volume 18 - issue 1 - Finn-Power International, Inc.

finnpower.com

volume 18 - issue 1 - Finn-Power International, Inc.

Finn-Power Attracts

Great Interest at

Brazilian Trade Fair

C5 Turret Punch Press

and E Press Brake

Displayed during

MECANICA See Page 19

X5 Turret Displayed

at FIMAQH

South American

Fabricators Interested in

Updating Fabrication

Technology See Page 22

Tech Tips

Finn-Power Part

Removal Options See Page 2

LP Reduces Labor Costs…

Integrated Automation…

C5 Increases Production…

Volume 18 Issue 1 July 2008

See Page 4

See Page 12

See Page 20

Customer Profiles

Highlight Finn-Power’s

Product Range and Flexibility

A Finn-Power Publication

Americas Edition

FABTECH 2008

Las Vegas

Don’t Miss the Hottest

Show on The Strip…Or in

the Fab Shop! See Page 7

In the News…

Making

Headlines

with the

Trade Press

See Page 9

Tooling Articles…

Wila USA See Page 8

Wilson Tool

International See Page 16

Mate Precision

Tooling See Page 18


TECH TIPS

Finn-Power Part Removal Options

There are many different part removal options for Finn-Power’s family

of turret punch presses, combination machines, and lasers. These

options need to be selected carefully. You should determine your

need for machine time availability versus part sorting and stacking

requirements to ensure the most efficient use of your equipment. Remember,

one operation directly affects the other. For example, overall cycle time is

increased when the machine is sorting and stacking parts, depending on the

operation and the availability of a buffering option. Depending upon part size

and hole and feature intensity, the machine may be able to produce parts

faster than the machine can buffer, sort, and stack them.

Depending upon the machine or system, the options begin with simple

manual part removal and range from fully-automated flat stacking on pallets

to automated storage systems.

Machine Part Removal Options

Manual removal and micro-jointed parts in full sheets – An example of

efficiency improvement, which is dependent upon your part removal options,

is removing parts as individual pre-cut blanks compared to nesting multiple

parts on a sheet. The result is that the unload time is for one sheet of 10

micro-jointed parts rather than 10 individual single part unloads.

Easy-Snap microjointing

– The use of

scrap-less part

retension or Easi-Snap

tools further enhance

micro-jointed part

removal by jointing

the scrap to the parts

rather than breaking

them out of the

skeleton. Nested

micro-jointed parts

can be stored and

broken out later outside of the machine cycle.

Common-line, micro-jointed nests save even more

time and give better material utilization.

Trap door to bin removal of individual part sizes

500 mm (19.5" ) square – Another part removal

option available is that of a trap door. The current size

takes a 19.5" (500 mm sq) blank. This part removal

option allows for the automatic removal of parts from

the material skeleton into a box after the last punch hit or laser cut often via

conveyor without operator intervention. Again, you must balance the

trapdoor unload time off against the extra machine cycle time that it takes up.

As an option with the Finn-Power NC Express software, the trap door can be

automatically programmed with a variable delay to stay open for all or some

parts, thereby significantly reducing the trap door cycle time. Part pickup and

The FINN-ISH LINE is a publication distributed to Finn-Power customers,

prospective customers, employees, dealers, suppliers, and friends. The staff of the

FINN-ISH LINE requests article ideas and letters for future publication.

Editor Robert J. Kolcz rjk@finnpower.com

Associate Editor Tiina Ayaydin tiina@finnpower.com

Technical Editor Lutz Ehrlich lehrlich@finnpower.com

Contributing Editor Andrew McCarlie mccarlie@finnpower.com

Senior Correspondent Timo Laurinen timo.laurinen@finn-power.com

All registered trademarks in this publication are property of their respective owners.

2

by Andrew McCarlie, Applications Engineer

placement is not significantly affected by forms and holes on the part

profile and to a lesser degree material flatness.

Pick and place robots removing parts

from the sheet skeleton during part

processing and stacking on pallets.

LSR/PSR/LST – This is an option that is

typically used on punch presses and

laser/punch combination machines. The

part-picking robot typically picks a part

out of the sheet skeleton after the last

punch hit frees it from the sheet. It is then

stacked onto a pallet which can then be

feed into an automated storage system if

required. Much larger parts can be

extracted from the sheet using this option.

The time required for the robot /

unloader to extract the parts from the

sheet must be taken into account in the

overall part cycle time. Also part pickup

and placement is dependent upon the

number of cutouts and forms present on

the part profile as well as material flatness.

Pick and place robots stacking

skeleton free finished parts from a buffer

to a pallet. SGR/SBR – This unload

option can function while the machine

SG/SB is still processing parts until the

buffer is full. The parts are cut completely

from the skeleton which is cut up

allowing a truly skeleton free operation.

The finished parts are then stacked onto a

pallet which can be off-loaded manually

or attached to an automatic storage

retrieval system.

Skeleton unloader systems that

unload a full skeleton of micro-jointed

parts to a pallet such as on the Compact

Express, SG/SB/LP and Laser machines –

These unloading systems can be used as

the single main parts removal option on a

machine such as a compact express or as an extra unload option as part

of an SG or LP system. The parts can be broken out of the skeleton

outside of the machine cycle. This method of unloading is less sensitive

to material variation and part profiles.

Stacking/sorting/bin systems that stack skeleton free parts to a

pallet or bin. SG/SB STS systems – These two types of part removal

systems allow for removal of complete parts up to a certain size in the

case of the sorting bins. Both systems take time up from the processing

time to sort and stack the parts. The bin system has the advantage of

being quicker but is limited in size to 30" x59" . Scrap is tabbed to the

parts to provide for quick release and to avoid extra scrap punch hits

thereby speeding up the process cycle time. The finished part goes

directly to the next operation with no micro-joint removal.

