NEW FOLDING MACHINERY CNC-MACHINES BENDERS-BRAKES

For over 20 years, Roper Whitney has been producing quality folding systems for a variety of markets. Building on that experience, the Generation "2" Autobrake integrates advanced design with the features that have made the Autobrake the choice of professionals.

The Autobrake combines automated bending of angles up to 145o, material clamping, and material support into a single CNC controlled system employing wing bending techniques.
Manufacturing, service, and applications support are based in Rockford, IL U.S.A. Benefits of the Generation "2"

Autobrake system vs. manual or press brake bending are:
• Reduced labor costs
• Improved part accuracy
• Reduced setup time
• Minimized tool changes
• Improved part quality especially on soft and pre-painted material


Kombi Autobrake Features

INTEGRATED SHEET SUPPORT AND MATERIAL POSITIONING:

Work pieces are fully supported by the table beneath the clamping jaw, and automatically positioned to an accuracy of +/- .004" by the computer controlled automatic gauge. Sheets up to 700lb. (318kg) can be accommodated. Maximum 61" (1550mm) back gauge travel in less than 3 seconds is provided by our three stage design combining high speed with compact space requirements. Operation of the pop-up fingers is controlled by the integrated air system. Air supplied to the back gauge fingers must be clean and filtered with an operating pressure of 80-100 psi. The gauging system is constructed of heavy duty yokes riding on dual linear ways. The back gauge is driven by a servo motor for low noise operation and precision ball screw for high levels of accuracy. The servo motor automatically recovers from back gauge displacements as high as .625 inches. The 14 conveniently spaced fingers provide positive contact with the sheet edge at all times and have a minimum back gauge position of 0”.

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Synergy is the newest software designed for Roper Whitney’s line of powered folding machines. It is a highly advanced CNC system that takes the complexity out of programming and running parts. The full-color, graphical touch screen allows you to store, browse and search for parts, as well as create new parts on the fly.

The software also brings together information from the office-based Konstruct program and the field-based Konstruct Mobile with Roper Whitney’s technical support program Konnect.

Easy Windows-based touch screen control
Auto sequences the part
3-D part display
DXF file import capability

Computer specifications are:

• 15" high resolution anti-glare flat panel touch screen
• Integrated industrial computer with internal air cooling
• Intel Pentium-M 1.6 gigahertz processor or greater
• 512 megabytes of RAM memory
• 64 megabytes of video RAM
• 40.0 gigabyte hard drive
• 3-1/2 floppy drive
• DVD-ROM
• 40X CD ROM
• RS232 serial ports
• Ethernet ready
• USB 2.0 ports
• Sealed oil-tight enclosure The SYNERGY control manages all the machine motions (upper jaw, lower jaw, back gauge and bending beam) the software has a feature intuitive interface that allows an easy management of product drawings. During the operation of the machine, the SYNERGY control shows in real time the bending sequence or a single fold, with the position and movement of various parts (upper jaw, folding beam and back gauge).

Technical Data

Automatic sequencing of the part that is drawn.
Possibility of saving programs in folders and subfolders.
3D Part display.
Part simulation to verify bend sequence, material handling and collisions.
A search function is used to make it easier to identify a part.
Export of programs, library materials and back up to USB stick.
The actual values of the axis are shown on the display, as well as the motion of the machine in real time.
There are 3 different hems : Open, Closed or Tear Drop.
Capable of importing DXF files.
Konstruct offline programming
Konnect online service and operator assistance.

Precise
The bending sequence is calculated and optimized in relation to the characteristics of the piece and the actual measurements of the machine and the accessories mounted. It is possible to establish and /or modify the bending sequence calculated by the software, once “customized”,  the software saves the new sequence and uses it as a first option for the following similar profiles

In the illustration of the bending sequence and simulation, there are icons that show how to insert, rotate and flip the sheet.

