Metal Forming & Fabricating Showcase One

MODULAR TUBE & PIPE BENDING SOLUTIONS
Global competition increasingly demands more complex tube geometries in more exotic materials, placing higher market requirements on production processes and machines. For this reason, tube and pipe bending machinery builder Schwarze-Robitec GmbH (Köln, Germany) does not sell any ready-made tool series equipment. Instead, they offer a modular-configurable accessories program which is adapted flexibly to the specific project requirements and comprises single-stack tools and multiple-radius bending tools both for series and high-volume production.

Equipment is designed by application needs for the automobile, boiler and power plant, shipbuilding and offshore industries, all using high-quality materials and special hardening processes that optimize the precision, wear resistance, dimensional stability and thereby the endurance of the tools to ensure high repeatability and accuracy. “At the beginning of each project, we provide detailed advice with the aim of finding the absolutely best bending solution for the customer,” reports Harbut Stöhr, the managing director of Schwarze-Robitec. “The result is always a long-term convincing production solution at the highest level.”

The exclusive North American distributor for Schwarze-Robitec tube and pipe bending equipment is Trilogy Machinery, Inc., PO Box 70, Belcamp, MD 21017, 410-272-3600, Fax: 410-272-3601, sales@trilogymachinery.com, www.trilogymachinery.com.

ADVANCED FABRICATION SYSTEMS
Automation can play a very important role in reducing costs and increasing productivity. Prima Power North America, Inc. (Arlington Heights, IL) offers 2D and 3D laser solutions along with a new generation of punching, right angle shearing and bending, flexible manufacturing systems to suit the majority of applications.

Its Shear Genius® SGe machines combine punching and shearing for largely rectangular parts, while its LPe punch laser systems enable parts that require profiling and forming to be completed in one operation. To link machines together, Prima Power offers a range of solutions, right up to its Night Train FMS® system that will meet the needs of the most demanding applications. The latest Platino® Fiber laser machine has higher power and enhanced performance and delivers improved cutting quality, shorter cycle times, better process control and new automatic functions for unmanned operation. The highly specialized Laser Next 3D laser system offers astonishing performance and world-class efficiency in the high volume production of hot stamped and hydroformed automotive components.

The Shear Brilliance cell features linear drives, composite construction and servo-electric punching and shearing that saves material with higher material utilization, high quality parts with no nibble marks, automatic loading and fast sheet positioning, with table lengths up to 4,070 mm and 3,100 mm punching-shearing without repositioning. The 24 or 30 station turret minimizes set-up times and the 35 ton ram force allows high speed processing of very long contours in one operation. Shear Brilliance is easy to integrate with FMS, including automatic sheet storage and sorting and stacking of components.

The Laserdyne® 430 system provides precision laser processing, including drilling and welding, of metal and non-metal components for many industries, including aerospace, automotive, medical and consumer products.

The innovative eP-Series press brake combines productivity, accuracy, flexibility and reliability with high respect to ecological aspects – we call this concept Green Means®. The eP is available in three models, eP-0520, eP1030 and eP-1336, with different press tonnage and bending length to meet any production requirement. The press brake uses a servo-electric drive system to achieve sustainability, manufacturing efficiency and productivity through greater versatility, outstanding accuracy, lower power consumption and less maintenance, with no oil to purchase or get rid of.

The pulley-belt system is actuated by Prima Electro servo-drives to evenly distribute the bending force over the whole bending length of the machine, with gauges used over the whole bending length. The rigid and stable O-frame construction ensures tool alignment, even under stress deformation; excellent ram position accuracy and repeatability using bed-referenced linear encoders to measure upper and lower beam relative position; and great flexibility with no throat limitations for long parts (which is typical of a C-frame structure). Because there is no oil to expand and contract with heat changes, the press brake maintains its accuracy throughout the working day.

The Prima Electro Open Control is Windows-based with two processors, an operator-friendly 17 in touch screen user interface, 2D graphical on-line programming and 3D visualization for easy-to-use and effective Auto-Pol off-line programming. Block Laser safety equipment by Lazer Safe offers the most advanced levels of productivity and protection. An angle measurement option is available through high speed digital image processing technology that measures the angle of the formed work piece on every cycle with automatic correction of the bend program. The AQ-bending follower means there is no need of a second operator for supporting big parts.

Prima Power North America, Inc., 555 W. Algonquin Road, Arlington Heights, IL  60005-4411, 847-952-6500, Fax: 847-952-6590, sales@finnpower.com, www.finnpower.com.

FLEXIBLE, PRODUCTIVE BENDING & SHEET METAL FABRICATION
Simple to operate, accurate, and reliable – these characteristics define the new TruBend Series 3000 from TRUMPF Inc. (Farmington, CT). The machine’s new closed-frame design provides higher overall rigidity, and therefore higher precision than the previous generation. The backgauges can move across the entire length of the machine bed enabling unrestricted use when bending at the ends of the machine. Automatic CNC crowning makes for constant angles. As the fastest machine in its class, the TruBend 3100 also features a press force of 110 tons and 118 in of bending length in a space-saving design. The machine comes standard with a two-axis backgauge, with the option to expand to a four- or five-axis backgauge, making it possible to bend parts accurately, even when complex part geometries are involved.

