5 Reasons Why Your Business Needs Panel Bender Manufacturers？

A panel bender is an effective metal forming machine for jobs involving materials with up to 1/8 inch thick. In one process, it is possible to rapidly complete a complex part that requires very accurate radius forming, hemming, or offset bends. The same operations performed on a press brake could be painstakingly slow.

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“The use of time on a press brake actually moving up and down to produce a bend might be 15 per cent of an operator’s time,” said Bill Bossard, president, Salvagnini America. “The balance of time is spent handling parts, finding parts, doing first-article checks, etc. And what we constantly hear from customers is that they wish there were a way to minimize or eliminate setup time on a press brake. Everybody is trying to drive down setup time. But once you start adding automated features to a press brake to make that possible, the price rises high enough that a panel bender becomes a viable alternative.”

Any shop that produces a lot of box-shaped items – HVAC and cabinet jobs – in the right gauge may consider a panel bender a viable option. The question then becomes whether to choose a fully automated, semi-automated, or manually operated machine. The choice will come down to the type of work the shop is pursuing and price considerations.

Manually Positioned Options

To describe any panel bender as manually operated is somewhat of a misnomer. In the case of TRUMPF’s TruBend Center Series machine and Prima Power’s FastBend machine, the operator loads a part is onto the panel bender and all of the bends on one side of the part are performed at once.

On the TRUMPF machine, a part as long as 10 feet can be bent with an 8-in. nesting height. It accepts sheet as thick as 1/8 in.

This is TRUMPF’s first foray into the panel bending market. This machine was first unveiled in North America at FABTECH® Chicago in . Tom Bailey, product manager for the TruBend series at TRUMPF, said that the company is trying to differentiate itself in this market by launching a bender that it feels is flexible in unique ways, such that it sets itself apart from fully automated models.

One of the ways the manufacturer differentiates its panel bender is the manipulator used to move the part once the operator has positioned it for bending. The manipulator is a 2-axis design, which moves the part both in and out for bends, but also vertically.

“Most panel benders you see on the market use a single-axis manipulator that just moves a part in and out of the machine to complete bends,” said Bailey. “Being able to move the part vertically opens up some possibilities. For example, a traditional limitation of panel benders has been that you cannot have a part finish with a down bend, because the part would then be stuck inside the machine. With a 2-axis manipulator, that is not a concern.”

Another challenge for many panel benders is the forming of narrow channels. Because of the force required of the blank holders that hold the sheet down as a bend is completed, a certain minimum amount of flat material has to be clamped during bending.

“If your part gets too narrow, the blank holders are too large to hold onto the part anywhere,” said Bailey. “So, although in theory these narrow channels are an ideal application for a panel bender, generally it is difficult for machines to achieve these bends because of how they are designed.”

TRUMPF’s bender includes an auxiliary set of blank holders that have a smaller profile and can be moved into position automatically when a narrow profile is necessary.

Bailey points to doors and frames as examples of parts that might be ideally suited for the particular benefits of the panel bender the company offers.

“It could be the door and frame of an electrical cabinet, or it could be a door and frame for a building,” he said. “Regardless, they always consist of large panels and small channels. If you can do both, you have an ideal application for a panel bender.”

Although the company is working on a fully automated version of its panel bender, Bailey noted that the addition of an automated system doesn’t negate the value of a model with a manual positioner.

“Once you go to a system with automatic part rotation, you introduce limitations on geometries, because now you have another mechanical manipulator that has to fit on the part to be able to rotate it,” he explained. “Again, narrow profiles and down flanges become difficult to deal with.”

Prima Power’s panel benders range from a manually positioned model to a fully automated system. The Fast Bend, or FBe, is the company’s manually positioned model. As Paul Croft, bending product manager, Prima Power North America, explained, this model has become a go-to bender for special products.

“Because it doesn’t have a manipulator to move the part in and out, it allows us to bend certain geometries that couldn’t be made using the manipulator,” Croft said. “For instance, we can bend parts that are a couple of inches narrower because there isn’t a manipulator in the way. Also, because we use vacuum pads underneath the sheet to hold it in place and move it in and out of the bend, we can process parts with louvres in them, or that have a cutout in the middle.”

This bender also has two different modes: standard, in which the part is automatically fed during the bending sequence of every side, and press brake mode, in which the sheet is moved manually bend by bend, which is useful for very narrow profiles.

