FOCUS ON FOLDERS
Electro-kinetic bending on the Biegemaster BendTron .
The folding process is suitable for flexible applications because the tooling is not specific to the material thickness or angle required
simplify the set-up process by advising the operator where to put tool stations . Common tooling allows for rapid changeover between parts and makes it easy for a single employee to program , operate and set up the machine for any compatible part . While not ‘ a one-sizefits-all ’ solution , folders offer strong flexibility for a wide variety of needs .
Another advantage is part handling . Larger parts can be manipulated on the gauging , eliminating the need for multiple operators and increasing part accuracy . Folding machines clamp and bend the part when it is laying flat on the gauging table and the flange is being bent , which helps accuracy so that the operator does not need to ‘ manage ’ the part during the forming process . Larger parts that require two operators typically can be manipulated by one operator on a folder because the bulk of the part is resting on the table and the operator can rotate it by themselves .
Folders and press brakes complement each other in sheet-metal bending operations ; they each have individual advantages and benefits in the press shop .
Folding innovations
In this article , we highlight some of the latest innovations in global CNC folding and software innovations , technologies and software .
German folding specialist , Biegemaster , designed the Biegemaster BendTron to be its first generation to be driven completely by electric motors . The BendTron enables users to bend all common profiles with a bending length ranging from 4-15 metres with material thicknesses of up to 1.5mm ( steel ). It is particularly suitable for demanding roof , wall and façade profiles . Precise positioning is possible with an electronic back gauge and flexible sheet metal grilles .
“ Shaft-controlled bending is assured through fully electrokinetically driven bending joints for quiet and powerful operation . Inclined bending beams and optimised clamping beam geometry offer a high degree of flexibility and short counter-folds ,” added Biegemaster .
The Biegemaster Dura offers a wide range of applications for simple and quick bending of demanding roof , wall and façade . Common profiles from 3-15 metre bending lengths with material thicknesses of up to 3mm can be folded . It is optionally equipped with a hydraulic adjustable clamping beam for material thickness adjustment . There is an archive of all previously used projects on the machines and an intuitive control system via multi-touch display with a wide range of functions .
“ For double bends , the Biegemaster XBend bends material thicknesses of up to 2mm steel sheet metal automatically ( lengths of 3-12 metres ). Users benefit from high productivity and easy handling . Fully automatic bending is possible in two directions without turning the sheet around and an electronic back gauge ensures precise positioning . The clamping beam can be controlled with millimetre precision for perfect folds and automatic loading assistance is featured for the easy insertion of sheet metal ,” added the manufacturer .
Blech-Tec GmbH manufactures mini bending machines for small parts production . The BT-500 is a folding machine and press
The combination BT-500 folder and press brake in one machine . brake in one . Combining both bending processes offers flexibility , as both processes have their geometric advantages . The BT-150 is designed as a table machine for even smaller parts .
“ Our patented folding process yields a result with hardly any bending traces because the tool lies flat against the workpiece at all times . In addition , users benefit from the enormous precision of the BT-500 , which is designed for small parts , and the comfortable two-finger guide unit . The unique design enables different kinds of bending even in one program . The comfortable two-finger guide supports these new possibilities . It is designed as a compact freestanding machine , which can be operated while sitting or standing ,” said the manufacturer .
Folded and bent parts from Blech-Tec GmbH .
Companies in The Bradbury Group have been manufacturing rollforming machinery since 1959 . The Group has also developed a hydraulic folder , which features the Intelli- Fold™ Controller made by its partners at Beck Automation . The Intelli-Fold™ Controller features resident programs and a graphic display that allows operators to save time by sketching a part profile and then entering its dimensions and angles . Screen prompts guide the process .
Bradbury folders come with free firmware downloads from Beck Automation and controllers with optional office-to-folder download capability . Standard models are designed to handle 30-gauge to 11-gauge metal and are available in five lengths – 13 ’, 21 ’, 26 ’, 33 ’ and 40 ’.
“ Programming and machine operation are easily learned . Repeat accuracy is +/ -1 / 2 degree . Machine design allows open hem , closed hem and teardrop hems . Two-stage hydraulics combine fast cycling with soft starts and stops for reduced wear and tear on folder and operator . Two-position back gauges minimise travel time . An optional stop can be used to create tapered sections . Beammounted slitter and form tooling options further enhance productivity . Wherever possible , we have incorporated readily available standard components to simplify service and reduce downtime ,” said the company .
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