new shear genius by finn-power

NEW SHEAR GENIUS
BY FINN-POWER
®
NEW SHEAR GENIUS
BY FINN-POWER
®
FINN-POWER's new Shear Genius® provides
applications, the new Shear Genius® gives you a
more capacity, quality and cost-efficiency for flex-
combination of three things:
ible sheet metal working than any comparable
system.
· flexibility for meeting customer requirements
· low manufacturing cost, and therefore
Based on 17 years of work on right angle shear
· short pay-back time.
technology, and co-operation with hundreds and
hundreds of fabricators with a large variety of
This amounts to competitive edge in today's
demanding business environment.
2
The Shear Genius® Philosophy
The most economical and efficient way of producing sheet metal components is to punch a sheet
and shear components loose with an integrated
right angle shear for direct, automatic exit into
a box or for automatic stacking. This is the core
of the Shear Genius® philosophy.
LOADING
PROGRAMMING
PUNCHING
SHEARING
It is difficult to optimize blank sheet size for
flexible production requirements. With Shear
Genius® you can use standard size raw material.
Moreover, major savings can be made through
efficient nesting.
Reliability & manufacturing economy
based on experience
No other manufacturer can come near to FINNPOWER experience in integrated right angle
shear technology. This core competence has
helped us engineer new, productive features into
a proven concept for more productivity.
By combining several work stages into an automated process, the Shear Genius® concept
saves manual work, floor space and investment in
separate machine tools, tooling and energy.
Welcome to new Shear Genius® benefits.
3
THE COST CUTTING SOLUTION
FOR HIGH-QUALITY FABRICATION
The vast majority of all sheet metal components
ever needed are rectangular. Also parts with
two or three straight edges are perfect for fabrication with a right angle shear.
a 90º angle. One stroke detaches the component.
Today, right angle shear technology is used
throughout the industrial world in applications, in
independent production cells, or as central units
within automatic material handling systems up
to factory-wide FMS level.
Micro jointed or nibbled components often require an additional work stage, as edge quality
must be improved by grinding. A right angle shear
produces sufficiently high edge quality for practically every purpose. The flat component is usually
ready for the next work stage as such once it is
exited from the machine. For example, there is no
oxide layer at the edges to be removed before
painting.
Here are some of the reasons why:
1) Avoiding the cost of pre-cutting
Pre-cutting is a time-honoured method, but it
is also a waste of time and money. Moreover, it
is extremely difficult to achieve anything like
the accuracy of components manufactured by
an integrated right angle shear. FINN-POWER's
right angle shear has two blades mounted at
4
2) Just the right edge quality
3) Practically no consumables
As for consumables, FINN-POWER's right angle
shear technology uses only energy and compressed air. The blades have several cutting
edges – enough for years of production with an
occasional sharpening.
N
4) Modern, safe technology
As a mechanical solution, right angle shear is also
environmentally friendly. There is no need for
gases, cooling water with chemicals etc., nor a
need to arrange venting to the outside, as required of laser cutting machines.
5) Don't pay for material you don't need
Modern production planning and nesting software allow optimizing the use of raw material – a
significant cost item in the production of sheet
metal products. Compared with traditional
methods, an integrated right angle shear can
save up to 10% of raw material costs.
The Shear Genius® method makes maximum
use of material and e.g. eliminates skeletons, a
cause of costly waste management when using
the micro-joint method.
6) Simple to automate
– minimum manual intervention
Shear Genius® automates loading, punching &
shearing with secondary work stages, as well
as component exit. It eliminates manual separation of components from micro-joints. With material handling equipment, sorting and stacking
can be reliably automated.
Integrated right angle shear for
l more parts
l better parts
l at a lower cost
Shear Genius®
FINN-POWER's basic Shear Genius® package
consists of
l Programming software
l Automatic loading equipment
l 300 kN hydraulic turret punch press with 20
tool stations and capacity up to 200 tools
l Integrated right angle shear
There are two Shear Genius® models for standard size sheets (max.)
SG6: 1,500 mm x 3,000 mm (60" x 120")
SG64: 1,500 mm x 4,200 mm (60" x 160")
5
FINN-POWER
PUNCHING FEATURES
Solid engineering
Both the turret punch press and the right angle
shear frame have been re-designed for additional
rigidity to accommodate the forces due to
increased speed and performance.
Hydraulics
A full 300 kN punching force is available, with nibbling speed on 1 mm centres up to 1,100 hits per
minute. As a result of digitally servo controlled
ram, stroke speed is fully and individually adjustable in both directions. Other benefits include the
availability of different punching modes (punch,
slow punch, downforming and marking). For marking, punching speed up to 3,000 hpm can be
used.
