ISMR November 2016 | sheetmetalplus.com | 41| sheetmetalplus.com | ISMR November 201640

www.salvagninigroup.com

“We expect double-digit growth this year and are seeing steady increases

in our sales, staff, income, production and order book,” Pierandrea Bello, Product Manager, Salvagnini told ISMR at this year’s EuroBLECH. “We are also opening new subsidiaries around the world – we have just opened a new subsidiary in Thailand and now also have offices in Canada and the UAE. Customers want us to be closer to them and this is the right way to do it.”

Salvagnini exploded into EuroBLECH this year with a raft of new sheet metal technology innovations and launches. These included the global debut of its new automatic P1 panel bender, a new FMS S4-P4 line equipped with an MC8+ system with intelligent software, an improved automatic tool change feature and MAC 2.0 software on its B3 press brakes, a smart FlexCell and the launch of its new Office programming suite, Stream. It also outlined its Industry 4.0 philosophy to ISMR, with a strong focus on making machines smarter and more adaptive, able to react intelligently to the data they receive.

the new challenges of digitisation laid down by Industry 4.0. Now fully automated and adaptive, this panel bender, Bello told ISMR, is ‘a viable alternative to the traditional press brake given its particularly low cost per bend’.

“Just like the other larger models in the range,” explained Bello, “the P1 panel bender now features the ABA automatic blank- holder adjustment, to enable it to process different parts in sequence with set-up in masked time, and CLA/N negative auxiliary blades that effectively boost the machine’s versatility to enable it to process different parts in sequence with set-up in masked time. It can run parts of up to 1,250mm and has one of the lowest costs per bend in the panel bender market (up to 5/6 cents of a euro per bend, which is much lower than an equivalent

bend on a press brake). So, productivity and flexibility are its key characteristics.”

P1, like the other panel benders in the Salvagnini range, uses MAC 2.0 adaptive technology, which means that it is not dependent on the quality of the material being processed. The panel bender measures any variations in the material being processed in masked time (thickness and tensile strength) and, if these variations turn out to be outside

the acceptable tolerance range, they are compensated for automatically by adjusting blade movements, resulting in consistent bend quality even when dealing with variations in the material within the batch

and reducing waste, even when producing batches of limited quantity.

P1 can process panels with a maximum bending length of 1,250mm and a maximum height of 127mm. It features average power consumption not exceeding 3kW, silent running and a footprint of less than 8 m2 for ease of shipping and installation.

“The P1 can handle a large thickness range from 0.4mm to 2mm. This machine truly unlocks hitherto unthinkable application scenarios in terms of the type of panels that can be produced,” Bello told ISMR.

Flexible manufacturing systemsAt EuroBLECH 2016, the S4+P4 punching/shearing panel bending FMS line displayed by Salvagnini was fully in line with the principles of flexible smart manufacturing with numerous functions integrated into the individual machines making up the system and its new MC8+ smart connection module.

“Starting with the S4, there are two new features being presented at EuroBLECH. The first concerns the new adaptive control of manipulator axis movements to compensate automatically for variations in external environmental conditions, ensuring greater accuracy and ease of use. The second concerns nine holding pincers, which now come in a smart version, opening independently, and are managed by a further improved and automated system, to unlock new application scenarios and drastically reduce holding scrap,” explained Bello.

The new MC8+ multi-function system, a Salvagnini world premiere, is located between the S4 punching/shearing system and P4 panel bender. This is a smart, compact connection capable of performing eight different functions. These include conveying; rotating; stacking; de-stacking; overturning; unloading; balancing (S4-P4) and optimising flows passing through the line. With its operational features and smart Packmode, Stackmode and Dynamic Buffering software functions, this intermediate automatic module

ISMR was also given a sneak preview of its IoT (internet of Things) project, LinkS, which it is running in partnership with Microsoft. It plans to launch this in 2017.