Punch part removal using the punching slug chute – This

method can be used on all punching machines and involves using a

large rectangle (1" x3" – 25 mm x 75 mm) as a mini right angle shear

to free parts that fit inside the size of the punch. This is done by

sequencing this large rectangle to be the last hit in the punching

sequence. The freed part goes through the die down the slug chute and

out the slug conveyor. The operator diverts these slugs which are small

parts from the slug conveyor into a separate container as they fall out.


PRESIDENT’S CORNER

New Opportunities…New Solutions

When Finn-Power and Prima

Industrie S.p.A. joined forces last

February, the acquisition created

the 3rd largest sheet metal fabrication

manufacturer in the world, with a product

offering that is by far the widest in the world.

Our new group now has a turnover in excess of

400 million euros and employs 1,700 persons.

As we steadily and carefully consolidate our

many resources, we are very excited about our

ability to provide the sheet metal fabrication

world with a complete product line consisting

of machines, cells, and systems to satisfy any

customer need or requirement.

New equipment technology has always

been the lifeline to growth for sheet metal

fabricators. And the new realities of the sheet

metal fabrication industry match our combined

product lines perfectly, with a comprehensive

range of laser cutting, punching, shearing,

bending, and automation. We have designed

versatility to individual work stages by

integrating them with automated material

management and making automation as flexible

as possible. Our modular approach adapts to a

multitude of production needs and changes.

Our goal has always been to improve our

customers’ productivity.

The “Greening” of

Sheet Metal Fabrication

For the past decade, Finn-Power has

pioneered servo-electric products into the sheet

metal fabrication industry. We introduced the

first servo-electric turret punch press – the E5

work center – in 1998. Since that time, our

family of energy-saving products has grown to

include the second

generation of servoelectric

punch

presses; the LPe6

servo-electric

punch/laser

combination; the E

series servo- electric

press brake; and the EBe servo-electric Express

Bending cell.

All Finn-Power servo-electric machines

provide our customers with such benefits as:

Higher precision

Higher repeatability

Higher quality of end product

Less energy consumption (50% less than

hydraulic models)

Lower maintenance costs

Lower operating costs

Higher reliability

Ease of operation

Less noise & vibration

In the Words of Our Customers

This issue of the FINN-ISH LINE contains

several customer profile articles that highlight

Finn-Power’s product range and flexibility:

Day-Brite Lighting, Tupelo, MS, (see page

12) has earned a well-deserved reputation for

manufacturing quality industrial and

commercial lighting products. In 2004, the

company’s challenge was to find a way to go

from product design, to fabricating the part,

and have it

ready to

assemble to

within one day.

To achieve its

goal, Day-Brite

chose two Finn-

Power Shear

Genius flexible

manufacturing

cells, a Night

Train Material Management System, a robotic

hydraulic press brake, and two servo-electric E

press brakes.

“With the Shear Genius, we’ve eliminated

blanking since we are able to fabricate

full-sized sheets and nest the parts,

ensuring part consistency and squareness

from one run to the next.”

“The integration of the Night Train with

its management system was a big feature

for us. We run a great deal of 24/7,

including ‘lights out’ over the weekend

on some of our larger volume products to

get a jump on production.”

“The E Series press brake is a

phenomenal piece of equipment. With

the Finn-Power E Series press brake, we

have seen increases in our productivity,

quality repeatability, and reduced set-up

and programming times. We estimate

savings of 35-40% bending with the new

press brakes over the older models.”

“The integrated automated system was

the key to Finn-Power over the

competition. None of the other machine

producers had this capability. Finn-Power

was head and shoulders above the

competition.”

Produits Métalliques Bussières, Inc.,

Quebec, (see page 4) was formed in the early

1990s to service the growing job shop market in

3

by Tomas Hedenborg, President

Quebec. By 2005, the company’s old turret

punch press was overloaded, and the company

began looking at ways to increase its

productivity. After an intensive search of the

latest automated

technology on

the market,

PMB executives

chose the Finn-

Power LP6

laser/punch

combination

with the LSR

load and

stacking robot.

“Not only have we been able to bring all

the laser work in-house from the

subcontractors, but the quality is much

better with the LP6. In addition, we have

the flexibility to use either the laser or the

turret punch press.”

“The LP6 is 40% faster – and in some

cases 60% faster – than our earlier

machine. The Finn-Power LP6 /LSR has

tripled our productivity capability

compared to our earlier fabrication

equipment.”

“We also changed our production

philosophy with the new equipment. We

used to batch manufacture our parts.

With the Finn-Power equipment, we nest

everything…and this has made us more

efficient.”

Prática Technicook, Pouso Alegre, MG,

Brazil, (see page 20) is a manufacturer of

professional ovens found in grocery stores,

industrial

kitchens, and

hotels. By 2006,

the company

had outgrown

its fabrication

equipment and

needed to add

more capacity.

Prática

Technicook

chose the C5 hydraulic turret punch press from

Finn-Power which was installed in January

2007.

“Before we installed the Finn-Power C5,

we had the capacity to make six ovens per

day. With the C5, we now produce 10

ovens plus four refrigeration units per

day. We have more than doubled our

production…with less labor and less

expense in tooling.”

“95% of what we produce is stainless

steel. Everything is fabricated on the C5,

which amounts to 45 metric tons of

stainless steel per month.”


CUSTOMER PROFILE

Laser Punch Combination Increases Productivity &

Flexibility at Quebec Contract Manufacturer

“While we are a small business,

even our competitors are impressed

by our Finn-Power equipment.

When our customers see the LP6,

we gain in credibility and it gives

us increased visibility.”

In 1978, Clément Bussières founded Recouvrements Métalliques Bussières (RMB),

St. Henri de Lévis, Québec, to supply the construction industry with metal siding.

When the business first began, Bussières had only a mechanical press brake and

shear to fabricate his molding products. Soon the company grew and a sister company,

Produits Métalliques Bussières, Inc. (PMB) was formed in the early 1990s to service

the growing job shop market in Quebec. In the early days, PMB manufactured various

metal supplies mainly for the construction industry.

