BENDING + AUTOMATION
4 BENDING Bending Bending is a procedure for forming a flat, sheet metal workpiece. It immediately follows cutting in the processing chain. The workpiece lies on a bottom tool with a v-shaped opening. A wedge-shaped tool (punch) presses the workpiece into the v-opening and thus bends it to the desired angle.
BENDING 5 Air bending During air bending, the upper tool presses the workpiece into the bottom tool opening, however without bottoming. The workpiece rests solely on the two edges of the bottom tool during the entire bending process. The bending angle is determined by how deep the top tool plunges into the bottom tool. Air bending permits bending at various angles without a tool change. Stamping During stamping, the stamp presses the workpiece into the die with a pressure that is much greater than during air bending. Since the stamp and die have the same angle, the workpiece is stamped out. As a forming process, stamping allows very high angle precision. Different sheet thicknesses and spring backs of the material are balanced out through pure bending force. The Bystronic pressbrakes generate an extremely precise pressure. This creates a stamping process of the highest quality. In addition, smaller radii and shanks can be generated than with air bending. Dynamic crowning Bystronic has long used dynamic crowning on the Xpert model range pressbrakes. This unique compensation system adjusts the curvature of the lower beam automatically during bending. State-of-the-art dynamic crowning makes this correction in real time and with the latest sensors. Users can therefore achieve exact, constant bending results, and this even with bent parts that are more than 9.8 ft long. Crowning 4 Precision Precision is the most important yardstick for pressbrakes. Slight deviations from the desired bending angle are physically unavoidable. The bending angle can either be basically inexact or can vary across the entire bending length. During air bending, compensation systems balance out these errors. Bystronic uses the unique hydraulic dynamic crowning technique on its pressbrakes: The stamp and die are specifically curved to balance out the deformation caused by the bending process. Another decisive factor is the behavior of the workpiece during bending. For precise bending results, state-ofthe-art sensors provide all required information to the pressbrake controller. This data is evaluated here and an intelligent bending process is implemented thanks to automatic corrections.
6 BENDING Requirements and solutions Bystronic offers the most varied assortment of pressbrakes on the market. All models offer unique benefits: High to very high positioning and angle precision High to very high flexibility, which is especially relevant in production of individual parts, small series and complex jobs Huge selection of bending tools Simple machine programming and state-of-the-art CAD/CAM software Machine operator support with bending aides, stop systems, and visual functions Machine Sheet thicknesses Tonnage Bending length Typical range of materials Xpert 40 0.020 0.060 in 44 US tons 3.4 ft Xpert 80 0.020 0.197 in 88 US tons 5.0 ft Xpert 60 320 0.060 0.312 in 66 350 US tons 6.7 13.4 ft Xpert 250 1000 0.120 0.625 in 275 1100 US tons 16.7 33.4 ft Xpert Tandem 0.060 0.625 in 132 2204 US tons 16.7 66.9 ft Xact Smart 0.060 0.312 in 55 330 US tons 5.2 13.4 ft Xcite 80 E 0.020 0.120 in 88 US tons 6.7 ft Not all products listed in this brochure are available in all countries.
