29 November 2022

The design of the two X-Press 165/3000 and 80/2000 with automatic tool changer

For Effediemme a steel and metalworking company, we made two new hydraulic press brakes that differ in tonnage and length: the first 165 t for 3100 mm, and the second 80 t for 2100 mm. They were specially designed at the customer’s request to be used in pairs, with the addition of the Agile² automatic tool changer, which allows the two press brakes to be associated with the same magazine and equipped through a single system. In collaboration with Argesystems, we have implemented this automatic tool changer tailored to our Gasparini Industries press brakes for companies that demand the most from their machines. In this way they can achieve a significant improvement in efficiency, which then translates into a marked increase in productivity.

The most important advantage is the possibility of being able to carry out the tooling and bending process at the same time: in fact, while one of the two press brakes is being tooled, the other remains operational and can therefore continue its work process independently.

Agile² is the single-bending machine that is characterized by its ease of use, automatic tool configuration and cleaning, compatibility with Wila and Promecam tools, and a simple and intuitive user interface. It also ensures less risk of accidents at work and thus makes the work process more convenient and safer.

But how does the tooling process work?

  1. Job setup
    The operator begins by selecting the bending program from the CNC for the relevant press brake and starts the machine setup. He then brings the machine to the working position, enables the Agile² automatic tool changer and opens the door on the machine side, thus being able to initialize the process.
  2. Tooling phase
    The shuttle picks up tools from one of 10 combined racks of punches and dies, and places them inside the work area.
  3. Preparation for bending
    Once tooling is complete, the operator closes the door and enables the press for the bending process..

Regarding the characteristics of the two press brakes, in both cases the bench-beam span is 500 mm, with a Y-axis stroke of 300 mm. The clamping system is a pneumatic type with micro-adjustment for Wila tools.

The 165-3000 press brake is equipped with Gasparini’s Adaptive Bending System: the patented system in which a sensor located in the upper beam detects the deflection of the latter since bending begins. The CNC drives the pistons in the lower beam until the measurement of the second sensor placed on it is equal to that of the first. In this way, the two beams are perfectly parallel, allowing total control of the angle.

The main technical features of the press brake

The backgauge for the 165-3000 bender is 5-axis (X-R-Z1-Z2-X6) CNC-controlled, while that of the 80-2000 is 4-axis (X-R-Z1-Z2).

Sliding front supports were provided for both, but for the 165-ton bender they were suitably machined to allow installation of the Laservisor angle control system with automatic positioning. In addition, wireless foot pedals were chosen.

To reduce waste and increase productivity, the two hydraulic press brakes are designed with the ECO energy-saving system, which provides only the power needed for the bending process. During the production cycle, oil stress and energy waste are reduced by up to 50% compared with the standard version.

The CNC is of the ESA S 660 W type, with 3D visualization. Tele-Link remote service functionality has also been arranged, and communication standards conforming to Industry 4.0 Intelligent Factory models have been installed.

The safety system is of the DSP-AP laser type with PLC: it generates a visible laser beam in accordance with EN12622. The beam protects the operator from the danger of crushing between punch and die. Thanks to CNC-controlled motorized positioning, the transmitter and receiver automatically position themselves at the exact height according to the tools in use and the working conditions.

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