Simply the line
Automatically punches, cuts and bends sheet metal without intermediate handling. The ideal solution for any production strategy, be it kit, single-batch or series production.
100% flexible automation
The S4+P4 line punches, shears and bends sheet metal totally automatically, without any intermediate handling. Among other benefits, the line allows to produce on demand and just in time, to increase capacity and velocity, to reduce lead time, to process different materials without retooling, to optimize manpower activities.
The integrated adaptive technologies make the S4 intelligent and able to automatically adapt to variations, eliminating waste and corrections, while guaranteeing high machining quality:
- the centering control system measures the incoming sheet and adapts the program to the actual dimensions measured, if necessary;
- the manipulator changes its dynamics according to the size and weight of the sheet, opening the pincers according to the percentage of sheet machined;
- an automatic system checks the thermal expansion of the manipulator’s axes and compensates any variations, guaranteeing extreme positioning precision;
- the shear automatically records the clearance and, depending on the thickness and the material, modulates the required force in-cycle.
Storage and automatic loading/unloading devices increase the autonomy of the system, regaining efficiency both in individual processing steps and throughout the production process. The wide range meets practically any layout or configuration requirements, adapting to the most diverse production strategies.
The S4 punching-shearing center maximizes process efficiency: all the loading, punching, forming, separation and unloading operations are automatic, done by a single system that eliminates semi-finished parts, does not require manual intervention and assures extreme repeatability.
The P4 uses universal bending tools which automatically adapt in-cycle to the panel geometry, without machine down times or manual retooling, allowing batch-one or kit productions.
The integrated adaptive technologies (advanced sensors, bending formula, MAC3.0) make the system intelligent and able to automatically adapt to changes in the material and the external environment, eliminating waste and corrections, and extending the range of products that can be made.
The P4 offers customized solutions, including auxiliary tools and additional devices for special geometries or different loading/ unloading solutions.
The multi-press head has a die-structure that houses up to 96 tools needed for production. Each tool is actuated individually and is always available. The multi-press head guarantees high punch-die alignment precision, and thus machining quality, with reduced cycle times, eliminating in-cycle set-ups and the related waiting times.
Accurate referencing, fast scrap-free processing
The manipulator centers the sheet when machining begins. It has a maximum stroke of 3030 mm which allows sheets of up to 3048 mm to be machined without regripping, and has 9 pincers with independent opening, extending the possibility of machining nests without any holding scrap and reducing scrap by optimizing sheet metal use. It has a patented hand-over system that modulates the dynamics according to the weight of the sheet metal being processed.
Integrated shear: freedom of choice
The shear is composed of two 500 mm blades, which are independent and orthogonal to each other, equipped with blankholders, for cutting any length. Installed next to the multi-press head, the shear is unique on the market, ensuring optimal, constant alignment and superior machining quality. It also ensures advantages in terms of process quality as, compared to separation by punch, it reduces the cycle time, does not erode the material, improves optimization and minimizes scrap.
Universal bending tools
Upper and lower blade, counterblade and blankholder are the four universal tools used to process the whole range of thicknesses and machinable materials, from 0.4 to 3.2 mm, during the cycle and without machine down times or manual re-tooling.
The sheet metal is centered, just once at the start of the process, against controlled mechanical stops: the cycle time is minimized and any precision errors are all absorbed by the first bend. The mechanical stops are a further guarantee of finished panels of the correct size, every time.
Proprietary bending formula
Developed over the years, the bending formula defines the force and manages the movements of the universal tools, analyzing different parameters in real time, including deflections, temperature and thickness, guaranteeing the precision, repeatability and quality of the finished product.
MAC3.0 detects any differences in the mechanical characteristics of the material compared to their nominal value during the cycle, adapting the movements of the bending unit and the manipulator to compensate them.
Digital transformation and Industry 4.0 are key topics for staying competitive on the market. When adopted, they can implement and manage complex, integrated, highly automated high-performance systems, and can help to develop simple solutions that require no structural changes to the production layout, making the world of smart manufacturing much more accessible.
The S4+P4 line punches, shears and bends sheet metal totally automatically, without any intermediate handling. Set-up in masked time delivers high productivity and makes kit and batch one production possible.
Case study: Binder
In this case study, you will learn how Binder optimized its Hungarian plant dedicated to sheet metal production. Binder employs 40 staff in 4-shift operation, and annually produces about 5000 tons of sheet metal, being supplier for shopfitting, cold room construction as well as rack systems and shelf construction.
Case study: Pramac Ibérica
In this case study, you will learn how Pramac Ibérica, Spanish power generators manufacturer, solved its problems of flexibility, velocity, capacity, precision, and safety, while reducing its cost and lead time. Thanks to Salvagnini Pramac Ibérica is now able to produce 15% faster and to broaden its capacity by 40%.
Case study: Erhart
Austrian company Erhart GmbH has invested in a Salvagnini S4+P4 production line, which sped up the production time by at least 40% while reducing energy consumption by 55%.
Case study: Henke
With the introduction of a Salvagnini S4+P4 line, Henke is now working much more cost-efficiently, producing higher quantities in a much shorter period of time.
Industry has changed: flexibility and efficiency are fundamental requirements for managing increasingly smaller batches or rapid item turnover rate. And developments in technology have in some way upset the balance between workloads, with increasingly fast systems which however need to be guided by more and more specific machine programs, the generation of which is increasingly time-consuming. This is why software is increasingly crucial to improving the efficiency of machinery.
OPS is the Salvagnini modular production management software which optimizes the entire production process, exchanging real-time information between the machinery and the factory ERP/MRP.
Salvagnini’s IoT solution, increases the global efficiency of the line. LINKS allows real-time monitoring of the machine’s performance and independent analysis.
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