED ensures contact of the sheet with the reference. Ultimately We analysed the main hidden elements to focus on in the selection of a press brake, to ensure that it is a profitable investment over time, capable of: reducing operating costs; maximising productivity; achieving the most in terms of processing quality. By doing so, even the end client can count on a standardised and reliable supply.
What is a Press Brake and How Does It Work? Press brakes are powerful machines used to bend sheet metal into various shapes and angles. From the sleek curves of a car body to the sturdy frame of a refrigerator, press brakes play a crucial role in manufacturing across many industries. Operating Principle: How Does a Press Brake Work? Imagine a giant sandwich maker. The bottom slice of bread is the die, a sturdy, precisely shaped mold. The top slice is the punch, a matching shape that presses down on the sheet metal. The press brake applies immense force, causing the metal to bend permanently into the desired shape. Key Components of a Press Brake Ram This is the moving part of the press brake that houses the punch. It travels vertically, applying the bending force. It runs vertically along the Y axis and is positioned by numerical control at specific positions according to the operation to be performed. There are independent Y1 and Y2 axes that regulate the possible unbalance of the machine’s main ram (in a hydraulic press these are the different strokes that the cylinders can perform). Bench The bench or bed is the fixed part under the beam where the dies are installed. It can contain a crowning system to compensate for the crossbar deformation, especially in machines two meters/6’ wide and up. Such a system can be found in a variety of versions which embrace different design philosophies among manufacturers or are based on specific machine types or families. Excellent results are possible through the use of a hydraulic crowning system. In this case, a number of high pressure and low flow rate cylinders are inserted within the machine bench to compensate for the frame deformation during the pressing phase by producing a counterforce from underneath. Lateral Frames Represent the side plates or shoulders that define the width of the machine frame. These can also be different: for example, machines with synchronized hydraulics almost always have a gap, called throat, so a sheet that is wider than the distance between the shoulders or columns can be inserted into the machine frame. Punch This tool replicates the desired bend profile and makes direct contact with the sheet metal. Punches come in various shapes and sizes to accommodate different bend angles and materials. Die The die is the stationary counterpart to the punch, providing the form for the bend. It can be a simple V-shaped die for basic bends or a more complex shape for specific profiles. Clamping System This mechanism securely holds the sheet metal in place during the bending process, ensuring accuracy and preventing slipping. CNC The CNC (Computer Numerical Control) is the core of the machine. The operator interface device used to program the sequence of machine movements through direct input of parameters/programs or off-line programs, which are normally created by the technical department as directed by the production management. Very often the CNC allows several setting/input options such as numerical mode or graphic mode: the former requires the operator to enter the data for the desired part directly in the appropriate fields on the program screen; the latter is more user-friendly, especially for a non-expert operator, and requires the use of 2D or 3D graphics showing the shape of the desired end product as well as the bending sequence. Sheet Metal Supports These are very often optional accessories. If fixed and sliding on a guide, they only serve to support heavy and/or bulky workpieces during processing. If mobile (followers), they serve to “accompany” or follow, the sheet metal as it swings due to the bend forming process. They work during both upward and downward sheet movements. Rear Backgauge This device ensures that the bend is positioned correctly in the part to be produced. It usually consists of a beam on which two or more finger stops (backgauges) are mounted. They are able to move sideways to find the correct position. Choosing a press brake: first, the basics! Here are some key terms to familiarize yourself and to for accurately determining bend parameters for your sheet metal: Tonnage: the force required to perform the bend. Inside radius: the inner curvature of the bend. The smaller the inside radius, the tighter the bend. This value is crucial in sheet metal working because it affects the strength of the bend, the aesthetic appearance of the finished part, and the choice of tools to use. Minimum flange length: the shortest possible length of the flange to prevent breakage. Imagine folding a sheet of paper. If you fold it too sharply, it will tear. The same applies to sheet metal. The minimum bend length represents the point beyond which the material can no longer be bent