Prima Power PSBB – a Compact Flexible Manufacturing System · Prima Power PSBB – a Compact...

Prima Power PSBB– a Compact Flexible Manufacturing System

The BendThe CombiThe LaserThe PressThe PunchThe Shear

The SystemThe Software

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Prima Power PSBB– a Compact Flexible Manufacturing System

Upper and lowerwagons for rawmaterials

Servo-electricShear Genius® SGepunching & formingunit

Servo-electricShear Genius® SGeshearing unit

Sorting conveyors,C 1500

Sheared part buffer,SPB

Loading device, LD

Tulus® graphicaluser interface

Scrap conveyors

Automatic, servoelectric panel bender,EBe

Unloading systemwith tilting un-loadingtable,TUT

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5 6 7

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Buffer area for partsto be bent

Input and outputwagons for parts

Picking & stackingrobot, PSR

Position conveyor Bend part turningdevice, BTD

Loading deviceof EBe

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Flexible production Material flow can be arranged in flexible ways to transferparts directly to automatic bending, balance the differenttime requirements of bending and punching/shearing, toexit material from the system and to bring new materialinto it.The flexible and versatile buffering function ensuresthat optimum operation in terms of manufacturing cost andthroughput time can always be chosen,whatever the manu-facturing task at hand.

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Basing on decades of experience in modular FlexibleManufacturing Systems Prima Power created the compactPSBB line, which processes blank sheets into ready-bent,high-quality components automatically. PSBB stands forpunching – shearing – buffering – bending.

The productivity offered by this concept derives from inte-gration of

- Versatile servo-electric punching

- Integrated servo-electric shearing

- Servo-electric bending

- Automatic, flexible material flow and

- Sophisticated software

Flexible ways to produce

- Direct material flow from topunching/shearing cellbending cell

- Use of whole stacking area for buffering indirect connection

- Simultaneous stacking on tables/wagons andretrieval of components from tables/wagons tobending cell

- Use of whole stacking area in unattendedoperation

Some of the illustrations show equipment without safety devices and some with optional equipment

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PUNCHING AND SHEARINGShear Genius cell®

The vast majority of all fabricated sheet metal componentsare rectangular, so a highly economical method to producethem is to perform first punching and then shear the com-ponents loose in the same automatic process with an inte-grated right angle shear. Also, parts with two or threestraight edges are perfect for fabrication with a right angleshear.

Shear Genius® provides more capacity,quality and cost effi-ciency for flexible sheet metal working than any comparable

system.T ty years of experience in right angle shear tech-hirnology combined with proven field performance in nearly3,000 applications throughout the world has allowed pro-viding Shear Genius® with major benefits:

- automated flexible fabrication- no skeletons,less punching scrap – savings in raw material- no nibble marks- higher productivity- low manufacturing costs- fast return on investment

SERVO-ELECTRIC PUNCHING

The inherent benefits of servo-electric technology includeenergy efficiency, versatility and accuracy and low mainte-nance cost.This amounts to superior fabrication capabilitiesand operation economy, i.e. remarkable savings. As thepunching stroke is NC-controlled, in addition to high per-formance punching outstandingly accurate forming capacityis available. High repeatability facilitates forming, roll form-ing, marking etc. and shortens set-up times. Performancevalues of servo-electric punching are truly impressive.

PSBB

MultiTool®6 x A sizeindexable

Index Tool,Ø 31 - 89 mm.

Ø 51 mm max.

Ø 51 mm max.

Ø 51 mm max.Ø 51 mm max.

Ø 51 mm max.

Ø 51 mm max.

Ø 51 mm max.

Ø 51 mmmax.

MultiTool®MT4AU

4 x A size

MultiTool®MT4AU

4 x A size

MultiTool® MTH164 x Ø 16 mm

+ 12 x Ø 8 mm max.