FINN-POWER's servo hydraulic punching system
automates overload protection and provides the
greatest flexibility for all kinds of punching, forming and special applications.
Flexible tool holder concept
The 20-station turret layout is customer-specific. Various tool holder sizes can be changed or
switched from station to station. Any major tooling style can be chosen, and you can often use
your existing tooling. Up to 200 tools can be simultaneously available with Multi-Tool® technology.
Fast Auto index system
Up to 10 index stations can be installed.
The fast auto-index system is based on a double
AC servo motor; punch and die are mechanically
engaged and disengaged using vertical movement
and without punching stress to the locking system. Tool rotation can be programmed in 0.001°
increments and throughout 360° rotation. The
system automatically selects the shorter path
to desired angle.
Each of the servo motors rotates a gear of its
own for high speed, acceleration and accuracy.
Digital synchronization is used instead of belts or
mechanical clutches.
6
Automatic clamp setting and moving
FINN-POWER's patented automatic clamp setting PCS is a standard SG feature. It automatically positions sheet clamps according to numerical program. Possibility of punching or shearing
the clamps is eliminated
When part programs are changed in an automatic work queue, clamp settings change automatically, if needed, without wasting operator
time.
Dead zones can be completely eliminated with an
optional 4th clamp and using individual one clamp
move when the other clamps hold the sheet. This
ensures excellent accuracy. Also traditional repositioning can be used.
Indexable upforming
The safe and natural solution for sheet metal
forming is from below the sheet. Using a hydraulically actuated die holder and die movement, the
common hazard caused by conventional, high
forming dies scratching of the sheet, collisions,
bending of the components etc. is automatically
avoided.
With indexing possibilities the sheet can be used
more effectively and at reduced tooling cost.
With the optional upforming unit, versatile forms
up to 16 mm in height (incl. sheet thickness) can
be made.
Tapping
FINN-POWER options can be added to increase
the number of work stages that Shear Genius®
can perform, thus eliminating the need for separate machines and manual work stages.
A six-station servo driven tapping unit (option)
can be installed for extensive threading capacity.
Alternatively, a one-station unit utilizing the fast
index system and accurate ram control is available.
Part removal
Component exit up to size 500 mm x 500 mm
can also be arranged through a large work chute
(option). Either ready components, detached
material for further processing, or material nibbled loose to make openings can be evacuated.
7
MORE THAN THE SUM
OF ITS MODULES
Finn-Power's totally new Shear Genius® has
been designed and built for maximum accuracy
and manufacturing speed to give outstanding
productivity.
Frame constructions are extremely robust to
meet the requirements of very high axis speeds
and acceleration rates. The distance between
the modules has been increased for easy maintenance; automatic central lubrication is standard.
Multi-function manufacturing solution
The combination of a 3,144 mm working area,
optional four clamps and the extremely high positioning speed allowed by rack and pinion drives
means that more functions – punching, forming,
tapping, bar coding, and shearing – can be performed flexibly as a single, multi-purpose work
Loading and squaring
Shear Genius® features fast, electric motor and
inverter driven loading for sheets up to 200 kg.
Double sheet checking and sheet measuring as
well as squaring functions are integrated in the
gripper mechanism. Squaring takes place on
machine table, with no auxiliary table needed
and can be selected on or off depending on stack
quality.
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stage and with a single clamping. No auxiliary
time is wasted in sheet repositioning during the
process. This means that the range of components that can be produced on one and the
same equipment is truly vast.
The 3,144 mm working area allows punching etc.
of a full 3,000 mm sheet with a single clamping,
as well as shearing of components up to 2,350
mm in length. For longer components, a single
repositioning is needed before the shearing
stroke. This allows both very high production
speed and component accuracy.
A rack & pinion system actuates the X movement direct from the motor. The solution
improves accuracy and allows high acceleration and speeds. Two synchronized servo motors
are used to actuate the Y movement for speed
and accuracy.
Outstanding, guaranteed accuracy
Shear Genius® accuracy reaches new levels
through a totally new actuation mechanism for X
and Y movement of the coordinate table and by a
new, optional fourth clamp.
Easy manual loading
The intelligent right angle shear
FINN-POWER's new right angle shear is extremely fast in operation.
Programmable blade height and automatic stroke
depth adjustment combine to allow shearing
speed up to 110 m/min. In the right angle shear,
sheet holders are programmable, allowing shearing close to forms.
