MANZONI MACHINERY

MANZONI MACHINERY Innovative Solutions for Cold Forming

The revolutionary machine that

has changed the world of

cold forming headers

Completely built in steel, thanks to the revolutionary sliding system

without bronze liners, Manzoni Absolute Zero Clearance , it is able to

manufacture at high speed, complex shape parts with great precision.

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MANZONI MACHINERY

INNOVATIVE SOLUTIONS FOR COLD FORMING

Manzoni Machinery machines are the result of a new study that has changed the headers construction

technique. Indeed, thanks to a great work of research, for the first

time on this kind of machines have been applied innovative

technologies that allowed the use of new and more resistant

materials. Furthermore the machine has been conceived with a

new timing diagram that along with a design caring about the

masses in movement, it permits to reach high speed of work,

smoothly, without loss of balance and in total absence of

vibrations. The result is a machine of innovative design, completely

built in steel, of small size, able to manufacture at high speed

complex shape parts with great precision, with exceptional

characteristics of stability and sturdiness.

Sliding movement without bronze liners Manzoni Absolute Zero Clearance

Differently from traditional headers, Manzoni Machinery machines do not use bronze liners. Indeed ram and

transfer are mounted on special bearings specifically developed for this application. This assure the total

absence of any play and, therefore, an high heading

precision even at high speed. Manzoni Absolute

Zero Clearance®

permits to produce with great

precision parts with very tight tolerances.

Furthermore, thanks to the absence of plays,

punches are always aligned and no adjustments

are needed, drastically reducing the time of

change over.

Manzoni M odular S teel Frame

Manzoni Machinery machines, differently from traditional headers, are built only with special steel using the

Manzoni Modular Steel Frame®

concept. The machine�s frame is made of steel with a special assembling

technique that assures sturdiness, rigidity and high resistance to overloads. Compared to machines with cast

iron frame, it�s possible to reach higher heading tonnage while containing

machine�s dimension. This allow a big space saving on the shop floor. Headers

built with the Manzoni Modular Steel Frame®

are 3 times more tough than

traditional machines.

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MANZONI MACHINERY

Easy and fast tool change thanks to the system Read, Set & Go®

In order to make the tool change easy for the operator and above all, to reduce downtime, Manzoni

Machinery machines are conceived with the comfortable system Read, Set & Go®

that allows any operator

on the shop floor, even without experience, to quickly and easily set up the header. Indeed

the position of all machine�s mechanical devices is clearly indicated by indicators,

readers and displays that allow the operator to set up the machine as it was last

time the same reference has been produced. This assures a drastic reduction of

change over time. Furthermore the ergonomic design, the lower frame and

the great accessibility of all adjustments make the operator�s job easy and

comfortable.

Innovative Timing Diagram

The machine is based on an innovative timing diagram that, analyzing time and masses in movement, it

permits to reach high speed of work, smoothly, without loss of balance and in total absence of

vibrations. This great steadiness is the key factor

that allows Manzoni Machinery machines

to reach high speed without

mechanical stress and with very

low noise emissions.

Easy Move Control Panel®

with user friendly Touch Screen

A comfortable touch screen colours control panel, easily moveable where needed, allows

the operator to control all functions of the machine, without the need to move around.

Based on a advanced technology computer, it is user friendly and simple

to understand. Thanks to its big memory it can save the

complete set up of the machine under an article number so

that next time the same part will be produced, the machine

adjustment will be a lot more quick and easy.

MANZONI MACHINERY

High speed bushing cut off

A special system of cams and levers produces a very high cutting speed and

gives to cut off precision and accuracy. The knife is guided trough all its

length to avoid even minor flections that may reduce blank�s precision and it

does not require any adjustment during job change. For this reason Manzoni

Machinery machines are particularly suitable for the manufacturing of high precision parts

where accuracy of cut off it�s necessary.