BENDING 7 Part geometries Easy Moderate Complex Xpert 40 + 80 Xpert 60 320 Xpert 250 1000 Xpert Tandem Xact Smart Xcite 80 E optimal area of application Sheet thicknesses According to user statements, users process this typical range of materials on this model. The exact values can be found in the table (page 6). Process speed Expanded performance through a range of equipment, such as high-speed packet, Fast Bend +, Energy Saver
8 BENDING Xpert 40 + 80 Compact speed machine for small and medium-sized parts Customer benefits Maximum process speed via high acceleration of the upper beam and back gauge Ideal when there s a shortage of space and capacities fluctuate: The machine can be operational or mobile in less than five minutes Process controlled reduces electric power consumption by up to 30 percent and decreases wear Flexible tool selection and press capacity of up to 88 US tons offer a wide range of application High ease of use through ergonomic design and individual customizable work environment
BENDING 9 1 Maximum process speed 2 Individual adjustable work environment 3 Fast Bend E safety system 4 Optical stroke triggering 5 Adjustable monitor 1 2 3 4 5 Xpert 40 Xpert 80 Tonnage 44 US tons 88 US tons Bending length 3.4 ft 5.0 ft Open height 22.4 in 22.4 in Standard stroke 7.9 in 7.9 in Max. high speed 11.8 in/s 11.8 in/s Max. working speed 0.975 in/s 0.975 in/s
10 BENDING Xpert Top-of the-range machine with very high position and repetition accuracy Customer benefits Worldwide, the most extensive database, which can be simply expanded with additional material characteristics and parameters The only machine that doesn t produce angle errors. It offers the highest repetition accuracy on the market First class bending results thanks to pressure reference technology with fully automatic, dynamic crowning The wide range of equipment packages guarantee a customer-specific and flexible machine specification At the press of a single button, perfect bending results are achieved independent of operator knowledge Fully comprehensive CAD/CAM: there are only six mouse clicks between 3D data file and 3D part
BENDING 11 Crowning 4 1 Hydraulic dynamic crowning 2 removable Bending line laser 3 Optical bend guiding system 4 Tablet Control 5 Bending aids 6 Laser angle measuring system with automatic correction LAMS 7 PartID (part identification) 2 1 3 4 5 6 7 Xpert 60, 100, 150, 200, 250, 320, 400, 500, 650, 800, 1000 Tonnage Bending length Open height Standard stroke Max. high speed Max. working speed 66 1100 US tons 6.7 33.4 ft 19.6 25.5 in 8.4 14.3 in 8.5 in/s 0.750 in/s
12 BENDING Xact Smart The fast entry into bending technology Customer benefits Swiss quality at attractive conditions Intuitive operation enables a fast entry into bending technology Comprehensive know-how. Benefit from Bystronic s many years of experience with bending technology in the sheet metal processing business Lean processes. Bystronic software solutions optimally integrate the Xact Smart into your production environment Become a world class manufacturer. Experience long-term growth with a reliable business partner who offers you an extensive portfolio of services from the offer through to shipping
BENDING 13 1 Intuitive user interface 2 LED workspace lighting 3 5-axis back gauge 4 Hydraulic tool clamping 5 Laser safety system 1 2 3 4 5 Xact Smart 50, 100, 160, 225, 300 Tonnage Bending length Installation height Standard stroke Max. high speed Max. working speed 55 330 US tons 5.2 13.4 ft 17 23 in 6 12 in 5.5 in/s 0.375 in/s
14 BENDING Xcite 80 E An electric pressbrake that works both quickly and reliably whilst also being attractively priced Customer benefits More parts are produced and jobs completed in shorter time, in comparison to other comparable pressbrakes. This is possible due to the modern drive system, combined with the hydraulic tool clamping system, flexible fast back gauge system, and simple machine operation The Force Dynamic Drive (FDD) system provides speed, power and constant pressure along the entire bending length, whilst also ensuring minimal deflections in both upper and lower beam. Parts are therefore completed quickly with consistently high quality Xcite is of high build quality providing long lasting performance. This ensures that precisely formed parts leave your company on time due to the corresponding bending work being completed reliably Parts are formed at a low cost due to the Xcite being priced attractively both in its initial purchase price and also low maintenance costs in the future Xcite is versatile. Optimal use is achieved when forming small and thin parts, but it is also adept at bending thicker parts, and also large batches with high speed
BENDING 15 1 Bending line laser 2 Machine control 3 PartID (part identification) 4 5-axis back gauge 5 LED workspace lighting 6 Tablet Control 2 1 3 4 5 6 Xcite 80 E Tonnage Bending length Open height Standard stroke Max. high speed Max. working speed 88 US tons 6.7 ft 22 in 6.7 in 5.85 in/s 0.975 in/s