Index tool,Ø 31 - 89 mm

MultiTool® MT24-824 x Ø max. 8 mm

Drop-in Index Tool3 x B size

Index ToolØ 31 - 89 mm

MultiTool® MT4B4 x B sizeindexable

Drop-in MultiTool®8 x A sizeindexable

Standard

20 hole turret

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Indexable formingØ 89 mm / 16 mm max.

max. 280 tools or

80 indexable tools


MultiTool®24 x Ø max. 8 mm

Drop-inIndex Tool3 x B size

Drop-in MultiTool®8 x A-size, indexable

Drop-inMultiTool®3 x B-size

Index ToolØ 31-89 mm





Alternative

16 hole turret

MultiTool® MTH164 x Ø 16 mm

+ 12 x Ø 8 mm max.



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max. 384 tools or

128 indexable tools

Customer specific layout with 79 tools, of which 39 index tools.Customer specific layout with 81 tools, of which 25 index tools.

Customized turret design

Either a fully customized 16-station all-index turret or a 20-station turret can be chosen. A totally re-designed turretcan be chose ; it can be customized and optimized for anynrequirement. Simultaneously, 384 tools can be available inthe turret; thus unnecessary set-ups can be easily avoided.The maximum number of index tools is 128.

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Servo-electric Shear Genius®

- Servo-electric punching, forming and bending- Servo-electric shearing with automatic clearance

settings- Loading, punching, forming, tapping, shearing and

part sorting in a single unit- Max. sheet size of raw material:

SG 1530: 3,074 mm x 1,565 mmSG 1540: 4,300 mm x 1,565 mm

- X-traverse 3,144 mm; Y-traverse 1,605 mm

Two performance levels: Pure Dynamic- Punching force 230 kN 300 kN- Positioning speed 127 m/min 150 m/min- Max. hit speed 1,800 1/min 2,500 1/min- Up to 384 tools with Multi-Tools®- Low running costs – no expensive consumables- Power consumption 5 kWh

A wide range of options

There is a wide selection of optional equipment and fea-tures with which the standard machine can be customizedto meet specific requirements. Most of these can also beinstalled later as machine upgrades:

- Extra clamp and individual movement- Multi-Tool® stations- Upforming- Part identification with different types of marking tools

SERVO-ELECTRIC INTELLIGENT

RIGHT ANGLE SHEAR

Automatic clearance setting (ACS) of the intelligent servo-electric right angle makes changing from one material thick-ness to another automatic and fast, saving time and addingproductivity.A wide range of thicknesses can be sheared,upto 5 mm aluminium.

Intelligent part sorting

N a sew shear has unique system to sort part and scrap.If there are any trims or leftover on the sheet, it is sortedout through the shear frame and conveyor.

Outstanding accuracy

As the right angle shear is an integral part of the cell andnot a separate machine, and since the sheet is firmlyheld throughout the fabrication process, high componentaccuracy is achieved.

Support of large work pieces

When shearing large pieces an automatic lifting mechanismintegrated in the conveyor holds the parts for high accuracy.

Programmable sheet holder

The lateral forces caused by the shearing action arecompensated using pneumatic sheet holders for excellentshearing quality and high tolerances. In the right angle shear,sheet holders are programmable, allowing shearing closeto forms.

ngmax.

Scratch free production

A new is having moving brushes also in front andoptioninside of the turret ,which preventsand in front of the sheareffectively the scratching of sensitive materials.The move-ment activated by the program when needed.is

Pure Dynamic

brushes up,

sheet movingbrushes down,

sheet processing

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Shear Brilliance – a new generationof advanced fabrication technology

The new, fully servo-electric Shear Brilliance features lineardrive technology in sheet positioning and raises manufactu-ring speed and productivity up to a new level.With long tra-vel of the coordinate table full working area can be used wit-hout repositioning, accurately and at great speed. Thesheets are pre-positioned during machine operation whichreduces loading time dramatically.

New generation punching technology, very high toolingcapacity, the large common working area for punching andshearing as well as high-speed co-ordinate table move-ments combine to provide truly outstanding productivity.

New generation Servo-electric punching

Up to 35 tons of servo-electric ram force allows very longcontours, using one hit instead of two. As fewer hits areneeded production is faster. Despite the ram force speedhas not been compromised.1,300 hpm is the fastest full for-mat hit rate in the market. This adds again productivity.