As the company evolved, many other industries were added to PMB’s list of

clients, including outdoor recreation, heating, transportation, agricultural controls,

electrical panels, etc. Bussières’s son Steve joined the company in 2000 with some new

ideas and a strong commitment to grow the job shop side of the business. “We bought

our first turret punch press, and a few years later purchased TIG, MIG, and spot

welding equipment to open up the subcontractor market,” explains Steve Bussières.

“Through hard work, new equipment and software procurement, and retaining our

workforce, the job shop business has grown to

80% of total sales, compared to 20% back in

2000.” Today, the company has a 24,000square-foot

facility and 30 employees.

“A few years ago, tolerances were not as

important as they are today,” adds Dominic

Fournier, production manager. “In the past,

the tolerances were not tight with our lowtechnology

machines. But today our

customers have demanded more accurate

parts with tighter tolerances and zero defects.

We grew with our customers and this has led

to our search for quality fabrication

equipment.”

According to Bussières, by 2005 PMB’s

old turret punch press was overloaded, and

the company began looking at ways to

increase its productivity. “We also wanted to

add laser capacity,” says Bussières. “We were

subcontracting all of our laser work.”

After an intensive search for the latest

automated technology on the market, PMB

executives chose the Finn-Power LP6

laser/punch combination with the LSR load

and stacking robot. “After seeing the laser

punch in action during a Finn-Power

Technology Trip to Finland and Italy, we

knew it was the machine that filled all our

needs,” explains Bussières. “We wanted to

commit to automation, so the LP6 with the

LSR was a logical choice to allow us to

eliminate micro joints and add lights out

operation.”

The Finn-Power LP laser/punch

combination represents proven technology

and intelligent integration of punching,

forming, tapping, and laser cutting in a single

unit for the most varied sheet metal

operations. Optimum use of the Finn-Power

4

Steve Bussières (right) and Dominic Fournier, general

manager, Produits Métalliques Bussières, Inc., chose the

Finn-Power LP6 laser/punch combination with the LSR

load and stacking robot to modernize their plant and

increase productivity.


LP6 means that a fabricator can use the turret

punch press where it is easier or faster and the

laser where it is the most effective. The LP

allows the user to look at the parts to determine

the optimum process for every production.

Other benefits of the LP6 include:

Reduction of piece part costs – faster

punching time, reduction in direct labor

assigned to set up and punching, and

reduction of number of manual

operations.

Ability to utilize full sheets while

eliminating the need to shear to size

blanks being processed.

Increased machine utilization – if

load/unload system is purchased with the

LP, unmanned operation can be achieved

from load, punch, upform, laser cut,

unload, and sorting of parts in one

machine.

“The automated LP6 combination machine

has more capacity than two manual machines,”

notes Fournier, general manager. “And the LP

has dramatically reduced our labor costs. Instead

of four operators over two shifts, we now have

just two operators…and finding qualified labor

is getting more difficult each year.”

The Finn-Power LP combines the unique

C-Series 20-station turret punch press with the

latest generation of CO2 lasers. The punching

part of the LP consists of a 30 ton (33 US ton)

turret punch press that has excellent forming

capabilities – .630" high (16 mm) with no die

interference, auto-index, Multi-Tool ® ,

programmable clamp settings, and brush tables.

Other features of the LP6 include:

A Rofin Sinar 2,500 Watt, diffusioncooled

CO2 SLAB laser that is integrated

into the LP6.

The focal length lens can be changed in

seconds using a cartridge technique. No

tools are required. The cartridges are

available in 5" and 7.5".

“Not only have we been able to bring all the laser work

in-house from the subcontractors, but the quality is much

better with the LP6. In addition, we have the flexibility

to use either the laser or the turret punch press.”

Integration of the laser and the punch is

accomplished with the part piece flowing

from the turret punch press to the laser

without the release of the clamps. The

flow of material is from the load side to

the unload side, eliminating the timeconsuming

method of loading and

unloading from the same side.

The O-frame of the turret punch press is

The Finn-Power LP6 combines the unique C-Series 20-station turret punch press with the latest

generation of CO2 lasers. Optimum use of the Finn-Power LP6 means that a fabricator can use the

turret punch press where it is easier or faster and the laser where it is the most effective. The LP6

allows the user to look at the parts to determine the optimum process for every production.

5

separate from the laser, assuring that no

vibration will be transferred to the laser.

This provides added reliability and

uptime of the system.

Tool Holders – Finn-Power incorporates

an individual tool holder concept that

allows customers to design their own

turret layouts. Unlike other designs,

specific tool stations are not machined

into the turret. Finn-Power offers the

only flexible selection of tool holders in

the industry. Any tooling style from Mate

Precision Tooling or Wilson Tool

International can be installed in a Finn-

Power turret. Up to 10 auto-index,

forming, or Multi-Tool ® stations may be

installed in a Finn-Power turret.

Auto-Index – Finn-Power’s unique autoindex

system precisely rotates the punch

and die in their tool holders. Rotation in

.001 degree programmable increments

gives the machine the ability to rotate

beyond 360 degrees, thus allowing the

system to automatically select the shortest

path to rotate to a programmed angle

input into the NC part program with

simplicity, speed, and reliability. PMB has

six full-tonnage auto index stations.

Multi-Tool ® – Finn-Power’s Multi-Tool

stations increase the number of tools

available in a turret, thus reducing set-up

and increasing productivity. The Multi-

Tool system allows multiple tools to be

put in one station. Finn-Power Multi-

Tool offers 6, 8, 10, or 24 different

punch/die combinations in only one

station-a turret within a turret. PMB has

four Multi-Tool stations.

Upward Forming System – Finn-Power’s

upward forming option provides more

accurate forming and greater forming

heights up to 16 mm (.63" ) and 5" in

diameter. Another advantage is that all

dies are at the same height, and there are

more high-forming dies in the turret,

thus, reducing risk of material damage

and increasing machine uptime.

continued on page 6


continued from page 5

“Not only have we

been able to bring all the

laser work in-house from

the subcontractors,” says

Bussières, “but the quality

is much better with the

LP6. In addition, we have

the flexibility to use either

the laser or the turret

punch press.”