Industry 4.0 focus“It is good for machines to communicate with each other but, above all, they need to be smart and self-adaptive in every respect, from set-up to real-time running of the actual bending or cutting stages,” Bello told ISMR. “In the age of Industry 4.0, to be effective you need intelligent and adaptive machines that can store and communicate data. The key is to enable them to act on the information they are receiving e.g. to change tooling etc. Our focus therefore has been to try to make the machines more intelligent. You can see that demonstrated here on all the machines on our booth.

“MAC 2.0 functionality is included in all our bending machines (panel benders and press brakes). During the bending process, the machine is able to analyse the characteristics of the material from the resistance that it encounters. It then adapts the bending

position of the blade for a successful bend. This is the first pillar of 4.0 - the adaptive, intelligent machine. The other pillar is the software. We are therefore launching our new STREAM process-orientated software, which makes programming easy and enhances efficiency, here at EuroBLECH,” he added.

The STREAM software suite is integral to the new Digital Factory production model proposed by Salvagnini. Serving as the production operating system, this software is no longer program-centric, instead focusing on the finished product to be produced, its value and the relevant production process. In Hanover, Salvagnini gave a practical demonstration of concepts linked to Industry 4.0, the Internet of Things and Smart Manufacturing.

“STREAM represents a change of perspective for us. We want to move the focus from the program to the final product, its work-stream and the values of that work-stream. The customer can evaluate and choose the best work-stream to make a sheet metal part. It is our own software and will be available in 2017,” explained Bello.

Originally conceived as the range’s entry-level model, the space-saving, energy-efficient P1 panel bender, designed for high productivity and repeatability accuracy, was shown at EuroBLECH in an enhanced version, ready for

FACE TO FACE INTERVIEW

SMART, ADAPTIVESOLUTIONS

Salvagnini exploded into EuroBLECH this year with a raft of new sheet metal technology innovations and launches.

Pierandrea Bellodemonstrates SAM,the Salvagnini smartmachine monitoringapp, on a smartphone

STREAM represents achange of perspectivefor us

Panel bending on the Salvagninibooth at EuroBLECH 2016 ISMR SAYS:

“Salvagnini outlined its Industry 4.0 philosophy to ISMR,with a strong focus on making machines smarter andmore adaptive, able to react intelligently to the datathey receive”

Pierandrea Bello,Product Manager, Salvagnini

A demonstration on the new P1panel bender at the Salvagninibooth at EuroBLECH 2016

handles the logical management of material flow between the S4 and the P4, saving a lot of space.

The P4 lean-2520 panel bender in the line has also been enhanced with a series of new options. The versatility of the CLA SIM automatic auxiliary blade setting unit, for positive and negative bends, means productivity and flexibility can be combined, with the option of processing a series of different parts in sequence (making it possible to produce actual kits of parts). The new CUT option to bend and cut profiles, even on different materials and thickness in sequence up to the maximum bending length, leads to further reduction of incoming sheet scrap. Additionally, the range of panels that can be produced with this machine has been extended, taking the maximum bending height from 165mm to 203mm and the depth of return bends on the short sides from 30 to 45mm, while also reducing the dimensions of the smallest panel that can be handled. P4lean-2520 also has embedded MAC 2.0 technology.

The Industry 4.0 production model is the new standard by which machine tool manufacturers are being judged. Salvagnini therefore also presented its automatic FlexCell ZERO cell, a smart and flexible FMC that integrates three smart machines with OPS-FlexCell integration software. The Flexcell on display at EuroBLECH featured an integrated L5 laser cutting system, a P2lean panel bender and a B3 ATA press brake.

“The customer will be able to use the display to choose which product to produce and the OPS-FlexCell software - handling feedback from the laser on the positioning of parts required for that given kit - will transmit the information to the downline machines, which will set themselves up completely autonomously,” explained Bello. “It is at

The Industry 4.0production model isthe new standard bywhich machine toolmanufacturers arebeing judged

Above: The new P1 electr ic panel bender

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www.salvagninigroup.comFACE TO FACE INTERVIEW

this point that the FlexCell starts to optimise because it knows how the parts have been stacked (having received the information from the laser) and automatically decides the work sequence based on machine optimisation or how the parts have been set on the stack.

