unique in bending Hämmerle bending machines Unmatched 3-point bending technology
Intelligent concept, optimal bending processes The highly precise Hämmerle 3-point bending machines enable the forming of simple and complex parts and they ensure cost-effective and time-saving production. Tool systems, programming, and peripherals are conceived for easy application and easy operation. With a very large stroke of the upper beam and generous clear space to the front and rear of the machine, the system provides optimal bending capacities with the highest flexibility. Thus the most advanced and efficient processing can be achieved. Most important performance features Tonnage Bending lengths Stroke Backgauge system Entire type series overfloor construction Safety: CE and EMC certified 800 2250 kn 100 4100 mm 65/400 mm 6 axes
3-point technology The innovative Hämmerle machines offer flexible tools and unique technology. In contrast to free bending or air bending, with the 3-point bending process, the bending angle of the workpiece is determined by three precisely defined points in the lower tool. Thus the desired angles are achieved by a CNCcontrolled depth setting of the bottom tool groove. Because there is compensation for machine-related, external, and material-dependent influences, a consistent bending angle is achieved across the entire bending length. Variable bending angle The most important components of the Hämmerle 3-point bending system are the hydraulic cushion and the bottom tool holder with an integrated CNCcontrolled wedge system. While the top tools are supported in the hydraulic cushion, the bottom tool holder with the wedge system enables a variable, precisely-repeatable setting of the groove depth of the bottom tools. Constant bending pressure The hydraulic cushion compensates for the machine s deflection and assures consistent bending pressure along the entire bending length. At the same time, the cushion protects the tools and the entire system against overload. Precisely defined bending points The lower tools with variably adjustable groove depth achieve a forming similar to coining. When the bending process is completed, the sheet metal not only contacts the two edges of the V opening, but also the adjustable bottom point of the lower tool. Thus the three points that determine the bending angle are all on the same side of the workpiece. The necessary data for angle settings and cut lengths are thus calculated on the basis of empirical values. The top tools supported by the hydraulic cushion follow the bending line of the lower beam. a The working principle of 3-point bending a Hydraulic cushion in unloaded condition b Hydraulic cushion in loaded condition c Bottom tool with height-adjustable groove depth b c The bottom tool holder is equipped with an integrated sliding tool unit controlled by the CNC so that four different positions can be approached. This way, hemming operations can be performed without changing tooling within a bending sequence.
4 Important components Tool clamping Thanks to the hydraulically operated top and bottom tool clamping system, the segmented tool system can be changed out in a very short time. At the same time, the length can be adjusted so flexibly that even multi-sided parts can be bent at different stations. The tools no longer need to be aligned, for the individual segments are centered automatically. Safety systems The Hämmerle 3-point bending machines have contact-free safety systems on the operating side that are integrated into the safety doors. These not only have a distancing effect; they can also be switched on as a control unit with the touch of a button. The back side of the machine is also secured against entry by a light curtain. Operator terminal Programming, control, and visualization of the processes occur via a comfortable operator terminal with a 15-inch active TFT LCD color screen. The modern, clearly arranged touch pad keyboard with graphic operator guidance makes work easy. In addition, an input keyboard is available. User software Bybend supports process control through simple dialog control in a professional Windows interface. The software is suitable for graphical and numeric programming. It enables automatic calculation of the cut lengths and calculates the bending sequence with collision control. In addition, Bybend offers numerous other important functionalities that significantly help the user. For example, there is a tool setup plan, input control, and program administration. Extensive databases contain the parameters for parts and tools as well as bending-technical data for example, empirical values for the bending allowance and angle setting enabling efficient production planning. The Bybendpart user software complements Bybend. It enables the import and export of data for processing by cutting and bending programs. The display of the bending programs occurs in 3D.