Servo-electric Shear Brilliance®

- Max. sheet size of raw material 3,100 mm x 1,565 mm- X-traverse 4,070 mm,Y-traverse 1,640 mm- Common working area 3,100 mm- Loading, punching, forming, tapping, shearing and

part sorting in a single unit- Servo-electric punching, forming and bending

- Positioning speed up to 210 m/min- 35 ton ram force- Hit speed up to 1,300 1/min- Up to 576 tools with Multi-Tools®- Servo-electric shearing with automatic clearance settings- Low running costs – no expensive consumables- Power consumption 8 kWh

In the same process using linear drives you gain more preci-sion,which is always a valuable quality factor.

Bigger working area

Working area is maximized with longer X- (4,070 mm) andY-traverses (1,640 mm).When working with 3,100 mm x1,565 mm sheets you can punch in all edges of the sheet andfully utilize the whole area.

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New coordinate table with linear drives

A light weight and rigid composite construction allows coor-dinate table length of 4,070 mm length and this, in turn,3,100 mm punching – shearing without repositioning.Thelightness of the coordinate table increases speed.

Fast and extremely accurate positioning with linear drives.Positioning is very fast, which again saves production time.

Fast material loading

With a new type of loading solution, raw material loadingis mainly done in hidden time, therefore material loadingtime from last shearing hit to first punch of new materialis minimal.

PSBB

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24 hole turret

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MultiTool®10 x Ø 16 mm max.

MultiTool®6 x A size

Indexablehigh forming

Index Tool8 x A size

MultiTool®4 x 16 mm +

12 x 8 mm










Index Tool3 x B size

Index Tool8 x A size

MultiTool®4 x 16 mm +

12 x 8 mm





Index ToolØ 31 - 89 mm Ø 51

mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

Ø 51mm max.

30 hole turret

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Index Tool3 x B size

The wide selection of Multi-Tools® andIndex tools adds versatility and reducesset-up times.

Vast tooling capacity

The Sheet Brilliance turret offers ahuge tooling capacity (up to 576) in a24 or 30 station turret which ensuresminimum set-up times and maximumtool quantity in single set-up.Tool sizescan be chosen by the customer whichadds flexibility required in modern pro-duction.

A wide range of options

There is a wide selection of optionalequipment and features with whichthe standard machine can be custom-ized to meet specific requirements.Most of these can also be installedlater as machine upgrades:

- Upforming- Inkjet, labelling device- Extra clamp and individual

movement- Multi-Tool® stations- Lifting brush tables, etc.- Flexible automation

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The automatic Express Bender solution, featuring PrimaPower's servo-electric technology,offers outstanding bene-fits through very fast operation, flexibility for small seriesproduction,and low energy and low maintenance cost.

Servo-electric Express Bender

- Max. bending lengthsEBe 4 2,250 mmEBe 5 2,650 mmEBe 6 3,350 mmEBe 3820 3,800 mm

- Capable of even most intricatebending tasks – with off-line programming

- Excellent bending accuracy and surface quality- High repeatability- High productivity and flexibility thanks to automatic

tool change ATC and loading in hidden time- Two operating modes for optimum surface quality- Power consumption 9.5 – 3.5 kWh1

Bending quality is excellent as required by e.g. design prod-ucts. This is achieved through precise control of bendingaxes, fast and smooth bending, open programmability,and the fact that the construction is immune to variationin thermal conditions.

Express Bender can be customized using a wide range ofoptions.

AUTOMATIC BENDINGExpress Bender EBe

Automatic unloading andstacking add unmanned

production capacity

PSBB

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Bend press

EBe has two frames: the stationary main frame (1) and theC frame (2).The C-frame mounts within the main frameand supports the upper and lower bending blades.

The upper tool (3) consists of a tool holder bar with toolsegments that can be composed to match the size re-quired by the work piece and to contract for part exit.The tools composition of the upper tool is made at 4 mmsteps.The upper tool holder can allow contraction of toolsegments for disengagement, several spaces between toolsegments and their compaction.