Produits’ customers of today demand more accurate parts with tighter

tolerances and zero defects. When the subcontractors were doing the

company’s laser cutting, it facedmany quality control problems. With the

LP6, Produits controls every step of the process – from the loading of the

sheet through unloading of the part. The automation gives them a

capacity to cut stainless and polished material without scratching the part.

Loading and

Stacking Robot

The Finn-Power

loading/unloading and

stacking robot (LSR) is a material and part handling robot that can be

integrated into the LP6 laser punch. The LSR loads sheets to the laser

punch and stacks finished work pieces onto stacking pallets.

The LSR gripper has 24 suction areas, each of which can be

controlled separately. In the programming system, vacuum areas are

selected, and vacuum area values are automatically generated to the LP6

laser punch and the LSR robot.

According to Bussières, the LP6 is 40% faster – and in some cases

60% faster – than the company’s earlier machine. “We now have the

automation to run overnight,” explains Bussières. “This automation has

dramatically increased our productivity. The Finn-Power LP6 /LSR has

tripled our productivity capability compared to our earlier fabrication

equipment.”

“Prior to purchasing the Finn-Power automation, we set up teams to

train and create a new mindset for our employees,” says Fournier. “We also

changed our production philosophy with the new equipment. We used to

batch manufacture our parts. With the Finn-Power equipment, we nest

everything…and this has made us more efficient. We no longer have to

shear blanks. With the automation, we can utilize the economies of

nesting full-sized sheets.”

NC Express Programming Software

Another area of satisfaction for PMB is the Finn-Power operating

software. The NC Express CNC programming system is a user friendly,

integrated, and automated tool for managing Finn-Power equipment in

the most efficient manner. NC Express is a tooling, nesting, and

optimizing software package designed to easily integrate into an existing

6

manufacturing environment, taking full advantage of the CAM features

and the Finn-Power machine tool product line. “With the Finn-Power NC

Express, it is easy to nest parts with the laser and turret punch press

capacities,” explains Fournier.

New Markets

The Finn-Power automation has also opened up new markets to

PMB. “When the subcontractors were doing our laser cutting, we faced

many quality control problems,” says Bussières. “But now we control every

step of the process – from the loading of the sheet through unloading of

the part. The automation gives us the capacity to cut stainless and polished

material without scratching the part.”

While sales have continued to grow 15-20% per year at PMB with the

addition of the Finn-Power equipment, Bussières estimates his company

still has untapped capacity in the LP6. “Our target was to have this

machine handle production for the next 2-3 years by itself…and it is

almost two years since it was installed,” says Bussières. “We can continue

the same rate of growth for another two years with the LP6.”

With the difficulty in finding qualified labor, PMB is concentrating

on automation for future growth. “We are looking at robotic press brakes,”

explains Bussières. “All of our future thinking will be around automation,

including maybe the Night Train Material Management System and

another LP6. We see additional benefits every day. While we are a small

business, even our competitors are impressed by our Finn-Power

equipment. When our customers see the LP6, we gain in credibility and it

gives us increased visibility.”

The Finn-Power loading/unloading and stacking robot (LSR) is a material

and part handling robot that can be integrated into the LP6 laser punch.

The LSR loads sheets to the laser punch and stacks finished work pieces onto

stacking pallets.


FOCUS ON TOOLING

by David Bishop, Business Development Manager, Wila USA

Fast, Flexible & Friendly…Developing a Cost

Efficient Tooling Package for Today’s Job Shop

Purchasing a new press brake can be a pretty daunting task. And

after you’ve finally selected the press brake that you want, you’ll

have to decide which tooling system you’re going to use in your

new machine. Of course, the last thing that you’re going to want to do is

spend a small fortune on a long list of punches and dies. And you

shouldn’t have to. So, how can you get tooling for your new machine that

is fast to set up, flexible in meeting the majority of your needs, and

friendly to your budget?

The first place to start is to get assistance from someone that has a lot

of experience in tooling applications, like your local Wila regional business

development manager. He’ll help you to select a versatile set of tooling to

maximize your productivity and produce parts of the highest quality using

the smallest number of tools possible. For example, if you’re working in a

job shop environment, you’re most likely bending materials that fall within

a thickness range of 26 ga. to .250". If so, applying the following

guidelines will help you to minimize the number of tools that you’ll need

to produce a wide range of parts.

Punches

With few exceptions, all punches should

be able to be loaded and unloaded vertically.

Sliding tooling in and out the end of the

machine is time consuming and costly.

For air bending applications, use acute

angle punches whenever possible for bending

materials of .250" (6.3 mm) in thickness and less. They are fairly strong,

have more than adequate compensation for springback with virtually all

material types, and can bend almost any angle you’ll ever need to produce

on a press brake. Some can also be used in hemming applications. They

are also lower in cost than gooseneck punches, making them less expensive

to replace when damaged.

Use gooseneck punches for bending parts that have return bends and

complicated bend sequences. Their large relief areas make them extremely

versatile and helps to reduce the need to make punch changes when going

from one part configuration to another.

When the open height allows, always select tall punches

(6" /152.4 mm and

taller) when tooling

up a new press brake

as they are always

more versatile than

short punches. As a

general rule, we

recommend that you

leave approximately 4"

(100 mm) of space

between the punch

and die after the

clamping system,

punch, die, and

crowning system, filler

8

block, or die holder (whichever applies) have been installed for part

handling.

Some applications will require punches with special tip angles, and/or

special tip radii. If you are going to need them for your new press brake,

try and order them in advance of the delivery of the machine so that you

are not waiting for them after your machine arrives. Wila can normally

ship punches with modifications to the tip angles and/or radii within ten

business days following receipt of order.

Dies

When possible, use acute angle dies to air bend everything. Today’s

advanced CNC controls accurately determine the proper amount of die

penetration that is required to bend practically any material to any angle.

