Automatic metal punching & shearing system Salvagnini S4Xe.40
|Maximal cutting capacity 40 kg/mm (steel)||4268 x 1650|
|Maximal sheet transverse (to allow rotation of workpiece), mm||4532|
|Minimal sheet dimensions (X x Y coordinates), mm x mm||370 x 300|
|Piercing technology||Multipress head|
|Denotation of multi-cylinder head and tool position number||H2/76; H3/96; H4/72; H5/64; H6/84|
|Piercing tool changeover time, sec||0|
|Option to use two or more tools at the same time||Yes|
|Minimal material thickness, mm||0.5|
|Maximal working thickness, mm||5.0|
|Maximal piercing thickness for stainless steel (680 MPa), mm||3.5|
|Maximal piercing thickness for aluminum (200 MPa), mm||2.0|
|Sawing technology||Simultaneous or independent cuts along X and Y|
|Gap adjustment between blades||automatic|
|Length of blades (X and Y coordinates), mm x mm||500 x 500|
|Maximal piercing thickness, mm||5.0|
|Maximal cutting thickness for stainless steel (680 MPa), mm||3.5|
|Maximal cutting thickness for aluminum (200 MPa), mm||2.0|
|Maximal speed (raising and lowering), mm/s||132|
|Maximal speed of worpiece X-coordinate travel, m/min||96|
|Maximal spindle speed, rpm||163|
|Maximal pressure, t||30|
|Maximal X-coordinate rapid traverse, m/c2||15|
|Working cycle power consumption, kW||21.6|
|Standby mode power consumption, kW||0.7|
|Maximal sheet thickness with enlarged clamp opening, mm||5|
JOB.CONSOLE is the set of software packages that are integrated into the SiX controller to graphically manage and supervise the system. JOB.CONSOLE provides the operator with all the information he needs to run production, thanks to the following modules:
- Salvagnini Console. The main system controlling console, which allows intuitive saving and editing programs directly via a user-friendly graphic interface and moving parts of the system in semi-automatic mode, under the guidance of the graphic interface.
- Maintenance Manager. Database that analyzes the movements and cycles of the components of the system, allowing simple and structured management of maintenance activities.
- SDEX. Salvagnini compiler that interprets programming instructions based on geometrical notions and defines the production cycle, optimizing sheet movements and cycle times.
- JOBS4Xe. Application for dynamically programming the day's production. The operator can create a series of programs called “job” (or list) on the screen. JOBS4Xe allows a series of jobs to be prepared, edited or suspended, without stopping the current production.
- DBHT. Graphical database that checks the punching tools present in the operating head. The system warns the operator if the punch set-up defined is not compatible with the part to be produced.
- EasyData. Integrated diagnostic software for interactively browsing the documentation. EasyData provides information about each of the components managed by the Salvagnini CNC digital controller, using photos, part codes and automatic filters.
A single structure with no stops for tool changes: Multipress Head
Patented by Salvagnini, the multi-press head consists of a die-structure in which the punching stations are fitted with all the tools needed for production. Contrary from traditional punching machines where one press is used and the tool change mechanism is automatically moving and setting-up the necessary punching tool, S4Xe is employing as many presses as there are tools (up to 96 different tools). That’s why each tool can perform independently or perform combined tasks while no stopping is required for tool change since the tools are always available. This specific working principle of multi-press head function makes the S4Xe unbeatable in terms of both cycle time and tool life. The Salvagnini company offers 5 different multi-press head configurations, with different numbers of stations, to meet the diverse production needs of each and every customer.
Eliminated waste and balanced kit production: Integrated Shear
The shear is adjacent to and integrated with the multi-press head to create a single structure, what makes the machining center an extremely compact, unique multi-function system ensuring an extremely high degree of efficiency and performance ratio. The shear of the S3Xe machine consists of two 500 mm independent orthogonal lower blades and two upper blades that are also orthogonally positioned, mobile, and equipped with blankholders. That way, the shearing device permits cuts of any length along both orthogonal (the X and Y) axes and can shear the uploaded sheet into parts of any size as necessary, without holding scrap from punching/shearing area or from the places where the sheet has been held by the blankholders.