Like the TruBend, the FBe gives a company flexibility to run complex parts that have special requirements that would be difficult to manage on a fully automated system.

Semi-automated Options

Formerly, one of the main advantages of manually positioned benders was that they allowed single-piece flow. This is useful for kitting work – you can run a left-hand panel, a right-hand panel, the top to an assembly, and so forth, and everything is collected at the end in one kit ready to go to welding. There is an 8-second tool change between each part, but that is still much faster than a press brake. While manually positioned benders are still effective in this respect, a lot of shops that do kitting are drawn to semi-automatic panel benders if a manipulator isn’t an issue.

The semi-automatic panel benders on the market require an operator to place the part in the machine. From that point, a manipulator takes hold of the part and processes it completely. The operator then simply removes the part and follows the same process again.

Salvagnini refers to its semi-automated models as its Performer series. These are made available in three standard sizes, encompassing bending parts from 4 ft. long to 8 ft. long.

“These machines aren’t customized to the needs of each customer,” said Bossard. “We equip them with a series of features that are already pre-engineered and can be selected however the customer would like to put them.”

If you have been to FABTECH at any time in the past six years, no doubt you have seen Salvagnini’s P1 or P2 model churning out parts. The parts are loaded manually, but once the part is on the table, the machine takes over. In the past five years, all of the Performer series machines have been upgraded to include automatic thickness measurement, angle control, automatic setup, and automatic blank holder adjustment. Bossard said the series has proven popular for kit sequence manufacturing, which might include single-piece part flow of as many as 10 pieces that would go to welding assembly afterward.

The P1 is distinct in that it is a fully electric machine. For this reason, it can bend sheet only to a maximum of 16 ga. All other Salvagnini machines (and those of its competitors) bend sheet up to 1/8 in.

When the P1 was first released a few years ago, it did not include automatic setup, which meant it required about a 5-minute setup time between one type of part and another. This detracted from its value for kit manufacturing. The addition of this capability has automatically made it more valuable to shops. The P1 can handle sheet up to 62 in. by 39 in., with a maximum bend length of 49 in. and bend height of 5 in.

The P1 also now allows for a “last bend down.”

“The last bend down creates the requirement to have an additional safety circuit to protect the operator when he reaches in to remove that piece,” Bossard explained. “That has been available on our other machines for several years, but the specific safety circuit has now been designed such that we can include it on the P1.”

The P2lean can handle sheet up to 98 in. by 62.9 in., bend length of 85.82 in., and height of 6.49 in.

Both machines are ideal for kitted manufacturing. The challenge, of course, is that you still require one operator per machine.

“Even with a part with 16 bends in it, the machine is going to spit that part out in less than a minute,” noted Bossard.

Prima has two models in this semi-automated line, the BCe and BCe Smart. As Croft explained, these machines have the processing speed of a fully automated bender, but with the ability to do a single piece or kitted assembly.

“What it really boils down to is production requirements,” Croft said. “Arguably, you could purchase two BCe benders for the price of one of our fully-automated EBe panel bending systems. The EBe is really designed to be included in a full automation cell, whereas the BCe and BCe Smart machines are designed to be stand-alone units.”

The BCe Smart is Prima’s newest foray into the panel bending market, and it was really designed to bring the price down for customers. With those design demands, some basic limitations have been put on this model.

“Generally, we find that the majority of the market doesn’t need any more than 80 in. of bending,” said Croft. “It is the only machine that is one-size-fits-all to keep it at a reasonable price point. Other machines that we make can go up to 140+ in.”

The other difference between the BCe and the BCe Smart is in the loading/unloading. The BCe is a fully-enclosed unit that runs a part into the enclosure, processes it, and rolls it out once it is processed. The BCe Smart has a smaller footprint. The operator places the part directly below the manipulator, which then takes the part and processes it. An LED reference bar helps the operator pre-center the part. Safety for the operator is provided by a laser light guard. When the part is processed, the operator can simply reach in and remove it from the table.

Again, this type of machine is ideal for kitted parts.

“With this machine you have an average of a 10-second tool change between different parts,” said Croft. “If I have a part that has a 40-second cycle time, I am only adding 6 to 10 seconds to process a single part. That tool change could have taken 10+ minutes on a press brake, so if I’m still only at 50 seconds while able to run a one-piece flow, a lot of people can live with that. It is still going to be the most efficient machine you have if you want to do 50 or 500 parts at a time.”