without risk of breaking or excessive deformation. It's like a strength threshold that every material has. Our online calculator is your ideal tool for accurately determining bend parameters for your sheet metal. Try it now: vicla.eu/en/calculators/bend-parameter-calculator When Was Press Brake Invented? Press brakes, while a relatively modern invention, have a history dating back to 1882 when the first patents were filed. Early press brakes were labor-intensive affairs, relying heavily on manual operations. To create a bend, a mold was first crafted to match the desired shape. Sheet metal was then placed on the mold and surrounded by a mixture of sand and lead shot. Workers would then use a T-stake to pound on the metal, forcing it into the mold's shape. This process, while effective, was slow and often resulted in straight, simple bends. What are the differences between old press brakes and modern press brakes? 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. Types of Press Brakes: Powering Up Your Bends Press brakes come in various configurations, each suited for specific applications and production needs. Here's a breakdown of the most common types: Mechanical Press Brakes: A Look Back at a Once-Dominant Technology While mechanical press brakes once reigned supreme in metalworking shops, they've largely been replaced by safer and more precise alternatives like hydraulic and electric models. Despite their diminished role, these machines played a significant part in the history of metal fabrication. How Mechanical Press Brakes Work These robust machines utilize a flywheel to generate the powerful force needed to bend sheet metal. As the flywheel spins, it builds up momentum that drives the punch up and down. A clutch system engages and disengages the gear shaft, allowing for controlled movement. Key Advantages of Mechanical Press Brakes Speed and Power: Mechanical press brakes are renowned for their speed and impressive force, capable of handling challenging bending tasks. Simple Operation and Maintenance: Their straightforward design makes them relatively easy to operate and maintain. High Load Capacity: These machines often exceed their rated tonnage, offering unexpected power reserves. Why Mechanical Press Brakes Have Become Obsolete Safety Concerns: The inherent nature of their operation presents significant safety risks. Limited Control: Mechanical press brakes offer limited control over punch speed and movement, impacting bend quality and accuracy. Advancements in Technology: The emergence of hydraulic and electric press brakes, with their enhanced safety features, precision, and energy efficiency, has made mechanical models less desirable. Notable Manufacturers Brands like Mariani and Omag were once highly regarded for their innovative mechanical press brake designs. RG Promecam Hydraulic Press Brakes: A Legacy of Innovation The RG Promecam hydraulic press brake, a brainchild of Italian-French inventor Roger Giordano, stands out for its distinctive low-profile design and compact footprint. Unlike conventional press brakes that lower the upper beam to bend the metal, RG Promecam machines ingeniously raise the workbench using a central hydraulic system. This innovative approach offered simplicity and reliability, significantly impacting the evolution of Italian press brake technology. A Unique Approach to Bending The unique design of RG Promecam press brakes allowed for the bending of large, closed profiles. The low-profile structure enabled these profiles to be embraced by the upper part of the machine, facilitating efficient bending operations. A Historical Perspective In the post-war era, RG Promecam press brakes gained significant popularity. They represented a groundbreaking innovation in metal fabrication, offering a compact and efficient solution for many bending applications. Safety Considerations While historically significant, these machines no longer comply with modern safety standards. They lack features like adjustable bending speeds and advanced safety mechanisms. To remain operational, significant safety upgrades are necessary. Hydraulic Press Brakes with Torsion Bar: Early Steps Towards Synchronization These press brakes represent a significant step in the evolution of modern synchronized press brakes, sharing a similar visual appearance. They operate by utilizing a hydraulic system to drive the downward movement of the main beam. Typically, these machines incorporate two or three primary axes of movement: X-axis: Controls the horizontal movement of the rear carriage. Z-axis: Controls the vertical positioning of the rear carriage. Y-axis: Controls the vertical descent of the main beam. A key characteristic of these press brakes lies in the mechanical connection between the two main hydraulic cylinders, facilitated by a torsion bar. This linkage ensures synchronized movement of the beam throughout the bending cycle, up to the lower dead center, guaranteeing consistent and accurate bends. The lower dead center, or the final position of the beam at the end of its stroke, is adjustable. Two nuts, positioned on the cylinders, allow