It is no longer necessary to purchase dies to match the included angles of

all your punches. This will eliminate the unnecessary duplication of die

openings, reduce the number of die changes that you will have to make,

and save you a lot of money.

Material Thickness “V” Width Angle Tons/Ft. Req. Inside Radius Min. Flange

26-20 ga. .236" (6 mm) 30 3.6 .039" (1.0 mm) .165" (4.2 mm)

18-16 ga. .394" (10 mm) 30 6.0 .066" (1.7 mm) .276" (7.0 mm)

14 ga. .630" (16 mm) 30 5.6 .105" (2.7 mm) .454" (11.5 mm)

12, 11, 10 ga. .945" (24 mm) 30 9.5 .157" (4.0 mm) .680" (17.3 mm)

.188" and .250" 1.969" (50 mm) 80 15 .328" (8.3 mm) 1.477" (37.5 mm)

Most parts can be bent with standard dies that are 2.165" (55 mm)

tall. Parts that have long down flanges require taller dies. While Wila has a

full range of standard dies that are 3.937" (100 mm) tall, they should only

be selected when required as taller dies are more expensive than short dies.

Try and use one die for each two to three material thicknesses that

you plan to bend. The following table provides some general

recommendations for the selection of a versatile range of dies to bend mild

steel in the thickness range of 26 ga. to .250"

As you can see, in most cases, you can use one die to bend two or

more material thicknesses and still get favorable results in terms of the

tonnage, inside radius, and minimum flange length requirements. In this

case, we would use a total of five dies to bend the entire range of materials

from 26 ga. to .250" . Of course, you may still need tooling for other

applications such as hemming, offset bending, large radius bending, etc.

But whatever your needs, when you combine Wila’s fast, flexible, and

friendly approach to tooling selection, you’re sure to get a cost efficient

tooling package that will pay for itself several times over the life of your

press brake.

For more information, please contact:

WILA USA

7380 Coca Cola Drive

Hanover, MD 21076 USA

Tel: 888-696-9452

Fax: 443-459-5515

Press Brake Productivity Web Site: www.wilausa.com


IN THE NEWS

Finn-Power in the Spotlight

Finn-Power sheet metal fabrication technology and its

customers continue to attract a great deal of attention

from trade publications throughout North & South America

CNC WEST – (December 2007/ January 2008)

This issue featured a 3-page cover article on an

installation of a Finn-Power Shear Genius, punch/shear,

Night Train material

management system,

and servo-electric

press brake

combination

machine at JB

Radiator Specialties,

Inc., Sacramento,

CA. “As we

implemented the

installation of the

Shear Genius and Night Train, we were at unprecedented volume levels at

Radiator Specialties. We were in new numbers that we had never hit before.

We would not have hit those numbers if we didn’t have the Finn-Power. We

would have had to depend on subcontractors.”

THE FABRICATOR – (April 2008)

This issue featured a 1/2-tabloid page article on the X5

turret punch press installation at Prolind Industrial,

Ltda., Sao Jose dos Campos, Brazil. “The X5 had the

best cost/ratio benefit of any of the machines that we

considered purchasing. We are

paying for the machine with

the profits that it produces. In

addition, we are no longer

using the services of the contract

manufacturer. It took only

three months with the X5 to

bring all the contracted work

in-house.”

MAQUINAS Y EQUIPOS – (May 2008)

This leading Argentine trade publication featured a

2-page article on the Shear Genius Flexible

Manufacturing Cell.

9

TOOLING & PRODUCTION – (May 2008)

TOOLING & PRODUCTION published a 2-page

article on the installation of two Shear Genius cells, a

Night Train

material

management

system, two servoelectric

E brakes,

and a hydraulic

robotic press brake

at Day-Brite

Lighting, Tupelo,

MS. “The

integrated

automated system

was the key to choosing the Finn-Power. None of the other machine producers

had this capability. Finn-Power was head and shoulders above the competition.

The competition had islands of automation, but the Finn-Power’s integration

of the Shear Genius and robotic press brake are all tied together with the Night

Train. It allows us to run lights out on the weekend.”

CANADIAN METALWORKING – (June 2008)

This publication featured a 3-1/2 page article on the

LP6 laser/punch combination with the LSR load and

stacking robot installed at Recouvrements Métalliques

Bussières (RMB),

St. Henri de Lévis,

Québec. “The LP6

is 40% faster – and

in some case 60%

faster – than the

company’s earlier

machine. We now

have the automation

to run overnight.

This automation has

dramatically

increased our productivity. The Finn-Power LP6 /LSR has tripled our

productivity capability compared to our earlier fabrication equipment.”


SOFTWARE UPDATE

by Kyle Plass, Applications & CAD/CAM Coordinator

NC Express ® Programming Software

Finn-Power’s NC Express CNC

programming system is a user

friendly, integrated, and automated

tool for managing Finn-Power equipment in

the most efficient manner available. NC

Express is a tooling, nesting, and optimizing

software package designed to easily integrate

into an existing manufacturing environment,

taking full advantage of the powerful CAM

features and the Finn-Power machine tool

product line.

NC Express is a scalable application – the

system may be used as a single part drafting

and tooling program or as a fully-automated

machine tool management system. Either way

the results are the same – optimized automatic

N/C code creation.

The system utilizes several technologies to

create a fabrication environment in which

individual parts or assemblies of parts can be

retrieved directly from the CAD database and

processed by NC Express for random part Justin-Time

(JIT) production.

NC Express provides an easy-to-use

Windows-based Graphic User Interface. Drop

down menus and icons ensure easy interaction

with the system and immediate productivity.

This user interface, combined with NC

Express’ powerful automation capabilities

facilitates optimum production, maximizes the

computer-controlled features of the machine

tool, and simplifies the effort required to

design and program parts for production.