Soft Kick Out Cam®

on die side

Kick out on die side is realized through cams with the special

profile Soft Kick Out Cam®

with a smooth and progressive

action that makes possible to easily produce very short parts

without the need of special tooling or too complicated and

expensive mechanical devices.

Kick out on punch side

K.O. stroke and K.O. position can be individually adjusted simply setting

P.K.O. cam. The long K.O. stroke permits the production of special parts

and in case of very short length the K.O. pins may be used to sustain the

parts while is ejected from the dies, giving more

time to fingers to grab them.

MANZONI MACHINERY

Punches always aligned: quick and easy change over

Thanks to the total absence of plays, punches are always aligned.

Avoiding the need of alignment at each tools change, change over time are drastically reduced.

Transfer fingers with M anzoni Extra Deep Forming ® system

Transfer fingers are designed with a special movement that allows the production of very special

parts. The Manzoni Extra Deep Forming®

system indeed, thanks to the quick and wide movement

of fingers, permits the production of parts with big heads and allows the

punches to penetrate into the dies to make extra deep holes. The

production of the same part on a standard header would require a

machine of bigger size, and therefore more expensive.

Manzoni Short Parts Holder®

In case of very short parts, the short blank can be steadily held between die and punch K.O. pins while is

ejected from the die, giving more time to fingers to grab it.

Extra transfer finger

All machines are equipped with an extra transfer finger to place the produced part as needed. The extra

finger is very useful for the production of rivets and rivet nuts because it make sure that parts are always

stripped out of the pin, avoiding in this way dangerous overloading to the machine.

Machine stop with transfer fingers open

To avoid tool damages, the machine always stops with transfer fingers open.

MANZONI MACHINERY

Wedged ram

Ram movement is realized through a new system that allows to discharge all heading forces on the wedge

instead of loading connecting rod and crank shaft. This eliminates all plays and wears

allowing a high and steady heading precision, even after several years of work.

Wire feeding: linear with grippers or standard with wire feed rolls

Customer can chose between a linear wire feed with grippers and a standard system with wire feed rolls.

The linear wire feed assures higher cut off precision, reduces wire change

time and can handle a wide range of wire diameters

without the need of any

change.

Tool set up made easy thanks to the innovative system Manzoni S low M otion Ram®

The advanced technology inverter along with the vector motor, allow the

operator to approach punch and dies

at extremely low speed, to check and

avoid any possible tool damage. A

simple touch of an icon on the

touch screen activates the

Manzoni Slow Motion Ram®

mode.

MANZONI MACHINERY

Controlling the power to save energy

The main motor of the machine is another innovation in this field. For the first time, indeed, has been

installed on a header a vector motor with double encoder and torque control.

Manufactured in Italy by a company leader in this field, the motor is controlled by an

advanced vector driver and it�s in constant dialog with 2 encoders installed

on the crank shaft and the motor. This powerful system guarantees a perfect

torque control allowing the header working always with high

performance, even at low speed. The new vector control

releases power to the motor

only when is needed, allowing

low consumption and

important energy saving, that

reach even 50% of traditional

machines.

Main electrical cabinet on board

Electrical cabinet is designed and manufactured in Italy using Telemecanique products and

fulfils all CE requirements. The use of advanced technology products has allowed to

increase the calculation power while containing dimensions of the cabinet.

Therefore the cabinet has been integrated into the machine, inside the sound

enclosure, eliminating those cumbersome cables always left on the floor and

allowing at the same time, big space saving and easy movement around the

machine. The electrical circuits are easily accessible by an external door directly

into the sound enclosure.

MANZONI MACHINERY

Manzoni Teleservice Assistance®

Beside a fast and timely on site technical service, MANZONI MACHINERY provide his customers with the comfortable and efficient

Manzoni Teleservice®

Assistance. In case of an anomaly, an engineer

located at the headquarter, thanks to a fast modem line, can

connect his computer with the machine in the plant and

detect any potential defect without the need of travelling

with the inevitably long waiting time for the customer. With

Manzoni Teleservice®

Assistance is possible to perform an

alarms diagnosis, check data log, verify functions state and, in case of a new

software release, upgrade the PLC.