The fixed lower tool (4) holds the work piece in positionduring the bending procedure.It consists of a single elementthat is fitted to base beam.

There are two bending blades, the upper one (5) to makenegative (downward) bends and the lower one (6) to makepositive (upward) bends.

Two operating modes

The Prima Power solution offers a choice of two inter-polation modes of operating blades for optimum surfacequality, also ensured by brush tables. With the “rollingmode” there is no relative friction between blade andmaterial, which saves the material surface from damagesand reduces wear of the blade.With the standard “circu-lar mode”, the contact point remains constant whereasthe contacting point of the blade changes during the bend-ing movement.

Programmable upper tool crowning device

The device is used for correcting the straightness whenthick material is bent or long bends are made.

Work piece centering system

The centering system offers a major advantage as the partis centered accurately in a single operation.

The two positioning pin units support two pins each.Theseare individually controlled by 3 CNC axes for parts witheven asymmetric notches.

Manipulator

During the bending sequence, the manipulator performs allsheet movements by NC control axes once the sheet hasbeen loaded onto the machine table.

Modern software

The latest generation of Prima Power bending software(Tulus® Bend and Master BendCam) includes numerousnew features that facilitate the process from programmingto operation monitoring and has been designed especiallyfor ease of use.

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Picking and stacking robot PSR provides high flexibilityfor picking and stacking. Parts are always placed directlyto stack and never dropped. Thus high component andstack quality is ensured.

PSR with buffering functions allows re-organization andoptimization of production flow Shear Genius®from /Shear Brilliance to EBe.

For adding unmanned process time or another machine tothe value stream the PSR can be connected to ComboTower or Night Train FMS ® storages.

The PSR benefits:

Productive process

- Maximum production capacity of- Shear Genius® (SG) / Shear Brilliance (SBe) and- Express Bender (EBe)

- Balancing of cycle times between individual processes- Intermediate buffer with direct connection to EBe- Improving utilization level of EBe- Stacking wagons, parts from external sources to

panel bender- Unmanned production- Large stacking area utilized for unmanned shifts

Added flexibility

- Flexible production- Possibility to re-organize part flow order beforebending

- Large stacking area allows kit production- Possibility to add parts from externals sources to value

stream- Stacking wagons, continuous process during part

removal

BUFFERINGPicking andstacking robot PSR

PS BB

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Loading from NightTrain FMS®

PSBB can be integrated as a key element in Night TrainFMS®

Loading from wagons

Up to four wagons can be installed in the system.

Loading from ComboTower

Equipped with a C storage the PSBB line isombo Towerthe perfect solution for lights-out production of eventhe most intricate components from a variety of materials,which can be can be changed, as programmed, automati-cally. Adding a second shelving unit to the Combo Towerprovides truly extensive capacity.

The modular Prima Power process automation allows opti-mum factory logistics and using the most economical typeof raw material.

Loading from cut-to-length line

Cut-to-length line can be integrated as part of PSBBwith loading device LD. Integration is possible withwagons, ComboTower and Night Train storages.

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Loading device LD long with rotating gripper option

Connection to cut-to-length line

Cut-to-length line with automatic material change

Loading device LD

Raw material connection for LD

Fast Loading Device FLD, for fast material changes

Automatic Night Train FMS® storage for raw materialsand stacked parts

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Loading device LD

Raw material connection for LD

Automatic Combo Tower storage for raw materials

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Loading device LD long

Upper and lower wagons for raw materials

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Loading options

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PSBB standard configurations

PSBB with PSR

PSBB with PCD

Standard solutions example for...for

... HVAC

... ensets & canopiesg

... lectric cabinetse

... ubcontractorss

When...

... there is high variation in production

... production requires intermediate buffering between processes

... large stacking capacity is needed

... high flexibility is needed

... external feed in to bending process is needed

Standard solutions example for...for

... steel doors

... steel furniture

... levatorse

... ome appliancesh

... steel facades

... ighting equipmentl

... etc.

When...