for precise adjustments to the end-of-stroke height, providing flexibility in bending operations. Control systems for these press brakes were relatively basic compared to today's sophisticated CNC systems. They were often equipped with simple positioners, lacking the internal memory and advanced programming capabilities found in modern machines. Synchronized Hydraulic Press Brakes: The Pinnacle of Bending Precision Hydraulic press brakes revolutionized metal bending by replacing mechanical systems with precise hydraulic control. Utilizing two oil cylinders to drive the punch, these machines offer significantly enhanced bending capabilities and accuracy compared to their mechanical predecessors. Advantages and Challenges of Hydraulic Press Brakes While offering superior performance, hydraulic press brakes come with increased complexity. They require skilled operators and can have higher maintenance costs due to the intricate nature of their hydraulic systems. Maintaining strict adherence to the machine's rated tonnage is crucial to prevent damage. Additionally, potential fluid leakage from the hydraulic cylinders remains a concern. The Rise of CNC Hydraulic Press Brakes The advent of CNC technology has significantly advanced hydraulic press brake capabilities. CNC-controlled machines feature automated systems that precisely control movement and timing, enhancing both accuracy and efficiency. Synchronized hydraulic press brakes represent the pinnacle of press brake technology. They employ two independent hydraulic cylinders and proportional valves to regulate the movement of the upper beam. This sophisticated configuration offers greater versatility, allowing operators to adjust each cylinder individually to compensate for variations in sheet metal thickness or irregularities. Electric press brakes or servo press brakes Electric press brakes, the latest innovation in press brake technology, remain a specialized solution for certain applications. While they offer speed, repeatability, and energy efficiency, they often lack the versatility of synchronized hydraulic press brakes, especially on large formats. Two primary methods are used to operate electric press brakes: ball screws and special belts. Servo press brakes utilize servo motors to power the punch. These motors, also known as servo-electric press brakes or electric press brakes, transfer mechanical energy to the punch via a pulley and belt system. Servo motors offer precise control over punch movement due to their numerous adjustment options. This translates to accurate bends and a quieter workplace. Eliminating hydraulic or pneumatic systems also prevents leakage issues. However, servo press brakes have a lower force capacity compared to other options. This limitation restricts their use in industries requiring higher tonnage. CNC press brakes CNC press brakes, versatile and automated machines, utilize computer numerical control (CNC) systems to deliver exceptional precision and repeatability. By incorporating CNC technology, businesses can significantly boost productivity, efficiency, and accuracy while reducing labor costs. Ideal for a diverse range of industries, including aerospace, automotive, construction, and electronics, CNC press brakes offer a powerful solution for various applications. To learn more about the specific benefits and capabilities of CNC press brakes, explore our in-depth article, CNC Press Brakes: A Comprehensive Guide Hybrid Press Brakes: A Technological Advance in Metal Bending Hybrid press brakes represent a significant advancement in press brake technology, offering a compelling combination of efficiency, precision, and versatility. Unlike traditional hydraulic press brakes, which rely solely on hydraulic power, hybrid models incorporate electric motors to drive the bending process. Key Advantages of Hybrid Press Brakes: Enhanced Precision: By minimizing oil usage and reducing the impact of oil temperature fluctuations, hybrid press brakes achieve a high degree of precision and repeatability in bending operations. Energy Efficiency: Hybrid systems significantly reduce energy consumption compared to traditional hydraulic models, leading to substantial cost savings. Versatility: Hybrid press brakes offer greater flexibility in bending operations compared to some electric models, particularly those using belt systems. How Hybrid Press Brakes Work: Hybrid press brakes utilize a combination of electric motors and a reduced hydraulic system. This approach minimizes oil volume, leading to a more compact and efficient design. Key Features of Hybrid Press Brakes: Reduced Oil Usage: Minimizes oil volume, leading to reduced heat generation and expansion. Electric Motor Drive: Utilizes powerful electric motors to drive the bending process. Precise Control: Enables precise control over bending parameters. Hybrid press brakes represent a cutting-edge technology in metal bending, offering a compelling balance of precision, efficiency, and versatility. By combining the strengths of hydraulic and electric systems, they provide a significant advancement over traditional