With the rise in material costs, labor, and

short run jobs, today’s demanding

manufacturing market is focusing more on ways

to automate the fabrication of greater quantities

of parts in less time and with fewer people. NC

Express offers a complete programming package

for Finn-Power machines that provides our

customers the ability to obtain high levels of

automation for less user interface and more

output.

GEOMETRY

The first process in programming a

component file is the geometry creation. NC

Express offers a full CAD package for

component generation. Alternatively, geometry

can also be imported from a standard DXF file

format.

Automation of importing of the geometry

can be done when using the MRP database

(OMS). Through this process, component files

can be generated from a DXF file or by using

parametric part scripting. During this process

the geometry, tooling, and storing of the

component file is accomplished.

TOOL PLACEMENT

NC Express’ Autotool will automatically

place optimal tool routines and tool placement

in accordance with the machines capabilities.

Additional automation of robot placement and

last hit orientation for unloading is set properly

for sorting of components. Any section of

tooling placed by the auto tool function can be

easily reorganized or replaced manually. Tool

placement features include:

Machine intuitive tool placement

Automatic and interactive tool placement

Automatic and interactive tool hit cycling

Automatic and interactive robot

placement

Text marking functions

NESTING

Nesting within NC Express can be done

statically or dynamically. During the nesting

process parts can be quickly moved by dragging

and dropping to the necessary location. For

quick part revisions, a single component file can

be edited at the part level and once the nest

layout is reopened the change will be promptly

updated for each part within the nest.

TRUE SHAPE NESTING

True Shape Nesting uses the true boundary

of the part as it appears in the drawing. This

allows a tighter fit between parts as compared to

rectangular nesting. True Shape Nesting allows

parts to be interlocked and provides

substantially higher material utilization.

Interactive part placement after auto nest

Automatically nest under or around the

clamps

10

Nests in zones to guarantee part accuracy

Nest in holes to gain higher sheet yield

RECTANGULAR/SHEAR NESTING

NC Express utilizes a rectangular nesting

algorithm to take advantage of the

manufacturing features of the Finn-Power Shear

Genius and Shear Brilliance. Unique features

include:

Automatic notch tooling recognition for

dynamic or static common line

Interactive Nest Tooling

Interactive Grid Nesting

OPTIMIZATION

Optimization is done automatically for all

Finn-Power machine types (punch,

shear/punch, laser/punch and laser). The

Optimizer references a pre-established tool

library verifying that all of the necessary tools to

produce the parts are available for use in the

machine’s

turret.

Once

confirmed,

machine

movement,

punching

and forming

operations, tool

changes and

sequencing are

optimized for efficient

machine operations

and throughput.

Additional

optimization features:

Automatic Repositioning and clamp

avoidance

Optimize index tooling based on angle

Automatic turret loading

Interactive optimization capabilities

Batch optimization for multiple nest

patterns

SIMULATION AND REPORTING

Full simulation of a nest will give the

programmer detailed information about how a

job will run at the machine. A full range of

reporting options will offer the programmer and

operator ample information to setup the


machine. The following are some items listed

within a report:

Tooling in a single nest or a run of nests

Nest layout

Part information

Time estimations per nest/part

KEY FEATURES

The following is a description of a few

features that help obtain the high levels of

automation within NC Express.

TEACH CYCLES

Teach Cycles allows the ability to teach

tooling, or cycled functions/routines, to a

specific geometry. A Teach Cycle is applied

when Autotool is run. The Teach Cycle works

off a given tolerance, material thickness, and

symmetry type. If geometry exists that has a

Teach Cycle libraried the same pattern or

tooling will be applied. The use for a Teach

Cycle can vary among machine types.

To the right, a Teach Cycle is created to

apply a cycled order of hits for a round punch -

extrusion – and a tap. This cycle will only be

used on material thickness 0.5 - 1.5 mm. The

tolerance is 0.03 mm for the hole sizes. When a

part would be Autotooled with the same type of

geometry the same exact tooling in the same

exact order will be applied throughout the part.

This eliminates the repetitive task of having to

place each of the tool hits for each and every

hole on the part.

AUTOMATIC FORM AVOIDANCE

During punching only NC Express knows

when a form exists within a nest to avoid

smashing the form by a non-form tool. Form

protection areas can be set for a special tool to

inform NC Express of the formed area on the

nest. If a non-form tool will cross the path of a

formed area within a nest, NC Express will

optimize the tool

path so that the

Ram will raise the

tool completely

up and then cross

over the formed

area avoiding the

possibility of

smashing the

form. No

additional axis moves are made in order to avoid

the form.

In addition to the form avoidance settings,

NC Express allows the setup of an exit angle

path to provide for automatic ordering of a

special tool when optimizing. This is especially

useful for a louver tool: time is saved during

part preparation and during optimization

because no additional work is needed to

manipulate the tool path within the optimized

nest.

ORDERS MANAGEMENT

SYSTEM (OMS)

NC Express comes standard with an

MRP/ERP interface to allow that customers can

control and track parts that have processed

within NC Express to be sent to the machine.

The Orders Management System is a database

in which production requirements are

determined. The parts required for production,

quantity, material codes, priorities and due dates

used to be processed for JIT fabrication. From

job shop to OEM, the OMS can benefit the

end user taking orders from the MRP/ERP and

processing them into nests.

AUTOMATIC

COMMON LINE CUTTING

For punching, shear/punch, and standalone

laser machine, NC Express offers fully

automatic common line cutting features.

Common line is activated in the nesting phase

and will help in reducing the scrap rate between

parts. Once a nest is created with parts and

tools in a common line the Optimizer will

remove excessive hits in order to avoid double

punching hits or double laser paths. Within the

shear/punch environment the nesting engine

will common line symmetrical parts, ignoring

tooling overlapping from notches. For nonsymmetrical

parts in the shear/punch

environment, the nest engine will check the

tolerance set and ignore tooling extending less

than the grid nesting tolerance.

