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Automated panel benders Salvagnini Р4lean-2516

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Specifications
Maximal grinding surface diameter, mm 2795
Maximal thickness, black steel (700Н/mm?), mm 1524
Max. permissible slanting for rotation, mm 2800
Maximal incoming sheet length, mm 2500
Maximal bending height, mm 165
Minimal thickness, mm 0.5
Average power consumption, kW 14
Max. steel thickness and bending angle, UTS 410 Н/mm2, mm 3.2 (± 90°) / 2.5 (± 120°) / 2.1 (± 135°)
Max. aluminum thickness and bending angle, UTS 265 Н/mm2, mm 4.0 (± 120°) / 3.5 (± 130°) / 3.0 (± 135°)
Maximal sheet thickness with enlarged clamp opening, mm 4
Max. stainless steel thickness and bending angle, UTS 660 Н/mm2, mm 2.5 (± 90°) / 2.1 (± 125°) / 1.6 (± 135°)
Maximal feeding distance, mm 660
Maximal bending pressure (blades), kN 1060
Design features

No time wasting: centering only once in masked time 

The sheet centering principle on Salvagnini panel benders represents a considerable advantage over similar technologies because the blank is centered only once, at the beginning of the machining cycle. On the P4, feeding and the centering cycle take place in masked time, thanks to the flying pincer carriage which, once it has positioned the blank, returns to its rest position while the centering cycle takes place. Since the centering system references the shape of the blank, finished panels are always dimensionally perfect because any deviation from specifications is absorbed by the first bend.

Universal tools with zero retooling time

The press is the functional heart of the Salvagnini P4 Panel Bender. It is composed of:

  • A solid structure on which the blankholder tool is installed;
  • The bending unit (bladeholder), a C-shaped structure that holds the upper and lower blades, as well as any optional tools (CLA, CUT);
  • The counterblade, which is joined to the press and works with the blankholder to firmly grip the blank while the blades are bending it.

The blankholder: a solution for all production requirements

In Salvagnini panel benders, the blankholder changes its configuration according to the dimensions of the panel being bent. The blades of the bending unit are universal so this is only the blankholder that automatically changes its panel holding length to provide a different bending angle. The blankholder can be composed in 5 mm steps, from the minimum to the maximum length. The central section is shaped to give the manipulator as much space as possible to advance.

The automatic blankholder set-up, the instant composition version, is known as ABA (Automatic Blankholder Adjustment) and is fitted on all **16 model machines. A programmable blankholder for automatic set-up, the U1, is installed in the **25 models where, like the ABA, it performs tool changes in masked time. With a set-up system like this, blankholder tool composition takes place in masked time and in-cycle set-up adjustment requires zero time.

The manual version, referred to as MLA (Manual Length Adjustment), allows fast and ergonomic set-up by inserting/removing light, modular segments and moving end segments along support guides.

Tools for special applications

Sometimes for special production needs, such as some tubular bends, or panels with complex bending profiles, it is industrially necessary to use special tools such as the T or P and CLA options. The T (P4-2725) or P (P4**16) option is a mechanism that can insert and remove an auxiliary tool under the blankholder quickly and automatically. The CLA tools are modular in length, engaging and disengaging quickly and automatically between the blank and the bending blades. They are used to make bends that are shorter than the side being bent. The CLA blades can be positive (for making upward tabs) or negative (for making downward ones).

Bending: fast, easy, economical

The manipulator moves the metal sheet along the horizontal surface. Installed on the manipulator, the turning device quickly and accurately turns the sheet with its side to be bent towards the press. The upper clamp firmly holds the sheet at a predetermined position. The bending unit makes the required number of bends by means of the bending blades, upwards or downwards, in a quick succession.

The manipulator: superior precision and versatility

Sheets are handled, gripped and rotated by the manipulator, clamp and rotator respectively. The sheet movement throughout the entire processing cycle is both fast and totally automatic. The upper rotating clamp movement control and adjustments help to reduce cycle times and control the clamping force. The innovative structure and digital drives of the electric motors of the latest generation mean that sheet clamping and rotation remain constant during the entire bending cycle. The continuous rotator on its part guarantees 0.01° angular resolution for higher production flexibility that enables manufacturing of even multi-faceted panels.

The ABT™ technology

Different batches of material often yield different results (bends more or less closed) and show variations in machine behavior because of changing atmospheric conditions (temperature). Inconsistent behavior affects part quality and requires the product to be continually modified, leading to considerable material waste. To enhance processing quality, repeatability and accuracy, Salvagnini has implemented proprietary technology known as ABT™  (Advanced Bending Technology) in its panel benders. This is a set of components, formulas, algorithms and devices which are integrated into a panel bender in order to provide unparalleled quality with low power consumption and a minimum layout.

Easy programming even for very complex bending sequences

Salvagnini Console. The main controlling module, which allows writing, editing and running programs directly via a user-friendly 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.

JOB P4. Application for dynamically programming the day's production. The operator can create a series of programs called "job" (or list) on the screen. JOBP4 allows a series of jobs to be prepared and modified without waiting for the job in progress to be completed.

Easy Data. 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. The system’s electrical and/or hydraulic diagrams are available in the main command console. The operator can: 

  • Search for specific text or codes in the diagrams;
  • Add personalized notes or photos to the image archive;
  • Print one or more diagrams from the documentation or export them in PDF or JPG format.

Load/Unload systems

P4 panel benders can be loaded manually (with HPT) or automatically. The automatic loader PCD picks sheets from a stack of blanks and feeds them to the panel bender in masked time (ie, during the operating cycle of the machine). PCD can also be used as a transporting link for the sheets coming from the punching/cutting system S4, at the same time. There are also solutions for automatic loading from compact (MVP) or extended (MV) tower tray stores. The proprietary PackModus software provides a fully balanced production process and optimally controls all intermediate stations, allowing the production line to operate without interruption.

P4 panel benders are well prepared for working integrated with manual, automatic and robotic unloading devices. The most popular panel bender unloading systems are: 

  • Manual: the operator picks up the bent part and brings it to the desired location.
  • Automatic: the connected equipment unit automatically transports the item to the next station (for welding, assembly, or painting).
  • Robotic with pallets: a robot unloads the finished parts and stacks them on pallets.
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