Programming Functions are:

• Bend angle
• Gauging distance
• Offsets for hem operations
• Programmable delay for back gauge
• Open, closed, or teardrop hemming
• Open hem height
• Clamping force
• Jaw opening
• Spring back compensation
• Tool selection-box tool or standard jaw
• Radius profile macro
• Customer alpha/numeric part number
• Information screen for entering of part related data
• Material handling instructions
• Programmable part counter

Real-Time Support with Maximum Up-time
Real-Time support for Roper Whitney products through Konnect allows customers direct contact to our technical support and service team. Features include:

Live audio and video on your equipment’s control system
Diagnose machine problems with our help
Share your machine’s control system so we can make necessary updates
Receive follow-up training or programming assistance
Konnect is available on all equipment powered by the Synergy Control System. To schedule a demo, or to learn more about how Konnect and real-time support can help your production line remain efficient, email our Konnect specialist at konnect@roperwhitney.com.

CONSTRUCTION:

The Generation "2" Autobrake is a plate and weldment steel construction, delivering superior performance and features in a simplified rigid design. End housings are a plate-type construction bringing drive components close together for improved stiffness and performance. Actuating mechanisms are secured in rigid mounts at the outside of the housings, allowing easy maintenance.


AB1216KT2 Kombi Position

The unique Kombi beam is a fabricated structural prism on which is mounted tooling to firmly clamp a broad range of materials and withstand the forces generated by capacity forming operations. Machined into the Kombi beam 180° from each other are the attachment surfaces for the straight and box and pan tooling. Tools are attached to the Kombi beam with standard socket head cap screws and grooves are provided to secure the tools even while the clamping bars are loosened for adjustment. Rotation of the Kombi beam is powered by a brake motor driving a sprocket and roller chain mechanism.

The upper beam is driven to programmed settings on both ends by a brake motor and eccentric drive of the beam with a connecting shaft. Clamping and hemming power is delivered to the clamp jaws by a series of spring washers to provide variable clamping pressures with a shock-absorbing end stop. This provides reliable clamping pressure regardless of material thickness. Integral to the upper beam are the ways with non-metallic gibing to guide and retain the upper beam within the end housings.

Actuating members rotate the bending beam into position from both ends of the machine, using a variable speed drive (VSD) for accurate control over programmed bend angles. Mechanisms are mounted within reinforced connections for improved performance.

The lower beam is a welded reinforced structure fabricated of thick steel keyed into the end housings. The lower beam is pinned in place, and close-coupled to the end housings and upper beam for improved rigidity. The advanced design of this beam delivers superior hemming results.

The folding beam consists of a thick plate for maximum resistance to bending forces with a machined seat to receive the standard .787" (20mm), .390" (10mm) or .275" (7mm) bending blades. A micrometer nut allows adjustment for large variations in material thickness.

Operating mechanisms of the Generation "2" Autobrake are enclosed within attractive end covers. Each cover is equipped with lift points for easy removal from the machine, presenting all moving parts for easy maintenance. Covers are nested on tapered mounts for easy attachment to the ends of the machine.

Part program operation and creation are accomplished on a pendant-mounted computer control, located at the
right-hand side of the machine. The computer control can be rotated into position for best use, and can be positioned to the rear of the machine.

Access to the Autobrakes’ electrical system is located at the right-hand portion of the machine through a quick- lock enclosure. This enclosure houses the power and control devices that drive the machine, and extends behind the right-hand cover for reduced machine length.

The angular shape of the covers and advanced machine design provide a smart modern appearance to the Generation "2" Autobrake.

 

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Simple and Reliable
Entering data directly on the screen, if errors occur, you cancel your choice with a click (button “undo” or “redo”). The profile can be drawn, edited and saved directly on the screen (touch screen mode) and data, such as length; angle and radius can also be entered manually, by selecting the affected side.

Graphical user interface complete with zoom, rotation, displacement, vertical and horizontal with a simple touch on the screen. Folds, round profiles, hems, and steps are inserted using the appropriate button and touching the screen like a blackboard on which to draw.


CROWNING SYSTEM:

Folding beam crowning is standard equipment on the Generation "2" Autobrake. This system consists of crowning cams, actuating tool, and interfacing features on the machine's bending beam.

The system provides a quick easy method for adjusting the center crown of the bending tooling to improve bend accuracy, and adjust the work material straightness when forming radius bends. The system is manually adjusted, and locked in place by the operator.

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