Browse by Editorial Category
Browse by Edition Date

April 2017

Skip Navigation Links.
Expand Applying TechnologyApplying Technology
Expand Drilling-Tapping-ThreadingDrilling-Tapping-Threading
Expand General EditorialsGeneral Editorials
Expand Medical ManufacturingMedical Manufacturing
Collapse Metalforming-Fabricating-WaterjetMetalforming-Fabricating-Waterjet
New Pulsed Fiber Laser Welding System
Resistance Spot Riveting (RSR) Technology for Joining Dissimilar Materials
More Handle Options for Semi-Automatic MIG Guns
All-Electric Tube Bender
Fast Bending Tool Changing for a Press Brake
Fiber Laser Delivers Faster Performance
Rotary Draw Tube Bending
Cut and Bevel Pipe up to 63" Diameter
Dallas Industries Delivers Two Complete Feed Lines to Adient
Automated Plasma Power Sources for High Precision Plasma Cutting
Welding with Arc Welding Robot and Table-Top Material Handling Robot
New Press for Fineblanking Requirements
Ultrahigh Pressure Waterjet
Mid-Sized CNC Laser Cutting System
Consumables for Air Plasma Systems
Waterjet Suited for Metal Service Centers and Aerospace
Expanded Metalforming Line
New Generation of Waterjet Pump Technology
SmartShop Fiber Lasers
Hydraulic Press Brakes with Multi-Axis Backgauge
Press Brake Tooling with up to 40 Degree Bending
Intuitive Information System for Press Brakes
New Laser Welding Solutions Speed Processing
Multi-Axis Rotary Forging Machine
Optimize Cutting Efficiency with High-Precision Fiber Laser
Waterjet Cutting Versatility
New Line of Press Brakes
Laser Surface Texturing with Multi-Axis Laser System
General Purpose Cut-off Wheel
Fiber Laser with an Air-Cooled Cutting Head
Hands-Free, Multi-Product Roll Forming Line
Automation for Piranha Ironworkers
Axial Tube Forming Machine
Modular Automation-Friendly Punching Machine
Software for Sheet Metal Cutting and Bending
Gas Regulators Feature Easy-to-Read Gauge Design
Cutting Discs for Titanium and Brass
Ultra-Thin Cutting Wheels Deliver Faster Cuts
Expand People In The NewsPeople In The News
Expand Replacement PartsReplacement Parts

show all editions →

Click here to watch Tutorial Videos >

Fast Bending Tool Changing for a Press Brake



Bystronic is expanding its bending process with a newly developed level of automation. With the new integrated Tool Changer system, the Xpert press brake can now swap tools automatically. "The state-of-the-art sensor system and integrated robotics technology create an exceedingly versatile and compact bending system that sets itself up," said a company spokesperson. "This solution is of particular interest for users who want to save time and increase quality but who do not want to forego flexibility.

"Sheet metal products are changing rapidly: a greater variety of shapes, increasing demands in terms of quality, and shorter product life cycles. This has an effect on sheet metal processing. In the past, jobs with 1,000 or more parts were usual. Today, the batch sizes are decreasing considerably. Small quantities are in demand. For companies that in addition to cutting also bend, this change means extra work. This impact is felt most strongly during the set-up and dismantling of tools on bending machines."

With the Xpert press brake and the integrated Tool Changer system, Bystronic is automating the process step that plays a crucial role in enabling users to bend parts quickly and with consistent quality. The Tool Changer sets up the Xpert with the upper and lower tools that are required for the job. "During manual operation, this step costs the user up to 70 percent of the entire bending time," said the spokesperson.

"Many users have reservations: Bending automation requires space, makes automated processing steps cumbersome, and thus less flexible. Hence automation only makes sense when processing large batch sizes of identical parts. With the Xpert Tool Changer, Bystronic provides a solution to this typical drawback of conventional automation systems," said the spokesperson.

The 6-axis robotic arm integrated in the Xpert press brake accesses the tool magazine, which is also integrated within the machine and houses a generous supply of bending tools. The entire automation system is located within the Xpert press brake. In addition to the advantageous ergonomics, this offers another benefit: The robotics system and the tool magazine are protected from dirt and ambient influences.

In combination with the Tool Changer system, the Xpert offers a bending length of 3 meters. The available press capacity ranges from 150 to 320 tons. As standard, the machine comes with an intelligent bending process control and fully automatic crowning. Both functions enable a wide variety of parts to be bent with maximum repetition accuracy. "In a logical next step, Bystronic is now extending this combination of variety and precision with an automation solution that decreases the user's workload and reduces sources of error within the bending process," said the spokesperson.

"With the Xpert Tool Changer system, users will never again bend a part using the wrong tool, or with a tool that has been incorrectly inserted into the press brake's upper or lower beam," said the spokesperson. For each bending job, the automation system fetches the appropriate toolset from the magazine and inserts it with high precision. Even when bending with several stations distributed across the bending length, the automatic tool changer positions all the defined tools with millimeter precision.

With constantly changing bending parts, users frequently need to expand a press brake's range of bending tools. In such cases, the Xpert Tool Changer system supports the user with intelligent sensors. The operator simply inserts new tools into the clamping system of the upper or lower beam. Subsequently, the Tool Changer scans the new tool and automatically integrates it into the magazine, without programming effort or the need to call in a service technician.

In addition to the normal position, the upper tools can also be rotated by 180° and inserted in the beam increasing the bending versatility, an option that usually poses difficulties for conventional automation solutions. If required, the 6-axis robotics can rotate all the upper tools and thus increase the range of applications of the existing tools.

In order to ensure sustained precise and gentle processing of parts that are to be bent, the Xpert Tool Changer system is equipped with a cleaning nozzle that cleans the whole length of bending table using compressed air. During the bending process, mill scale and cutting residues from the bending parts frequently drop onto the lower beam causing the operator to have to regularly clean a press brake. With the Xpert Tool Changer this is no longer necessary.

Bystronic has integrated the operator interface for the Xpert Tool Changer into the ByVision Bending user interface. This enables users to perform all the operating steps on the press brake using one touchscreen, regardless of whether they are controlling the tool change or the subsequent bending process. In addition to simple operation, this all-in-one solution also opens up new data evaluation possibilities: How frequently were certain tools used? Which tool was used to bend which part? When does preventive maintenance make sense? The analysis of these questions helps users to sustainably improve their processes.

For more information contact:

Bystronic Inc.

200 Airport Rd.

Elgin, IL 60123

847-214-0300

sales.us@bystronic.com

www.bystronicusa.com

< back

Email   email