press brake designs. Applications: Bending Across Industries Press brakes are incredibly versatile machines, used in a wide range of industries: Automotive: car bodies, engine components Aerospace: aircraft parts Construction: roofing, cladding, ductwork Appliance manufacturing: Refrigerators, washing machines Electronics: enclosures, chassis Advantages and Disadvantages: Weighing the Options Each type of press brake has its own set of advantages and disadvantages: Feature Hydraulic Press Brakes Mechanical Press Brakes Electric Press Brakes Hybrid Press Brakes Advantages High precision, good control, wide range of capacities Fast, simple, cost-effective Energy-efficient, quiet, precise control Combines benefits of hydraulic and electric Disadvantages Higher maintenance requirements, slower cycle times (compared to electric) Less precise control, higher noise levels Higher initial cost Newer technology, may have limitations in certain capacities Choosing the right press brake depends on your specific needs. Consider factors like production volume, required bend precision, material thickness, and budget. Bending Force Calculation: Bending with Confidence Calculating the bending force required for a specific bend is crucial to ensure successful and safe operation of the press brake. Here's a simplified formula for estimating the bending force (F) for a V-bend: F = T * L * S Where: F is the bending force (in tons or Newtons) T is the material thickness (in millimeters or inches) L is the bend length (in millimeters or inches) S is the material's tensile strength (in MPa or psi) Note: This is a simplified formula, and several factors can influence the actual bending force required. It's recommended to consult the material manufacturer's data and use more sophisticated bending force calculation methods for precise results. Maintenance and Safety: Prioritizing Care and Caution Proper maintenance and safety practices are essential for ensuring the longevity and safe operation of a press brake: Regular Inspections: Conduct routine inspections of all components, including hydraulic lines, electrical systems, and safety guards. Lubrication: Regularly lubricate moving parts according to the manufacturer's recommendations. Tool Maintenance: Properly maintain and store punches and dies to prevent damage and ensure accurate bending. Safety Guards: Ensure all safety guards are in place and functioning correctly. Operator Training: Provide comprehensive training to all operators on safe operating procedures, including lockout/tagout procedures and emergency stop procedures. Personal Protective Equipment (PPE): Always wear appropriate PPE, including safety glasses, hearing protection, and steel-toed shoes. Conclusions: Mastering the Art of Bending Press brakes are essential tools in metalworking, enabling the efficient and precise bending of sheet metal into a wide variety of shapes. By understanding the principles of operation, the different types of press brakes available, and the importance of safety, you can effectively utilize these machines to achieve your manufacturing goals. Press brakes are indispensable tools in any metalworking facility. VICLA offers a comprehensive range of modern electric and hydraulic press brakes designed to meet your specific needs. Contact VICLA today to find the perfect machine for your applications.
A CNC press brake is a modern machine for sheet metal bending. 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. Importance of CNC Press Brakes in Manufacturing CNC press brakes are highly versatile machines capable of handling a wide range of metalworking tasks. Their programmability allows for precise control over bending operations, ensuring accurate and repeatable results. From simple bends to complex geometries, these machines can efficiently process various materials, including steel, aluminum, and stainless steel. This versatility makes CNC press brakes indispensable in industries requiring high-quality, customized metal components. Types of CNC Press Brakes Hydraulic Press Brakes Hydraulic press brakes, known for their precision and power, utilize oil cylinders to control the bending process. While offering superior performance, they can be complex to maintain and may have higher operating costs. CNC hydraulic press brakes automate many functions, improving efficiency and accuracy. Synchronized hydraulic press brakes, a more advanced version, use two independent cylinders for precise control and greater versatility. Electric Press Brakes Electric press brakes are a newer technology, offering speed, repeatability, and energy efficiency. However, they may have limitations in force capacity and versatility compared to hydraulic press brakes. Servo press brakes, a type of electric press brake, use servo motors for precise control and quieter operation. They are suitable for applications requiring high accuracy and low noise levels. Hybrid Press Brakes Hybrid press brakes combine the best aspects of hydraulic and electric press brakes, offering exceptional performance. VICLA, a leader in hybrid technology, provides machines