... there are only a few components per nest

... the need of intermediate buffering is minimal

... external feed in to bending process is needed

... component stacking for external process is minimal

Prima Power flexible manufacturing solutions offering outstanding productivity for different applications and produc-tion needs.Most of the time solution can be found from stan-

dard manufacturing line configurations that are tailoredaccording customer needs with additional machine optionsthat fulfills production requirements.

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PCD – Picking and centring device

With PCD can flow directly from the machine cellpartsto the bending process and/or can be picked from a wagonwhere can be placed to multiple stacks. The wagontheyunderneath the PCD can also be connected to a ComboTower or Night Train FMS® storage.

Parts coming from the direct connection are positionedby PCD to be ready to be picked up by the loading gripperof EBe. Parts can then be either delivered to the bendingprocess or stacked on the wagon underneath the PCD.

Parts on the wagon can be picked up to the bending processby EBe loading gripper. Parts are always positioned beforebending. With an optional bend part turning device (BTD),parts can also be turned before the bending process.

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Cut-to-lenght line with automatic material change

FL storage for fast material changes

Loading devide LD long with rotating gripper option

Picking and centering device PCD with bend partturning option BTD

Unloading system with tilting unloading table TUT

Systems are customized using the wide Prima Power rangeof high performance machine tools, integrated cells, auto-matic material handling solution and software. Due to thewide range and modularity, the optimum solution can befound for every application and all system sizes.

The flexibility of Prima Power FMS technology extendsbeyond our own range of machines and cells.The standardPrima Power interface allows also the integration of othersuppliers' machines in the system.

Modular automation

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Automatic Night Train FMS storage for raw materials and stacked parts®

Fast loading device FLD for fast material changes

Loading device LD

Picking and stacking robot PSR

Connection to EBe with bent part turning device BTD

Unloading system with tilting unloading table TUT

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Storage connections for

more capacity and higher utilization

Integration of automatic storage capacity helps utilize bend-ing capacity to the full, allows connection with othermachines providing vast buffering capacity for optimum pro-duction flow and increasing unmanned production time.

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With Tulus software®

the process isat your fingertips

Tulus® Office

Tulus Office is a scalable software package that offers avariety of options connecting to machinery at the shopfloor.

Tulus® Power Processing

Tulus® Power Processing is a Manufacturing ExecutionSystems (MES) which is easy to connect with other infor-mation systems such as ERP. With Power Processingyou can control the whole production process, fromordering, programming and machine loading to all theway to the finished product and reporting.

Tulus® Power Processing makes the production processtransparent and easier to manage.There is always data ofthe production status and in which work stage each com-ponent is.

Tulus e-Kanban digitizes the ordering process®

Tulus e-Kanban can be used for all part ordering processes,not only sheet metal parts.Part's metadata is used to deter-mine where the order is placed,how large is the batch size,storage location,etc.Order can go either to ERP or directlytoTulus® Power Processing order management.Operatorsno longer need to look for paper orders because orders areentered digitally directly to where they are intended.

The Tulus® software family developed by Prima Power isa powerful tool for managing the entire PSBB process. Itconsists of several modules.

Tulus® Cell

Tulus® Cell is a machineuser interface which con-trols machine operation,tools, machining orderand sorting of the fin-ished parts.

Tulus® stacking & sorting management

Tulus® calculates automatically the part positions onthe pallets and in the boxes and the times at which theparts must be removed from the stacking areas manu-ally or, in the storage connection, automatically. Cassettechanges become automatic.

Tulus® Bend

The parts that come to the bending center are managedin Tulus® Bending view. With Tulus® you can controlthe bending of the parts as well as part stacking with robot(and manage stacking area of PSR robot and externalproduction).

There are three different modes for the Bending task list:

- Normal mode: parts are bent according to the se-quence in the task list.

- Search mode: parts are bent according to availability.Parts coming from SGe/SBe are handled first and partsfrom the cassette are bent from topmost stacks.

- Direct mode: parts coming from SGe/SBe are sentdirectly to bending. If there is another work active in thebending cell, it is interrupted until the direct mode parthas been bent.

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Prima Power PSBB – a Compact Flexible Manufacturing System · Prima Power PSBB – a Compact...

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