Punching-shearing center

For Salvagnini, punching is always a combined process of forming and separating parts, with the separation done either by shear or by laser. Part separation integrates the punching machine in a modern and efficient production flow, able to feed the workstations downstream, such as the panel bender.

In today’s production context, the role of the punching machine depends on the product: the parts to be produced, their geometries, the jobs planned, and the productivity required, are what determine the most suitable technological solution. In recent years, the laser has eroded part of the traditional punching market, but has not affected that of the Salvagnini S4 punching-shearing center, which, today as in the past, remains a competitive solution for companies looking for productivity, flexibility, reactivity and efficiency. The S4 performs all the part punching, forming and separation operations, destroying the skeleton to ensure that the parts flow progressively downstream: this eliminates the need for regripping and rapidly feeds the next production step.

Part geometries, increasingly small batch sizes, cutting quality and expected productivity are all factors that make the investment in an S4 more attractive than that in a traditional punching machine. High productivity is guaranteed because the S4 is a single work center, able to automatically produce finished parts without the need for regripping and/or re-tooling. It is the winning solution in production contexts in which lead times have to be minimized, because the integration of forming and separation processes drastically reduces throughput times. The S4 is the ideal solution in sectors requiring parametric jobs: more flexible than a laser, it drastically simplifies programming and reduces overall process times, from product design to production.

The S4 natively integrates the punching and separation operations and automatically manages the feeding, sorting and unloading cycles which, when possible, are performed in masked time. With the patented multi-press head, the tools are always available for nesting and multiple jobs, with no re-tooling in-cycle or manual intervention. The proprietary Punch&Cut algorithm optimizes the integrated shearing cuts for separating the single parts in the sheet in a fast, flexible and automatic sequence with no waiting times for unloading the part.

The multi-press head requires no re-tooling or tool changes in-cycle, reducing overall processing times. The multi-press head is a distinctive feature of the S4, comes in 5 models and can house up to 96 tools at the same time. It ensures high punch-die alignment precision, for high-quality machining. The head configuration proposed for each customer is designed to meet their specific production needs, and to minimize tool changes which, when required, are simple and very quick.

With conventional punching, productivity and flexibility depend on the number of tool changes in-cycle and the times for moving the sheet underneath the turret or single punch, and are influenced by the time required for the separation operations downstream. The S4, on the other hand, natively combines productivity and flexibility. Helping to maximize productivity are the multi-press head, which ensures that the tools are always available, the advanced manipulator cycles that modulate the dynamics and the integrated shear, which works in Punch&Cut mode. These unique solutions also improve the flexibility of the S4 as – whatever the geometries and materials being machined – they do not require re-tooling and can produce large batches, kits or batch one with equal ease. STREAMPUNCH, the programming software for generating the punching program, includes proprietary algorithms for optimizing nests and parts, while reducing scrap. STREAMPUNCH makes it easy to choose the best production strategy, and simplifies the programmer’s job with a user-friendly interface and interactive editing and simulation functions.

The S4 is a flow solution. In its basic configuration, it integrates feeding and unloading solutions that automate the production process and optimize each operation: at the infeed, a conveyor-centering device anticipates the loading of the sheet metal in masked time, positioning it correctly; at the outfeed, each part is automatically transferred to the next devices or the collection bins. 

In addition to solutions that optimize the efficiency of each operation, Salvagnini supplies automation and process software which, by suitably organizing the whole production flow, help to achieve greater autonomy for unmanned and lights-out jobs, reducing the impact of labor costs and the return-on-investment time.

The S4 is easy to configure and can work stand-alone, in-line, integrated into a flexible cell or for lights-out manufacturing. The loading/unloading solutions allow unmanned operations, enhancing the productivity of the punching-shearing center. The modularity of Salvagnini’s automation devices allows the production flow to be extended and/or modified, even after first installation. In addition to integrated automation, Salvagnini supplies a wide range of automatic loading/unloading and sorting devices which, coupled with a store, increase system autonomy and efficiency. These devices mean that different materials and thicknesses are always available for just-in-time jobs, minimizing waiting times for sheet metal feeding and reducing the risk of error or damage to the material resulting from human intervention.

The S4 is available in two sizes, for machining 3 or 4 meter sheets. Both models can be configured with one of the 5 heads available, with many customized loading/unloading automations. The model is chosen on the basis of an in-depth feasibility study. Salvagnini’s specialists help each customer to define the most suitable configuration for their production needs, evaluating a number of variables including the field of application, the production strategy and the production mix.

These challenges relate in particular to the recovery of autonomy and efficiency. Automating loading/unloading/sorting supports the high performance of the S4 and brings benefits to the whole manufacturing chain. Implementing simple, quick office software reduces the risk of turning programming into the bottleneck of production. Integrating ERP/MRP and process software for managing production automates the distribution of information, helping to create a lean, error-proof production environment.