Fully Automated Benders

The limitation for all of the semi-automated systems discussed previously is that none of them can be equipped for integration in a fully automated production line.

“If you had our EBe panel bender as a stand-alone system, you could throw a stack of 100 parts on the left-hand side of the machine and it would spit them out as completed parts at the end,” said Croft. “But the benefit of that particular system is that it can be automated even further with one of our larger systems. It could be combined with a laser or shear or a blanking machine, and with robotic automation for sorting and stacking.”

Croft emphasized that although the EBe can be sold as a stand-alone machine, it is really most efficient when it is part of a larger automated cell. “The fact that it can be incorporated into any number of larger-scale systems is the biggest upside,” he said. “The EBe can be made in 133 in. and 147 in.; those larger sizes wouldn’t make much sense in a manually loaded machine where the operator has to handle parts. That’s how it proves its worth on a shop floor – rapid part production without operator interference.”

The models and special tooling can vary more substantially than the semi-automated options. For instance, there are eight models in Salvagnini’s P4 line of machines. Two of these models include flange, or open, heights of 10 in. Panel benders usually have a maximum open height of 8 in. which is another limitation in the type of parts that can be processed on a panel bender. Gradually, however, the limitations are shifting.

The two new machines with the larger open heights have maximum bend lengths of 88 in. and 122 in. Bossard suggested that the 88-in. model is ideal for electrical box manufacturing, because electrical boxes have tall sides.

“It is also ideal for people making drawers for workbenches, and food service environments,” said Bossard. “The 122-in. machine is particularly good for transformer cabinets, which are made of heavy material like 14-ga. stainless.”

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The point is that these more sophisticated machines can be adapted to the needs of particular industries.

Growing Sophistication

Panel benders are an attractive product because they can do so much without human interaction, and the companies that make them are doing what they can to increase their sophistication to give users peace of mind in their operations.

For instance, Salvagnini has changed the drive systems on its panel benders to run on electric actuators. Other than the P1, which is an all-electric machine, its machines now use fluid power for the clamping of the part and the actuation of the bending blades. Everything else on the machines is electric.

“The use of fluid power is very effective for low-speed, high-torque actions, and that is what we are doing,” said Bossard. The elimination of large hydraulic tanks, pumps, and motors means less maintenance.

But as Bossard explained many other innovations are making panel benders efficient and effective for metal fabricators.

“For instance, we are using an eddy current device to confirm whether the correct material has been introduced in the machine,” said Bossard. “It will differentiate among aluminum, carbon, and stainless steel, just in case an operator is careless. And our machines measure the thickness of every piece of material that goes into the machine because thickness is the greatest variant to angle.

“We are also close to releasing some angle correction technology that accounts for mechanical property differentials,” Bossard continued.

Panel bending options have expanded in the past few years. If you have the type of complex parts that suit such a machine, you have much to consider – the size of parts, automation, and flange height requirements are just three issues.

Editor Robert Colman can be reached at [ protected].

Prima Power Canada Ltd., 224-210-, www.primapower.com

Salvagnini Canada, 905-361-, www.salvagnini.com

This guide is designed to provide an in-depth insight into the world of panel bender. Whether you are a seasoned manufacturing professional or just beginning to explore the possibilities of metal fabrication, this guide is designed to enhance your understanding of sheet metal bending machines, their types, applications, and best practices in maintenance and safety. Delve into the fascinating world of panel bending technology, where efficiency meets precision.

1. What is a Panel Bender?
2. Types of Panel Benders
3. The Working Mechanism of Panel Bender
4. Applications and Industries of Panel Bender
5. Advantages of Using Panel Benders
6. Choosing the Right Panel Bender
7. Maintenance and Safety

1. What is a Panel Bender?

Ever wondered how those sleek, perfectly bent metal panels in buildings, machines, and various appliances are made? The answer lies in a revolutionary piece of equipment: the Panel Bender. This innovative tool has transformed the way industries approach the bending of metal panels, offering precision, efficiency, and versatility that were once thought impossible.

At its core, a Panel Bender is a specialized machine used for bending sheet metal panels. It’s a game-changer in the metal fabrication industry, allowing for accurate and consistent bends. This is crucial in industries where precision is key, such as in the manufacturing of automotive parts, aerospace components, and high-end electronics.

The beauty of a Panel Bending machine lies in its ability to automate the bending process. Unlike traditional methods, which rely heavily on manual labor and are prone to errors, panel benders use advanced technology to ensure that each bend is perfect. This not only improves the quality of the end product but also significantly speeds up production times, making it a cost-effective solution for businesses.