COMPONENT

STACKING MANAGEMENT

For machine types requiring stacking of

components on a cassette, NC Express is

capable of automatically configuring the

stacking layout of the components on the

11

cassette. During the nesting process the user has

options to determine the layout of the cassette.

The nesting engine will nest parts based upon

stacking. This allows for NC programs to be

loaded within the machine and minimal setup

of cassettes by the operator when queuing the

NC files. The overall outcome of this feature

offers less setup time by the operator at the

machine.

For even more automation and time savings

for the programmer, if a robot exists on the

machine the user can take advantage of the

automatic robot suction cup setup via Autotool

to automate more of the process.

NEW RELEASE- V8.1

Coming soon! New version of NC Express:

Version 8.1. Major improvements include:

Multiple machines stored within one

geometry file (Binary CP)

External ERP/MRP integration

Improvements to tool hit optimization

Enhanced shear nesting/optimization

Numerous features/function additions for

laser environment (ex. new interactive

crop/scrap functions)

Various new features functions (ex. rotate

part 90° using space bar)

Die clearance setup & verification

Innovative part search function


CUSTOMER PROFILE

Day-Brite Lighting Shines Light on Integrated

Since its founding in 1923, Day-Brite

Lighting, Tupelo, MS, has earned a

well-deserved reputation for

manufacturing quality industrial and

commercial lighting products. To be sure, there

have been many changes over the years, many

lighting technology advances, and several

acquisitions – the latest being by Philips

Lighting in January 2008. Today, the company

has evolved into a major force in the lighting

industry with a facility that includes 350,000

square feet of manufacturing space and a

150,000-square-foot warehouse and 500 hourly

employees.

Perhaps one of the company’s most

dramatic changes occurred in 2002 when Day-

Brite management decided to find a better way

of manufacturing its lighting fixtures. According

to Scott Bratton, fabrication manager, Day-

Brite’s business had gradually moved away from

just commodity products to a more

architectural grade product. “The company’s

challenge was to find a way to go from product

design, to fabricating the part, and have it ready

to assemble to within one day,” explains

Bratton. “Our task was to find the best

equipment to accomplish this goal.”

Another challenge was to find fabrication

equipment productive enough to allow Day-

Brite to curb the growing amount of contract

work the company was forced to utilize local

job shops and bring it back in-house.

The Search for Automation

“Basically, we shopped around the world

looking for new equipment,” adds Charles

Philips, director, manufacturing & industrial

engineering. “We wanted to change the

direction of how we manufactured our highvolume

products at the Tupelo plant. We had to

modernize. We had two aging turret punch

presses and 11 large stamping presses with

progressive dies for high-volume runs. The dies

can cost up to $1-million and take up to six

months to produce. We had a new product line

we wanted to introduce – a high-bay fluorescent

– before our competitors did. The manufacturer

who brings its products to market first has the

advantage. So, we had to go quickly to market.”

Several Day-Brite technical teams crisscrossed

the globe searching for the fabrication

equipment. Bratton and Bob Dexter, plant

superintendent, visited Finn-Power’s facilities in

“The integrated automated system was the key to

Finn-Power over the competition. None of the other

machine producers had this capability. Finn-Power

was head and shoulders above the competition.”

12

Scott Bratton, fabrication manager, displays a part produced on the Shear

Genius fliexible manufacturing cell. According to Bratton, the benefits of

the Shear Genius included reduced labor costs, shorter lead times, higher

part qualify, and repeatability of that quality. The Finn-Power integrated

system allowed the company to introduce the new product to the market

for a total of $4 million in new product sales in 2005 alone.


Automation

Finland in October, 2002. “We saw many

facilities where multiple machines were

running with just one operator,” says

Bratton. “We decided that Finn-Power

would fit the needs at Day-Brite.”

Day-Brite began production of Phase

1 of the Finn-Power flexible manufacturing

system in September, 2004. The system

included: the Shear Genius punch/shear

combination, a hydraulic press brake with

robot, and six bays of the Night Train

material management system to tie it all

together.

Shear Genius Flexibility

With the Shear Genius concept, the

objective is to provide one machine

capable of transforming a full-sized sheet

into punched parts. These parts can be

moved to secondary operations utilizing

the sorting and stacking automation into

the Night Train material management

system and on to bending operations

without being touched by human hands.

As loading, punching, and shearing of

parts become automated, the result is

finished parts with a dramatic reduction in

scrap and manual labor while increasing

profitability.

Shear Genius functions with

sophisticated simplicity, able to perform

the most demanding jobs with minimal

set-up times and “lights out” operation.

The Shear Genius increases material

productivity through efficient and versatile

nesting programs. The level of automation

can be customized through Finn-Power’s

flexible modular solutions for raw material

storage, loading, unloading, sorting and

stacking. These features can be added later

as budgets allow and production demands

increase.

The Shear Genius ease of operation

does not compromise the cell’s per minute

part production, flexibility, or ability to

fabricate complex parts. On average, Shear

Genius reduces total manufacturing time

by 60% and saves one blank sheet out of

every 10.

The Shear Genius eliminates wasteful

skeletons and costly secondary operations,

such as deburring. Nibble edges on the

part exteriors were eliminated through the

use of the integrated right angle shear. In

fact, the same clamps that hold the sheet for

punching also hold it for shearing. In essence,

the Shear Genius allows the automated process

to begin with a full-sized sheet of material and

end with a finished part after automated

loading, punching, forming, shearing, and

unloading – all in one operation.

The Shear Genius eliminates wasteful skeletons

and costly secondary operations, such as deburring.

Nibble edges on the part exteriors were eliminated

through the use of the integrated right angle shear.

In fact, the same clamps that hold the sheet for

punching also hold it for shearing.

According to Bratton, the benefits of the

Shear Genius included reduced labor costs,

shorter lead times, higher part quality, and

repeatability of that quality. “On our older

turret punch presses, the consistency of quality

was left in the hands of our operators,” says

Bratton. “They would have to shear the blank

to a certain size and then load it into the turret

punch press. With the Shear Genius, we’ve

eliminated blanking since we are able to

fabricate full-sized sheets and nest the parts,

ensuring part consistency and squareness from

one run to the next.”