with: Microscopic precision: Ensures consistent and accurate bends. Energy efficiency: Up to 78% energy savings compared to traditional hydraulic press brakes. Versatility: Handles a wider range of applications than electric press brakes. Key Considerations: Force capacity: Hydraulic press brakes generally offer higher force than electric or hybrid options. Versatility: Hybrid press brakes are more versatile than electric press brakes. Maintenance: Hydraulic press brakes require more maintenance due to their complex systems. Energy efficiency: Electric and hybrid press brakes are more energy-efficient than traditional hydraulic press brakes. Noise: Electric press brakes, especially servo press brakes, are generally quieter than hydraulic press brakes. CNC Press Brakes Main Components: Bed, Ram, Punch and Die, Back Gauge Frame Also called beam, which is the movable part on which the punches are installed. It runs vertically along the Y axis and is positioned by numerical control at specific positions according to the operation to be performed. There are independent Y1 and Y2 axes that regulate the possible unbalance of the machine’s main ram (in a hydraulic press these are the different strokes that the cylinders can perform). The bench or bed Is the fixed part under the beam where the dies are installed. It can contain a centering (or crowning) system to compensate for the crossbar deformation, especially in machines two meters/6’ wide and up. Such a system can be found in a variety of versions which embrace different design philosophies among manufacturers or are based on specific machine types or families. Excellent results are possible through the use of a hydraulic crowning system. In this case, a number of high pressure and low flow rate cylinders are inserted within the machine bench to compensate for the frame deformation during the pressing phase by producing a counterforce from underneath. The lateral frames Lateral frames represent the side plates or shoulders that define the width of the machine frame. These can also be different: for example, machines with synchronized hydraulics almost always have a gap, called throat, so a sheet that is wider than the distance between the shoulders or columns can be inserted into the machine frame. Rear Backgauge Tthis device ensures that the bend is positioned correctly in the part to be produced. It usually consists of a beam on which two or more finger stops (backgauges) are mounted. They are able to move sideways to find the correct position. The axes, on the other hand, are: x: Forward and backward, sets the length of the bend (flange) from the center of the die to the tip of the fingers. r: up and down, adjusts the height of the stops/fingers to allow the fingers to reach the part better and so that dies of different heights can be mounted. z: left and right, adjusts the position of the stop/s on the table, to ensure that the back fingers are in the correct support position towards the punch and die. CNC Control System: How it Works A CNC press brake's brain is its sophisticated CNC system. This system interprets instructions and controls the machine's movements for precise, automated bending. Key components include Control System, Programming and Axis Control. Control System Hardware and software that processes commands and controls machine movements. Programming Operators create programs using specialized software to define bending parameters. The CNC system then translates these instructions into machine-readable code, specific to the press brake manufacturer. Axis Control The CNC system manages the vertical movement of the ram and the horizontal positioning of the backgauge. Additionally, some press brakes feature a crowning system that adjusts the bed's curvature to ensure uniform bending. Ram: The ram applies force to the metal sheet, creating the bend. Backgauge: The backgauge positions the sheet metal accurately before bending. Crowning: This optional feature helps prevent uneven bending by adjusting the bed's shape. 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 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 sheet metal bending brakes, 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. Industry 4.0 and Smart Manufacturing CNC press brakes are increasingly integrating with Industry 4.0 technologies, transforming them into smart manufacturing assets. This involves connecting machines to networks and equipping them with sensors and data analytics capabilities. Key benefits of Industry 4.0 integration include: Predictive maintenance: Using data analytics to predict equipment failures and schedule maintenance proactively. Real-time monitoring: Tracking machine performance and identifying bottlenecks in the production process. Improved quality control: Implementing automated inspection systems to ensure consistent product quality. Enhanced connectivity: Seamless integration with other manufacturing systems for streamlined workflows. Automation and Robotics Automation and robotics are playing an increasingly important role in CNC press brake operations. Sheet metal bending