Quick Change out of machine (options)

When frequent job changes are needed, the quick change out of machine allows important time saving as it

permits to the operator to prepare the next tooling on the bench, while the machine is producing. To change

job is therefore only needed to replace the various tools already set up and to run the machine without any

need of other adjustments. Downtime is drastically reduced.

Quick change kit consists of:

- punch block holder

- die block holder

- set up bench

- transfer jig

- electronic adjustment of cut off length

- electronic adjustment of kick out dies

- memory store of electronic adjustment under the article number

MANZONI MACHINERY

TECHNICAL SPECIFICATIONS

MA MB MC ME

Number of dies 5 5-6 6 6

Max wire diameter (600N/mm2) 8 mm 11 mm 20 mm 33mm

Cut off length 90 mm 100 mm 150 mm 220 mm

Max K.O. die side 90 mm 90 mm 140 mm 210 mm

Max K.O. punch side 22 mm 30 mm 42 mm 80 mm

Max head diameter 20 mm 24 mm 32 mm 50 mm

Heading tonnage 70 Ton 100 Ton 200 Ton 650 Ton

Max speed 370 pcs/min 280 pcs/min 180 pcs/min 110 pcs/min

Power 29 kW 38 kW 70 kW 150 kW

Weight 11 Ton 13 Ton 34- Ton 120Ton

Dimensions (included electrical

cabinet)

2.200 x 3.600

X 2.000h mm

2.200 x 3.600

X 2.000h mm

3.000 x 5.700

x 2.800h mm

4.200 x 8.000 x 3.500h mm

Max diameter Dies Ô50 x 165 mm Ô60 x 165 mm Ô94 x 238 mm Ô150 x 300 mm

Max diameter Punches Ô40 x 100 mm Ô45 x 105 mm Ô70 x 140 mm Ô120 x 220 mm

Knife Ô 26 mm Ô 32 mm Ô 56 mm Ô 92 mm

Bushing knife Ô 25 mm Ô 30 mm Ô 55 mm Ô 90 mm

MANZONI MACHINERY

EQUIMPMENT

STANDARD EQUIPMENT

Manzoni Absolute Zero Clearance®

Soft Kick Out Cam®

Manzoni Short Parts Stopper®

Manzoni Slow Motion Ram®

Manzoni Modular Steel Frame ®

Manzoni Extra Deep Forming®

Easy Move Control Panel ®

Read, Set & Go®

Manzoni Teleservice Assistance®

Double encoder vector motor with torque control

High speed bushing knife

Safety brake-clutch on flywheel

Positive K.O. on each station, independently adjustable

Display of position of K.O. pins inside dies

Pneumatic lock of backing screws

Extra transfer finger

Motorized lifting and lowering of transfer unit

Wire feed: choice between linear system with grippers or wire feed rolls

Double antibacklash system on wire feed rolls

Trimming station on last die, with cam always installed

2-hand jog system

Transfer unit set up jig

Double set of wire straightening rolls

Double lube system with filtration

Separate tanks for tool lube and machine lube

End of coil switch

Tool area lamp

Safety switches on all doors

Short feed detector with pneumatic release of first finger

Housing for load monitor sensors

Housing for induction coil heating system

Housing for air cleaner

Sound enclosure

Electrical cabinet and safeties made in compliance with CE standards

MANZONI MACHINERY

OPTIONS

Good parts conveyor

Scrap conveyor

Induction coil heating system

Quick Change Kit out of machine

MANZONI MACHI NERY: The only headers in the world guaranteed 3 years

Designed in Italy, built in China by Italian engineers.

ITALIAN QUALITY - CHINESE PRICE

MANZONI MACHINERY