What sets panel benders apart is their versatility. They can handle a wide range of materials, from thin aluminum sheets to robust steel plates, all with varying thicknesses and sizes. This adaptability makes them a valuable asset in any manufacturing setting, where the demands and specifications can change rapidly.

2. Types of Panel Benders

Diving into the world of Panel Benders, you’ll find a variety of types, each catering to different needs and specifications in the metal fabrication industry. Let’s explore the most common types of panel benders, highlighting their unique features and applications.

Manual Panel Benders: These are the simplest form of panel benders, requiring manual operation and control. Ideal for smaller workshops or low-volume production, manual panel benders offer simplicity and affordability. However, they do require skilled operators and are not as efficient for large-scale production.

Semi-Automatic Panel Benders: Offering a blend of manual and automated features, semi-automatic panel benders reduce the need for constant manual intervention. They are equipped with some automated controls for bending operations, making them suitable for medium-scale production with improved accuracy and speed.

Fully Automatic Panel Benders: At the forefront of technology are fully automatic panel benders. These machines are designed for high-volume production, offering the highest level of precision and efficiency. With advanced programming capabilities, they can handle complex bending tasks with minimal human intervention, significantly boosting productivity.

CNC Panel Benders: CNC (Computer Numerical Control) panel benders represent the pinnacle of panel bending technology. These machines are fully automated and controlled by computer programs, allowing for intricate and precise bends with high repeatability. CNC panel benders are ideal for industries requiring high precision and customization in their panel bending tasks.

3. The Working Mechanism of Panel Benders: How They Operate and the Bending Process Explained

To appreciate the ingenuity of Panel Benders, it’s essential to understand their working mechanism. This chapter delves into how these machines operate, explaining the bending process and the key components that make it all happen.

How Panel Benders Operate

Panel benders, whether manual, semi-automatic, or fully automatic, operate on the same basic principle: manipulating a metal sheet to achieve the desired bend. The difference lies in the level of automation and control. In manual benders, the operator physically manipulates the metal, while in automatic versions, this task is performed by machine-controlled elements.

The Bending Process Explained

The bending process in a Panel Bender typically involves placing the metal sheet on a workbench, securing it in place, and then bending it to the desired angle. The bending is achieved through a combination of downward force and angular movement, usually applied by a blade or bending tool. In advanced machines, this process is precisely controlled by software, ensuring consistent and accurate bends.

Key Components of Panel Benders

The effectiveness of a panel bender is largely determined by its key components:

• The Workbench: This is where the metal sheet is placed for bending. It needs to be robust and accurately aligned.
• Bending Blade/Tool: This component applies the force to create the bend. Its design can vary depending on the type of bend required.
• Clamping System: Essential for holding the metal sheet in place during the bending process.
• Control System: In automated benders, this is the brain of the machine, where the bending parameters are set and controlled.
• Software: For CNC and fully automated benders, software plays a crucial role in determining the precision and complexity of the bends.

4. Applications and Industries of Panel Bender: Diverse Uses Across Sectors

Panel Benders are not just limited to one industry; their versatility allows them to be a cornerstone in multiple sectors. This chapter highlights the significant applications of panel benders in various industries, underscoring their pivotal role in modern manufacturing.

Automotive Industry

In the automotive sector, precision and efficiency are paramount. Panel benders play a crucial role in shaping the metal components that form the structural and aesthetic parts of vehicles. From the bodywork to intricate internal components, the ability to produce consistent, high-quality bends is essential. The use of Panel Bending machines in this industry not only speeds up production but also ensures the durability and safety of the vehicles.

Construction and Architecture

The construction and architectural realms have seen a significant transformation with the introduction of panel benders. These machines enable the creation of complex, custom-shaped metal panels used in modern building designs. From decorative elements to functional components like cladding and roofing, the precision of panel benders ensures that each piece meets the strict aesthetic and structural requirements of contemporary architecture.

Aerospace and Defense

In aerospace and defense, the demands for precision are even higher. Panel benders are instrumental in manufacturing parts for aircraft and defense equipment, where every millimeter matters. The strength, accuracy, and reliability provided by these machines are vital in creating components that can withstand extreme conditions and stresses, ensuring the safety and efficiency of aerospace and defense operations.