Blade speed can also be adjusted individually in
both directions. Together with automatic shearing modes this optimizes operation speed.
The intelligent right angle shear always allows
using the optimum solution for the stroke to be
made in each case, e.g.
•
a single stroke for detaching a
1,000 mm x 1,500 mm
•
fast, multiple strokes in X direction
up to maximum sheet length
•
fast cut mode for detaching
smaller components
Programmable, pneumatic sheet holders operate
fast and keep the sheet stationary during the
shearing process. A sheet support mechanism
ensures accuracy when large components are
sheared.
Shear Genius® is an automatic system, but it
can also be used with manual loading for small
series manufacturing. FINN-POWER's easy-load
system allows convenient processing of even
small sheets, and the new up-and-down clamp
movement feature makes loading very simple.
Manual unloading also takes place in the same
position at the table edge.
Turret punch press and FMU
As Shear Genius® consists of a fast turret
punch press and a right angle shear, it can also be
used just as a stand-alone turret punch press
when shearing is not required. If unloading equipment has been included, it performs like a FINNPOWER Express Flexible Manufacturing Unit.
Blade clearance adjustment is automatic. The
right angle shear can be used for 0.5...4 mm mild
steel (aluminium up to 5 mm).
9
FEATURES FOR FLEXIBLE
PRODUCTIVITY
Simple Maintenance
All machine tools require maintenance. The
search for compact constructions has often lead
to technical solutions where service points
are hard to reach. Shear Genius® features fast,
easy and safe access to service points, most of
which are located in a single cabinet.
Shear Genius® is equipped with central lubrication and lifetime lubrication units to eliminate
machine operator time wasted in weekly maintenance. Servo motors and mechanical direct
drives are maintenance-free.
Sophisticated Programming Systems
FINN-POWER's software range includes solutions up to every level, including the PowerPlan
software, which comes close to being a fullfledged PPS in addition to an efficient programming tool and cell control.
Software for easy operation
FINN-POWER's Windows® based PowerLink cell
control allows unattended running of several programs as an automatic work queue. Thus, e,g, in
an FMS configuration, even 24-hour unmanned
operation is possible.
FINN-POWER's ControlLink software covers the
entire FINN-POWER product range. It is a user
interface for operating all machine functions. It
features user-friendly diagnostics, interactive
electrical drawings, full machine manuals, spare
part library, etc.
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Flexible material handling solutions
– integration
The construction is compatible with the whole
FINN-POWER range of optional material handling
equipment for sorting and stacking. Thus Shear
Genius® solutions can automate
•
loading with possibility of material change
during machine operation
•
component exit (std.)
•
scrap removal (punching and shearing) (std.)
•
sorting and stacking of components
Shear Genius® can also be integrated in Night
Train FMS® or, using SGR robot solution, with
subsequent bending by an automatic bending cell
or a FINN-POWER press brake equipped with a
robot.
11
TM
Finn-Power Oy
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2244
www.finn-power.com
Finn-Power International, Inc.
710 Remington Road,
Schaumburg, IL 60173
USA
Tel. + 1 847 885 3200
Fax + 1 847 885 9692
www.finnpower.com
Finn-Power Canada, Ltd.
1040 Martingrove Road, Unit 11
Toronto, Ontario
M9W 4W4
CANADA
Tel. +1 416 242 4431
Fax +1 416 242 7867
Finn-Power Italia S.r.l.
Viale Finlandia 2
37044 Cologna Veneta (VR)
ITALY
Tel. + 39 0 442 413 111
Fax + 39 0 442 413 199
Finn-Power GmbH
Postfach 54
D-85399 Hallbergmoos
GERMANY
Tel. + 49 811 55330
Fax + 49 811 1667
www.finn-power.de
Finn-Power N.V.
Tulpenstraat 3
B-9810 Eke-Nazareth
BELGIUM
Tel. + 32 9 382 9030
Fax + 32 9 382 9031
Finn-Power Iberica, S.L.
C/. Vapor 8
Poligono Industrial El Regás
08850 Gavá (Barcelona)
SPAIN
Tel. +34 902 302 111
Fax +34 902 302 112
Finn-Power S.A.R.L.
Techniparc, 5 rue Boole
F-91240 St Michel-sur-Orge
FRANCE
Tél. + 33 1 69 46 55 80
Fax + 33 1 69 46 55 81
Item 1125 // SHEAR GENIUS® // © Finn-Power Oy, October 2004
Flexibly yours