“This is where we see maximum flexibility,” he added. “The cycle can be optimised based on how parts are stacked upline, or on how machines downline ask for parts required to assemble complex products, or even based on the machines and what sequence is most logical to use them to produce a given part. We are demonstrating this here, interacting in real-time with the choices made by visitors to the stand who want to test its operation, confident in the result. What’s the secret? Having smart machines that talk with each other that are capable of setting themselves up on their own in very little time, most of which is masked. We call it ZERO, as FlexCell allows zero set-up time, zero WIP and zero limitations on feasibility of the parts.”

Laser and press brake innovationsThe L5 cutting system, presented as an integrated part of the FlexCell, incorporated a series of important upgrades and improvements. These included automatic nozzle change and process control, with improved cutting efficiency and waste reduction.

APC (Adaptive Process Control), a smart process management system, improves

initial piercing when cutting medium-heavy thicknesses as well as scrap reduction because it can monitor the cutting process. The AVS artificial vision system has also been refined - whereas before it centred on holes, it now also centres on shapes marked or engraved on the surface of the blank, extending the system’s range of possible applications.

At EuroBLECH, Salvagnini also presenting OnFly 4.0, the new “on the fly” cutting system, integrated into the Salvagnini Six NC controller, featuring new, refined control of acceleration on entering and leaving each cutting segment, which results in even shorter cutting times.

The L5 system integrated into FlexCell is teamed with an entirely new compact longitudinal automation solution (ADLL) comprising a grip unit and a rake that are an integral part of the structure and enable cutting to take place between the machine’s pallet change unit and the external area. MCL, the integrated cartesian part separation system, was also presented in a new improved version with features like the “blower”, designed to blow off the little bits of scrap that sit on the newly cut sheet.

The B3.ATA press brake, now integrated into the FlexCell FMC, has now also been upgraded with numerous automated devices that make it fully self-adaptive and able to offer entirely autonomous operation, in accordance with Salvagnini’s Industry 4.0 concept. The press brake can now handle the production of parts for kits using the ATA (Automatic Tool Adjuster) flexible tool set-up through which it can set itself up and adapt to

suit the part to be produced. Re-tooling times have been halved. New dedicated OptiPress software helps the operator to determine which sequence is most appropriate for the production job at hand.

“The Automatic Tool Adjuster feature on the press brake enables users to make parts that are different from each other. We have now made this feature much faster so that press brakes can now be used for smaller batch-work, rather than panel benders,” explained Bello.

High levels of accuracy and repeatability are achieved by equipping the B3 with the MAC2.0 feature. This function on the press brake is enabled by the combination of Angle- Measurement System (AMS) and SCrowning system. The former enables the material to be bent to the correct angle, while the latter keeps this angle consistent along the full length of the bend.

Focus on the future“I am optimistic for further growth next year, ”Pierandrea Bello told ISMR. “Our sales in Europe and Asia are good. With our new office in Thailand, in addition to Salvagnini South Asia (based in Malaysia), we can supply growing south-east Asian markets. Markets in the Far East and Middle East are also interesting. Here, at EuroBLECH, we are also seeing a lot of international visitors.

“We run two or three open Techno Forums in different countries every year and are investing more and more into showrooms (we now have showrooms in Austria; Japan; China; South Korea; Italy and the US as well as a new building and showroom in Sweden). Last year, we ran about 20 events. With our ‘smart, adaptive’ approach to Industry 4.0, I believe the future is bright for us.” n

The Automatic ToolAdjuster feature on thepress brake enablesusers to make partsthat are different fromeach other

Below: Salvagnini S4/P4 FMS l ine

Below: Salvagnini’s new FlexCell

Fi l ing cabinets made on the panel bendingline on Salvagnini’s booth

Below: B3 ATA press brake