In traditional systems, individual parts making up a multiple sheet or nesting pattern are processed sequentially once the whole starting sheet has been punched. Salvagnini’s Punch&Cut function, on the other hand, recognizes the punchings belonging to each individual part and accordingly groups them together and processes them separately. This increases the accuracy and repeatability by minimizing the stresses arising in the material, ensures further optimization of the production stream and balanced kit production or multiple productions (as it is generally required when on flexible manufacturing system line).
Automatically controls ramps and reduces cycle times: Manipulator
The manipulator (patented by Salvagnini) slides on guides integral with the lower part of the "C" structure, for high positioning precision; it has a lightweight movable symmetrical device, with 9 pincers and 9 mechanical references, for perfect centering and outstanding process reliability. The manipulator is equipped with two pairs of brushless motors: one pair uses proprietary hand-over kinematics while the second uses gantry control logic. This solution guarantees the following advantages:
- It greatly increases manipulator dynamics and maximum speeds;
- It reduces cycle times, allowing greater machine productivity;
- It guarantees processing accuracy, thanks to the perfectly balanced thrust;
- It enhances dynamics, even when processing thick material, or on type 40 machines (that can process blanks 4 meters (157”) long);
- It maintains accuracy, even with very long manipulator strokes.
Replacing tools, if such is required by the production, takes only a few minutes. It consists of releasing the tool holder magazine, which moves using dovetail guides, replacing the punch and die, and installing the tool holder back in place.
The S4Xe punching-shearing center can mount different types of feeding connections: from in-line conveyors and automatic destackers to automatic tower sheet stores - both single-tower sheet stores for solitary sheets and multi-tower storage systems for pallets with sheets. The MD store is an automatic store for packs of sheet metal that feeds the machine with single blanks in masked time (i.e., at the same time when the machine is performing other operations). This solution covers a wide range of storage needs, eliminating unnecessary material transfer and facilitating the just-in-time or kit production of parts using different gages and materials.
The punched and/or sheared parts can be automatically directed to different collection bins, to buffer stores, to one or more stackers, to intermediate stores or straight to other machining centers. Intermediate stores are ideal for even distribution of work within the production line. The parts after exiting S4Xe are dropped on one of the shelves in the warehouse and properly positioned thanks to the mechanical stop. Unlike other solutions available on the market, the Salvagnini intermediate store does not use the LIFO (Last In – First Out) working principle but, depending on the process to be performed next, place the shelf with required parts opposite the feeding conveyor of the next process in the production stream. The MC Cartesian unloading robot picks the punched and/or sheared parts up as they leave the S4Xe punching-shearing center and stacks them on one or more tables thanks to two manipulators with suction-cup gripping that run along a carriage and can rotate around a vertical axis. Manipulator rotation allows the parts to be stacked and positioned correctly for the subsequent processes. The two manipulators can work either independently or simultaneously if required by part dimensions.
Salvagnini automation concept
The systems offered by Salvagnini are extremely flexible, suitable for all production requirements and able to reduce production and operating costs while still providing the latest trending manufacturing features and the most competitive production strategies. Due to the wide range of available devices for material transportation, S4Xe can work in the unmanned production mode and can be easily integrated into flexible manufacturing systems (AJS or FMS). Various loading and unloading devices allow optimization of the production flow by eliminating unnecessary operations and the associated costs and providing at the same time high quality and profitable production.
S4Xe process programming software
Opera-OPS is a software package that can handle the requests from the company’s resources management systems. This program receives tasks from ERP systems, analyzes distinctive parameters such as numbers, codes, and priority dates of orders and deliveries; it generates a program for a single part using the available CAD / CAM applications, and creates the work programs for the machines of the system. If WMS application is available, it interfaces to management systems in real time and realizes full control of raw materials and semi-finished products through the entire production process, optimizing the location of pallets, providing storage place for packs and dynamically searching for available positions.