5 Backgauge system The highly dynamic backgauge system provides simultaneous movement of all six axes. The system is robustly built and has a vertically movable beam in the R-axis; individually mounted stop arms with integrated, brushless asynchronous servo drive; and digital axis control. The backstop arms in the X and Z directions can be positioned and corrected independently. Optionally available are straight, tiltable, quick-change or multifunctional stop fingers with four stop positions and two side stops. Workpiece support The front workpiece supports move on linear guides and spherical guide carriages; they can be parked next to the table. Adjustment in the X, Y or Z directions occurs manually. A special apparatus prevents crushing points. For machines with a capacity greater than 130 tons, reinforced support consoles are available. Bending aids The bending aids can, if desired, be built in on the operator side or on the backgauge side. Every one has three CNC-controlled axes. The rear bending aids offer an additional W-axis for side adjustment. The front bending aids can be lengthened if necessary or broadened with additional elements. The supports are equipped with synthetic brushes for scratch-free handling of the material. If heavy parts are being processed, supports with spherical rollers are available. The stepless hydraulic drive of the pivoting axes occurs in angles between 0 and 75. Advantages Robust machine frame design using stress-free steel construction Side frames, set beyond the length of the bed, allow full utilization of the maximal bending and backgauge length Newly developed, modular block hydraulics with proportional valve technology for highly dynamic upper beam control with optimal efficiency Standard built-in partial flow filter that increases the lifespan of valves, cylinders, and the hydraulic oil Constant bending forces and repeatable settings ensure even angle and side piece lengths Expansion possibilities Front and rear bending aids Table extension for front bending aids Reinforced front support consoles Additional stop arm X3, Z3 Complex stop fingers Side stops Table extension (parking place) Additional foot switch Workspace lighting Large, segmented tool selection Tool cabinet Bybend (2D) user software Bybendpart (3D) user software Robot interface Service & Support Bystronic s proven technology and extensive expertise produce systems that are extremely reliable. With its global network of specialized service and training experts and comprehensive spare parts inventories in the local markets, Bystronic guarantees that it will support what it sells. In addition to maintenance, spare parts delivery, and repair services, customers are also offered training programs as well as hardware, software, and operational support so that they are in a position to get the most from their machine investment.
6 Areas of application Sheet metal thicknesses Mild steel Stainless steel Aluminum Finished parts 0.5 12 mm 0.5 10 mm 0.5 12 mm 3-point bending machines are used everywhere where sheet metal parts must be produced quickly and flexibly, yet with the highest repetition and precision. Production of components for kitchen and office furniture Lift and transport equipment in medical and ventilation technology Machine and apparatus construction, etc. With its slim tool system, even complex hemming can be produced in one sequence. Therefore, the procedure is suitable for the widest variety of applications. Relay frame for electrical distribution unit 2 mm, mild steel Frame part for gas distribution unit 5 mm, mild steel Cable holder for tool machines 2 mm, mild steel
7 Results of comparison Hämmerle Conventional Due to the hemming unit and the slim tool system, complex parts can be produced in one sequence from a single blank. This shaped part was hemmed in the conventional manner. The disadvantage of this production method is the separate point welding and polishing. Hämmerle Conventional The 3-point process allows the forming of large parts in one sequence from a single blank. High-precision hemming of the long sides with a double bend afterward eliminates subsequent drilling, welding, and polishing. Conventional parts hemmed as welded construction without hemming require subsequent processing. Here the long sides were reinforced after the fact with angle irons, drilled, and the part was then polished. Customer benefits Greater utilization and bending lengths since the distance between the side frames exceeds the maximum tool length by 100 mm Minimal setup and programming times thanks to precise, repeatable settings and optimal user guidance Easy calculation of cut lengths and bending programs using empirical values based on database-supported control Sharply reduced production and handling times thanks to optimized bending sequences Sequential production of profiles and complex, multi-sided parts Quick, time-saving tool change Use of normal and extra-high tools due to an extra-large upper beam stroke and large open height This brochure may show parts that are not included in the standard equipment, but rather are available as options. For better identification of machine details, some safety equipment has been opened or removed for the pictures. Changes to dimensions, construction and equipment are reserved. For technical data, see separate data sheet. Certified in accordance with ISO 9001
Bystronic is a worldwide active supplier of application-oriented systems and services for the laser and waterjet cutting processes, as well as bending: economical, high-performance, reliable. Laser cutting Laser cutting systems for the innovative processing of a wide variety of materials and geometries Bending 3-point and air bending machines for high-precision working of sheet metals Waterjet cutting Waterjet cutting systems for cutting metals, glass, synthetics, ceramic, and many other materials Automation High-performance handling and automation solutions from simple loading systems to fully automated laser production cell with integrated storage system Software & Control User-friendly programming and operation with requirementoriented applications programs and interfaces to CAD and ERP systems Service & Support Competence and customer proximity with after-sales support available worldwide: local contact per-sons, prompt delivery of spare parts, and professional training courses Your contact www.bystronic.com Hämmerle/0808e/Printed in Switzerland Copyright Bystronic 2008