5. Advantages of Using Panel Benders: Boosting Efficiency, Precision, and ROI

Embracing Panel Benders in manufacturing processes brings a plethora of advantages, significantly impacting efficiency, precision, cost-effectiveness, and overall return on investment (ROI). Let’s delve into these benefits that make panel benders an invaluable asset in various industries.

Efficiency and Productivity Gains

One of the most compelling advantages of using Panel Bending machines is the remarkable improvement in efficiency and productivity. These machines can operate at a much faster pace compared to manual bending processes, significantly reducing the time taken for production runs. Automation reduces the need for constant human intervention, allowing for uninterrupted operation and faster turnaround times, which is crucial in meeting tight deadlines and increasing output.

Precision and Accuracy in Bending

Precision and accuracy are paramount in metal fabrication, and panel benders excel in delivering both. With advanced technology, these machines can achieve consistent and accurate bends, ensuring that every piece meets exact specifications. This high level of precision is especially critical in industries like automotive, aerospace, and construction, where even the slightest deviation can have significant implications.

Cost-Effectiveness and ROI

While the initial investment in a Panel Bender might seem substantial, the long-term cost savings and ROI are considerable. By enhancing productivity and reducing labor costs, these machines can quickly offset their initial cost. Additionally, the reduction in material wastage and rework due to their precision contributes to cost savings. Over time, the efficiency and quality improvements brought about by panel benders translate into a significant return on investment, making them a financially sound choice for businesses.

6. Choosing the Right Panel Bender: Key Factors for Making an Informed Decision

Selecting the right Panel Bender is crucial for achieving optimal performance and efficiency in your manufacturing process. This decision involves considering various factors to ensure that the machine you choose aligns perfectly with your operational needs. Let’s explore the critical aspects to consider when choosing a panel bender.

Factors to Consider

The selection process should start with a clear understanding of your production requirements, including the type of projects you handle, the volume of work, and the specific bending processes involved. This understanding forms the basis of evaluating the different types of Panel Benders available in the market.

Size and Capacity Needs

Size and capacity are pivotal factors. You need to consider the maximum size of the panels you will be working with and ensure the machine can accommodate them. Capacity also relates to the thickness and type of material the bender can handle. A mismatch in size or capacity can lead to operational inefficiencies or even damage to the machine.

Material Compatibility

Different panel benders are designed to work with specific materials. Whether you’re bending aluminum, steel, or any other metal, ensuring compatibility with the machine’s specifications is essential. This not only affects the quality of the bends but also impacts the longevity and maintenance needs of the bender.

Budget and Cost Considerations

Budget is a significant factor in any equipment purchase. While considering the cost, it’s important to look beyond the initial price tag. Evaluate the long-term costs including maintenance, spare parts, and the potential for upgrades. A cost-effective panel bender isn’t necessarily the cheapest upfront, but one that offers the best value over its lifespan.

7. Maintenance and Safety: Ensuring Longevity and Safe Operation of Panel Benders

Proper maintenance and adherence to safety protocols are crucial for the efficient and safe operation of Panel Benders. This chapter outlines key maintenance tips and safety best practices to ensure that these machines not only perform at their best but also provide a safe working environment.

Routine Maintenance Tips

Routine maintenance is essential to keep your panel bender in optimal condition. This includes regular cleaning to remove any debris or lubricants that may have accumulated, checking and tightening any loose components, and ensuring that all moving parts are well-lubricated. It’s also important to periodically check the alignment and calibration of the machine to maintain accuracy in bending operations. Scheduling regular inspections by a qualified technician can help identify and address potential issues before they escalate into major problems.

Safety Protocols and Best Practices

Safety is paramount when operating any industrial machinery, and panel benders are no exception. It is crucial to ensure that all operators are properly trained and familiar with the machine’s safety features and operating procedures. Key safety practices include wearing appropriate personal protective equipment (PPE), adhering to operational guidelines, and never bypassing safety mechanisms like emergency stops. Regular safety audits and drills can also help in maintaining a safe working environment.

Conclusion

In conclusion, the world of Panel Benders is vast and dynamic, with advancements constantly shaping the future of manufacturing and engineering. As a leading Chinese manufacturer and solutions provider in the realm of panel bending technology, Krrass stands at the forefront of innovation. With a commitment to quality and excellence, Krrass offers state-of-the-art Panel Bending machines that redefine efficiency and precision in metal fabrication. Visit www.krrass.com to discover how our expertise can elevate your manufacturing processes to new heights.

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