60 50 40 30 20 10 0 Information about: Bystar 3015 ByAutonom 3015 BySprint Fiber 3015 All machines are running. 16 BENDING Most important options Energy Saver Fast Bend+ Saves 20 percent time in comparison to conventional safety systems LAMS Measures and corrects the angle during the bending process Energy Saver Reduces machine energy consumption by up to 60 percent The machine creates less noise and less heat Optical bend guiding system The worldwide fastest bending process control leads the user to the perfect part quickly and safely PLC 10 0 1 1 0 0 11 0 1 1 0 1 010 0 0 0 1 0 01 1 101 10 1 01 00 1 1 1 1 1 10 01 011 010 1 0 0 1 0 0 01 10 1 01 0 1 1 0 10 01 0 OPC Interface External software Statistics Messenger Removable Bending line laser Position bent parts quickly and easily LED workspace lighting Illuminates the workspace perfectly and uses a minimum amount of energy OPC interface Enables machine and operational data evaluation
BENDING 17 Voice control Perform all important functions via voice entry Tablet Control Make corrections to the bending process easily on the tablet PartID (part identification) Identifies manufactured parts Condition Messenger Preventative functional machine testing Observer Web-based remote monitoring of location-independent machine status queries Optical Tool Detection System Camera system to test the tool setup
18 BENDING Most important options Flexible back gauge systems Double the axis speed of standard backgauges possible Hydraulic bending aids Makes bending large, heavy, and long-sided parts easier Material-friendly handling of sensitive materials such as stainless steel Hydraulic quick-clamping The automatic clamping of upper tools shortens set-up time by more than 20 percent Optical stroke triggering Triggers the stroke of the pressbrake with a simple foot movement Tandem operation Maximum flexibility for processing small to extra long bent parts Robot interface Allows to connect robots from various manufacturers
BENDING 19 Option Customer benefits Pressbrake Increase efficiency Reduce costs Simplify processes Be informed Xpert 60 1000 Xpert 40 + 80 Xcite 80 E Xact Smart Fast Bend + Fast Bend E Fast Bend S LAMS Dynamic Crowning Energy Saver Optical bend guiding system Optical stroke triggering Voice control Tablet Control PartID (part identification) Bending line laser LED workspace lighting OPC interface Condition Messenger Observer Flexible back gauge systems Hydraulic bending aids Hydraulic quick-clamping Tool prompt on a control panel Tandem operation Robot interface Increased open height, stroke, and throat Bar code scanner Remote diagnostics Optical Tool Detection System Standard Option
BENDING 21 Bending tools Perfect bending results thanks to the right tools. Original tools from Bystronic are capable of unleashing the full potential of the machine s characteristics, in order to ensure that your parts are always bent with utmost precision. Customer benefits: The quality of the tools is carefully matched to Bystronic press brakes and your applications Comprehensive range of original bending tools in order to cover all your applications. Available for a variety of clamping systems Original plus bending data: With every original bending tool, you also receive the relevant import data for your press brake s software For particularly challenging applications, our tool specialists will be glad to provide you with advice and support you with customized designs for special solutions A long service life under tough conditions thanks to deep tempering and the highest quality standards
22 BENDING Modern sheet metal processing without high-performance software is unimaginable these days. BySoft 7 offers a comprehensive range of functions and is still easy to operate. With BySoft 7, the user can quickly and easily design tailored parts and create cutting plans and bending programs with the push of a button. Furthermore, manufacturing processes are scheduled and monitored efficiently, thus maintaining an overview and finishing jobs quickly and economically. BySoft 7 Modular CAD/CAM software with 2D and 3D CAD as well as extensive functions for scheduling and monitoring manufacturing processes Customer benefits Existing drawings and models can be input, edited, and processed easily Reduction in parts costs, because BySoft 7 automatically nests parts perfectly. Raw materials are used in their entirety. This also applies to the processing of tubes and profiles Cutting plans and bending programs can be perfectly created with the push of a button. The correct cutting technology is automatically set and the bending process is automatically simulated and monitored Offers comprehensive options for scheduling and monitoring manufacturing processes Provides maximum transparency because all machine and job data are always available Efficient connection to ERP/PPS systems
BENDING 23 ByVision Bending Simple, user-friendly, and rapid control of pressbrakes With ByVision Bending, bending is as easy as daily interaction with a smartphone. The user interface provides you with all the important bending functions on a touch screen. Control the entire bending process with a few swipes of your finger. ByVision Bending also supports users with its extensive database, which includes parameters for all common sheet types and bending tools. Depending on material thickness and bending angle, the user interface determines the ideal bending process and suggests the appropriate tool.
