FEATURE ON BENDING & FORMING

Morgan Rushworth XPH now in Bison showroom

The Morgan Rushworth XPH hybrid press brake is now available to view in the showroom of Bison Machinery in Stafford. XPH hybrid press brakes feature an electro-hydraulic servo-drive system that reduces power consumption by around 60% while idling and 45% during bending in comparison with a traditional hydraulic press brake. In addition to these savings, the system allows for extremely fast approach and return speeds, up to 200 mm/sec.

Those seeking fast, accurate and responsive bending while at the same time looking to reduce costs and environmental impact should consider the XPH, says Bison Machinery. The hybrid system features independent units, produced by HAWE Hydraulik in Germany, fitted to each of the press brake’s left and right cylinders.

With this system the hydraulics run on demand when activating the foot pedal, rather than having a pump running continuously. This results in lower energy usage than a standard hydraulic machine as well as faster cycle times and high accuracy. In addition, without the constant running of a hydraulic pump, the machine is much quieter to use.

As well as power savings and high working speeds, the hybrid press brake uses far less hydraulic oil than a standard hydraulic press brake, greatly reducing waste when servicing.

The XPH hybrid press brake features the ESA VIS-875W CNC control which, while featuring advanced functionality, remains easy to use. Operators can quickly and easily produce a program at the machine using the intuitive 21-inch touchscreen interface, reports Bison Machinery.

AKAS laser tooling guards are standard and offer a vastly improved operator experience without compromising safety. A comprehensive range of options is available to tailor the machine to requirements, including six-axis or eight-axis configurations.

More information www.bisonmachinery.co.uk

E-Brake 35T Mini Cell at GS-Metaal

By choosing the SafanDarley E-Brake Mini Cell, metalworking specialist GS Metaal is able, to automate the bending of a wide variety of products up to 900 mm in length in a relatively small area.

Nowadays, skilled people are difficult to find. GS Metaal, based in Vriezenveen, Netherlands, wants to keep these people available for specific products which are complex to manufacture. With the SafanDarley E-Brake 35T Mini Cell, the company is able to manufacture repetitive items in batches.

To keep the Mini Cell running even at night, GS Metal has expanded the cell to include, among other things, a positioning conveyor to ensure that items are placed properly on pallets and can be removed automatically.

“It’s nice to see that when I am the last to leave there is still ‘someone’ working,” says a GS Metal representative. “The entire purchase process with SafanDarley went very smoothly and we were well informed at every stage. Recently, two employees successfully completed an offline course in robot simulation software RoboBend and are enjoying working on this machine.”

The E-Brake 35T Mini Cell is a compact automatic flexible bending cell equipped with a 25 kg FANUC robot serving a SafanDarley E-Brake 35T-1250 press brake. The E-Brake 35T Mini Cell is suitable for fully automatic production of small complex products. It also allows successive bending of different products without intermediate programming. By adding various options, such as an automatic gripper, tool changer, reversing stations, and infeed and outfeed systems, this machine is fully configurable to customer specifications.

As standard, the table stations in the E-Brake 35T Premium Mini Cell feature precision adapters that guarantee a fixed position, making it possible to have several different tables that are easy to change in accordance with requirements.

More information www.safandarley.com

The making of Ursviken’s largest press brake

Ursviken is currently amid its largest project yet: building a custom press brake with a bending length of 22.2 m and press force of 5000 T. Once complete, the company says it will be the largest press brake ever built in the industry, breaking its own record from 2021 when Ursviken built a press brake with a bending length 20.8 m. 

As of now, the manufacturing process is well underway, with delivery estimated at some point this autumn. The main challenges thus far related directly to the size of the machine.

“The first challenge our engineers had to tackle was creating a design capable of withstanding the press beam weight of nearly 400 T,” explains Martin Edeljung, production manager at Ursviken Technology.

On the manufacturing front, the handling of heavy components, including raw material that is up to 320 mm thick and weighing over 1000 T in total, presented its own set of challenges. The transportation of these pieces to and within the factory during various production phases, from cutting to welding and milling, required careful manoeuvring due to their size and weight.  

Looking ahead, Ursviken can still expect to face challenges in the planning and final assembly stages.

“Given the unique nature of this machine, everything must be tailor-made, adding complexity to the assembly process,” says Edeljung. “The disassembly, transportation of the finished machine in parts, and on-site assembly, will require meticulous planning and co-ordination.”

More information www.ursviken.com

How to bend server and switchgear cabinets

For those in the business of fabricating server cabinets, NEMA boxes or switchgear cabinets, precision, efficiency and flexibility are non-negotiable. The team at RAS Systems understands these demands and offers tailored solutions to address these challenges.

One of the biggest challenges in this industry is manoeuvring large and heavy profiles. Traditional forming systems like press brakes often fall short, making the process cumbersome and time-consuming. The RAS UpDownCenter-2 addresses this issue with its material handling capabilities, including automatic up and down folding sequences, and the PosLift part positioning system. These features minimise manual intervention, ensuring the handling of even the heaviest parts with precision and ease, says the company.

Multiple tooling changeovers coupled with tired and inexperienced operators often lead to inefficiencies and increased labour costs. The UpDownCenter-2’s automatic tool changer and one-click programming software reduce set-up times and enhance productivity, especially in jobs with small batch sizes. According to RAS, the automation ensures consistent quality and precision, reducing human error and ensuring high-quality outcomes.

Customers frequently request unique and complex designs, requiring a high level of flexibility in production. The UpDownCenter-2 excels in this area, reports RAS, accommodating both small and large batch sizes. Its ability to bend parts with embosses, large holes and oblique base shapes makes it suitable for custom designs. One-click programming further streamlines the set-up process, making it easy to switch between different production runs quickly and efficiently.

Processing various materials, such as milled steel, aluminium and stainless steel, is another industry challenge. The UpDownCenter-2 can handle a variety of material thicknesses. This capability ensures precision and consistent quality across different material types, making it a versatile solution for diverse production needs.

More information www.ras-online.de

Ensuring press brake (and staff) safety

Press & Shear understands that press brakes are the workhorses of sheet metal fabrication. However, their immense power necessitates prioritising safety to protect team members and the user’s capital investment. Here are some key safety measures put forward by Press & Shear, a specialist in the supply of sheet metal and fabrication machines, to implement in press brake operations.

The first tip is to invest in high-quality light curtains or laser scanners to create a safety zone around the press brake’s pinch point. These systems will automatically stop the machine if an operator enters the zone unexpectedly.

Ensuring all press brake operators undergo comprehensive training is also recommended, covering safe operation, potential hazards and proper use of personal protective equipment (PPE). Press & Shear can provide targeted training programmes tailored to specific machinery and applications.

Another piece of advice is maintaining a clean and organised work area around the press brake to prevent slip, trip and fall hazards. This activity includes keeping tools and materials stored away when not in use.

It is also worth implementing a programme for regular inspections and preventive maintenance of press brake safety devices and hydraulic systems. The team of service technicians at Press & Shear is here to assist with this crucial aspect of safety.

Ergonomic practices are a further recommendation, which involves the use of mechanical lifting aids like hoists or cranes for handling heavy sheet metal. This will minimise the risk of strain and musculoskeletal injuries to operators.

Then of course there is PPE. Metalforming shops should enforce the use of appropriate eye protection, cut-resistant gloves and steel-toed safety shoes.

More information www.pressandshear.com