The TruBend 3100 is ideal for entry into precision bending. The operating concept is simple and intuitive. The operator can draw and program parts graphically with modern multi-touch control. The exact bending parameters are calculated automatically based on data the company derived from decades of experience in precision bending. 3D visualization further simplifies the work and checks the program for potential collisions. Preexisting programs are easily imported either via a USB interface or a network connection.

Upgrading bending capabilities to the TruBend Series 3000 is simple since even third-party tools can be used without an adapter. Simply select from a number of different tool clamping concepts. Manual clamping comes standard, with the upper and lower tools secured with Allen screws. The quick clamp option facilitates rapid clamping of the upper tools with a lever, reducing set-up times. The fastest option for set-up is automatic hydraulic clamping. Each option automatically centers the tools, which are inserted vertically. A variety of components ensures that the new TruBend Series 3000 is a safe and ergonomic workplace. BendGuard uses a laser light field to monitor the area beneath the upper tool. If there is a break in the barrier – a hand interrupting the light field, for example – the machine will stop, protecting the operator from injury. This technology enables the operator to confidently run the machine at full speed for maximum productivity.

The BendGuard is positioned at the sides of the machine, next to the ends of the ram. In preparation for inserting tools from the side, the BendGuard can simply be moved so that it does not interfere. The position of the BendGuard is also easily and incrementally adjusted to accommodate upper tools of differing heights. The machine’s compact design features a small footprint, the interior space for the machinery is readily accessible, and it is quickly installed – since it is delivered completely assembled. The foot switch used to start the bending stroke is also easily repositioned. In addition, LED lights in front of and inside the machine keep the workpiece well lit.

TruBend Series 7000 precision press brakes are compact machines that offer a high-quality, efficient solution for the production of small bent parts up to 40 in. Typical applications include sheet metal parts used in the production of vending machines and electrical equipment as well as in the telecommunications and aerospace industries where bending such parts with large, heavy press brakes is typically inefficient.

The TruBend 7036 is the world’s most ergonomic press brake. Optimum working conditions and user-friendly operating elements are integrated into the machine design. The operator can control the machine while sitting down, and work without becoming fatigued, which helps ensure the quantity and quality of the fabricated parts. Gas spring supported pedals allow the height and angle of the foot rests to be adjusted. The arm support is also adjustable enabling every operator to set the workplace to his or her individual preference.

In addition, the monitor for the TASC 6000 control system of the TruBend Series 7000 can be adjusted electronically and set to the appropriate angle. Optional TRUMPF LED lighting illuminates the area in front of and behind the beam, ensuring correct lighting conditions precisely at the bend, without heat radiation. An optional laser diode also projects the bend line onto the surface of the sheet metal, simplifying the accuracy of guiding the workpiece into the back gauge.

The high performance TruBend 5130 press brake combines innovative technology with precision to reduce cycle times by up to 30 percent. The TruBend 5130 press brake offers flexibility for fabricators looking to bend a variety of parts. Whether the parts are large or small, complex or simple, ACB, the patented measuring technique, ensures that bending angles are correct, right from the start. Programming can be performed with TruTops Bend software, or right at the machine control.

The optical LED & positioning visually assists the operator, facilitating rapid set-up and bend sequencing. Uniform pressure over the entire length of the ram is distributed due to 4-cylinder technology. The TruBend 5130 press brake offer the following advantages:

• 4-cylinder technology increases bending space, accuracy and productivity
• ACB® (Automatically Controlled Bending)
• Press force of 141 tons
• Bending length up to 127 in
• Quick-change tooling system
• Extremely large installation height up to 24 in
• Intelligent 6-axis backgauge

For sheet metal fabrication, the TruPunch 2000 with SheetMaster Compact features an innovative on-demand drive technology where the hydraulic system only runs when the punch head is active, minimizing the energy consumption of the machine and the load on the system. The machine features a 50 in x 100 in working range and can process material up to 0.250 in thick. As part of the TruPunch product portfolio, fabricators also profit from high standards in punching performance, including impressive axes speeds, high maximum stroke rates, and short setup times. With full 360 deg tool rotation and tabbed sheet automation capabilities, the TruPunch 2000 is flexible as well as accurate.

The machine is controlled by a user-friendly touch screen interface that graphically displays the program and all essential information – keeping operators in control, regardless of their experience level. These and other features make it the ideal choice for fabricators in need of productivity and process reliability at a competitive investment and operating cost. The SheetMaster is the central element for automated loading and unloading of material. The small footprint of the SheetMaster Compact enables automated processing, even when floor space is limited.

TRUMPF Inc., 111 Hyde Road, Farmington Industrial Park, Farmington, CT 06032, 860-255-6000, Fax: 860-255-6424, info@us.trumpf.com, www.us.trumpf.com.