automation has advanced significantly in recent years. Collaborative robots (cobots) and anthropomorphic robots have revolutionized the industry, replacing traditional Cartesian robots. These automated solutions not only speed up the bending process but also reduce human error. Benefits of automated bending cells include: Increased efficiency: Faster bending cycles and reduced downtime. Improved quality: Reduced human error and more consistent results. Ergonomics: Relieves operators from repetitive tasks. VICLA has developed advanced solutions for automated bending cells. These solutions can help you streamline your production process and improve your bottom line. To learn more about how robotic bending solutions can transform your sheet metal fabrication, read our comprehensive guide “Robotic bending: advantages and limits”. As technology continues to advance, we can expect to see even greater levels of automation and robotics in CNC press brake applications.
Choosing a press brake can seem daunting at first, but it really boils down to understanding the kind of work you'll be doing and matching the machine's capabilities to your needs. Here are some key questions to ask yoursefl: what's the longest piece of material you'll need to bend? How thick will the material be? The bending length and material thickness will determine the tonnage (bending force) and throat depth (clearance between the frame and ram) that you need in a press brake. Bending length The length of the press brake depends on the maximum length of the part to work. 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. How Do I Calculate Press Brake Tonnage? Our online press brake tonnage calculator is your ideal tool for accurately determining bend parameters for your sheet metal. In just a few simple steps, you'll get detailed information on: Tonnage: The force required to perform the bend. Inside radius: The inner curvature of the bend. Minimum flange length: The shortest possible length of the flange to prevent breakage. You should always oversize the press brake capacity by around 20 – 30% with respect to your data in order to allow for the variability in the characteristics of the metal and so that you are not in danger of working to the limits of the machine’s 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 Length 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. Material Thickness Different metals have varying properties and behave differently when subjected to bending. For instance, aluminum is generally more malleable than stainless steel. Understanding the characteristics of the specific material you’re working with is essential in determining the appropriate press brake and bending parameters. Our Ultimate Guide to Sheet Metal Materials provides expert insights and practical advice. Explore now to choose the perfect material for your project. Operator Skill Level Complex press brakes offer advanced features and automation, but they often require skilled operators. If your team lacks the necessary expertise, consider the time and resources needed for training. Weigh the benefits of increased capabilities against the potential challenges of operator training and maintenance. Types of bending brakes There are many different types of press brake machines. Each of these comes with its own set of advantages and limitations. You can choose the right press brake based on your use case. These different types of press brakes are: Mechanical press brakes: These are the most basic type of press brake and are generally the most affordable. However, they are also the least versatile and can be difficult to operate precisely. Hydraulic press brakes: These are the most common type of press brake and offer a good balance of power, precision, and versatility. They use hydraulics to power the ram, which allows for more precise control over the bending force. Pneumatic press brakes: These are a good option for lighter-duty bending applications. They are quieter and faster than hydraulic press brakes, but they also have less bending force. Servo press brakes: These are the most precise type of press brake and are a good option for high-precision bending applications. They use servo motors to power the ram, which allows for very precise control over the bending position and force. CNC press brakes: These press brakes are computer-controlled and can automate many of the bending tasks. They are a good option for high-volume production runs or for complex bending jobs. Hybrid press brakes: These combine the power of hydraulics with the precision of electric motors. They are a good option for applications that require both high precision and high bending force. Tandem press brake: 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). Read our guide on What to know before choosing a tandem press brake. Secondary Factors to Consider For the Right Press Brake 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 clumping 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 V-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 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