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AUTOMATION 25
26 AUTOMATION Xpert Tool Changer Intelligent automation for fast and precise tool changing Customer benefits Save time and increase the bending quality thanks to the automated changing of upper and lower tools Precise and error-free positioning of the tool sets in the clamping system of the upper and lower beams, even with large tools (up to V80) Simple tool expansion at any time: Intelligent sensor technology automatically detects new tools and integrates them into the tool magazine Automatic rotation of the upper tools increases the variety of bending applications A high degree of ergonomics and compact handling, because all the tools are kept ready within the machine Precise and gentle processing of bent parts thanks to automatic cleaning of the bending table
AUTOMATION 27 1 Automatic tool detection 2 Short set-up time 3 Integrated storage for tools 4/5 rotation of the tools 1 2 3 64 5 Xpert Tool Changer Tonnage Bending length Open height Standard stroke Max. high speed Max. working speed 165 350 US tons 10.1 ft 27.5 29.5 in 16.3 18.3 in 8.5 in/s 0.750 in/s
28 AUTOMATION Mobile Bending Cell Mobile automation for high-speed bending Customer benefits Ideal for varying order situations. You manually bend complex small series and use automatic bending for large series Intelligent automation enables lightly-manned multi-shift operation on the Xpert 40 with a high degree of process reliability Plug & Bend principle. The Mobile Bending Robot can be set up on the Xpert 40 in just a few minutes. In spite of automation, the overall system remains compact and mobile Convenient offline programming of bending jobs. Subsequently, ByVision Bending allows the data to be imported in a simple process without interrupting the current bending job Simple upgradeability. The upgrade of the Xpert 40 with the Mobile Bending Robot can be carried out at any time
AUTOMATION 29 1/2 Mobile Bending Robot 3 Precise bending sequences 4 Mounting for blank parts 5/6 Automation as required 2 1 3 4 5 6 Mobile Bending Cell Max. load Max. part size Max. part weight Air supply Weight 22 lbs ca. 11.8 23.6 in ca. 15 lbs 5 7 bar 1.1 US tons
30 AUTOMATION Bending Cell Bending center for fully automatic sheet metal processing Customer benefits High degree of bending automation. Ideal for the processing of job lists and for varying jobs, from small batch sizes right through to large series Save time and process bending parts with high precision. 7-axis robot with a high load capacity offers maximum flexibility and precision during the bending process. Even when bending heavy parts, this enables jobs to be processed fully automatically and without errors High level of availability thanks to modular design. Depending on the set-up, the Bending Cell offers bending lengths of up to 13.1 ft, robot load capacities up to 595 lbs, and ample material storage capacities and a generous tool magazine Comprehensive automation concept from a single source. Bystronic provides the press brake, the automation system, customer service, and comprehensive guidance Convenient offline programming of bending jobs. Subsequently, ByVision Bending allows the data to imported in a simple process without interrupting the current bending job
AUTOMATION 31 1 load 198 595 lbs 2 tool capacity in the magazine 121.3 ft 3 rotation of the tools 4 Platform length 16.4 26.2 ft 5 gripper stations 5 8 2 3 4 1 5 Xpert 100 320 Max. part size ca. 118 59 in Max. part weight ca. 441 lbs Max. load 595 lbs Min. sheet thickness ca. 0.27 in Platform length 16.4 26.2 ft Max. plate stack ca. 27.5 in Max. stacking height of finished parts ca. 47.2 in Max. tool capacity in the magazine ca. 121.3 ft Number of gripper stations 5 8
32 BENDING Bystronic Collections LASER + AUTOMATION BENDING DEU SOFTWARE SERVICES + SUPPORT BENDING Bystronic Tools Best choice. Laser Bending Waterjet bystronic.com DEU Image brochure Tool catalog Not all products listed in this brochure are available in all countries. This brochure may show parts that are not standard equipment, but are available as options. For the better visibility of machine details, some safety covers may have been opened or removed for these pictures. The right to make changes to dimensions, construction, and equipment is reserved. For technical data, see the separate data sheets. ISO-9001-certified Bystronic Media Center Photographs Brochures Technical Data Sheets Videos Bystronic Videos on Youtube
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