Night Train

The centerpiece of the Finn-Power

automated sheet processing system is the Night

Train Material Management System, which is

the inventory and material transporting center.

The Night Train FMS provides a total solution

for unmanned operation for sheet metal

13

fabricators by automating system control, as

well as material flow within the system. This

includes supplying raw material as well as

removing and storing work in process.

“The integration of the Night Train with its

management system was a big feature for us,”

says Bob Dexter, plant superintendent. “We run

a great deal of 24/7, including ‘lights out’ over

the weekend on some of our larger volume

products to get a jump on production.”

Robotic Hydraulic Press Brakes

According to Bratton, the primary focus of

the robotic hydraulic press brake was to

eliminate 2-man operations on the press brake.

“We didn’t care about keeping the robotic press

brake running 100% of the time,” says Bratton.

“Rather, we had a series of parts that required

two operators to form a complete part. With

the robot, every time we form and make that

continued on page 14

With the Shear Genius concept, the objective is to provide one machine capabile of transforming a full-size sheet into

punched parts. These parts can be moved to secondary operations utilizing the sorting and stacking automation into the

Night Train material management system and on to bending operations without being touched by human hands.


continued from page 13

product we save about 40%…and that’s just

labor. And I get a better part. I don’t know how

much we save from blanking because that was a

cut to size blank that we bought on the outside

Day-Brite had a series of parts that required two operators

to form a complete parts. With the robotic press brake from

Finn-Power, the company reports a labor savings of 40% of

each part bent.

to process on our older turret punch press. We

run about 500 of the 2 x 4 size a month. Our

total savings is about 50%/part.”

Other benefits of the robotic press brake

include:

Provides unmanned bending at

maximum speed

Produces exceptionally consistent parts

Can be integrated into Finn-Power’s

Flexible Manufacturing System.

Results of Phase 1

Day-Brite began production on the first

phase of the Finn-Power in September 2004

with the first shift. In December the company

added the second shift, and in February 2005 it

added the third shift. “We average

approximately 18 hours of machine uptime,”

says Dexter.

Finn-Power’s Phase 1 introduction at Day-

Brite was a huge success,” says Bratton. “The

Finn-Power integrated system allowed us to

introduce the new product to the market for a

total of $4-million in new product sales in 2005

alone. While we hoped that the Shear Genius

would allow us to bring the contract work back

inside, we weren’t able to accomplish this at the

time because the Finn-Power system was

running at full capacity within six months.”

Phase 2 Begins

Phase 2 of the program began in March

2007 with the addition of another Shear Genius

cell; a Night Train extension of an additional

four bays; and two servo-electric E press brakes.

The new Shear Genius was the SG8 with a

maximum sheet size of 1,500 mm x 4,300 mm.

With this addition, Day-Brite brought back

75% of the fabrication that had been contracted

to local job shops. The remaining job shop

contracts mainly include laser cut parts. “Our

new Shear Genius runs nothing but pre-painted

metal, galvanized, and mirro aluminum,”

explains Bratton. “From a customer standpoint

it has helped us get products to our customers

faster. It has helped our design engineers with

product development. We dedicate our

machines and no longer have to contract

outside parts. We program the part, form the

part, and get it to them so we can now take the

product to market quickly. This has given us a

competitive edge.”

E Press Brake

The two servo-electric E press brakes have

upper and lower hydraulic tool clamping.

This Finn-Power press brake is a fast,

accurate bending solution. By applying

mechanics and electronics, a unique, patented,

mechatronic drive was developed. This drive is

based on the pulley principle resulting in a very

even distribution of forces in the top beam,

high accuracy, increased productivity, and

decreased energy consumption, and few

maintenance requirements. The frame concept

makes it possible to utilize the back gauge

system across the entire working length.

“The E Series press brake is a phenomenal

piece of equipment,” says Bratton. “Many of

our products have multiple forming operations.

With the Finn-Power E Series press brake, we

have seen increases in our productivity, quality

repeatability, and reduced set-up and

programming times. We estimate savings of 35-

40% bending with the new press brakes over

the older models.”

Reliability

Another important feature of the Finn-

Power equipment to Day-Brite has been

reliability. “We have not had any significant

downtime on the Finn-Power equipment,” says

Dexter. “The installation of the equipment went

very well. It was always on time – and when we

turned it on…it ran. Finn-Power did a very

professional job getting the equipment up and

running as well as servicing and maintaining it.”

“A key point to Day-Brite is on-time

performance to our customers,” explains

Bratton. “In 2006, we started out at 90%. Last

year, we came in at 93%, and this year our goal

is 95%. The Finn-Power equipment has helped

us reach these goals.”

“The Finn-Power integrated system allowed us to

introduce the new product to the market for a total

of $4 million in new product sales in 2005 alone.”

The two servo-electric E press brakes have upper and lower hydraulic tool clamping.

This Finn-Power press brake is a fast, accurate bending solution. With the Finn-

Power E Series press brakes, Day-Brite has experienced increases in productivity,

quality, repeatability, and reduced set-up and programming times.

14

“The integrated

automated system was the key

to Finn-Power over the

competition,” adds Philips.

“None of the other machine

producers had this capability.

Finn-Power was head and

shoulders above the

competition. The competition

had islands of automation, but

the Finn-Power’s integration of

the Shear Genius and robotic

press brake are all tied

together with the Night Train.

It allows us to run lights out

on the weekend. It was so

successful that we doubled the

size of the installation with a new Shear Genius,

the two E press brakes, and expanded the Night

Train. Future purchases being considered for

2009 include the EBe servo electric bender, the

X5 stand alone turret punch press, and another

E Series servo-electric press brake.”

Day-Brite’s business had gradually

moved away from just commondity

products to a more architectural

grade product. The company’s

challenge was to find a way to go

from product design, to fabricating

the part, and have it already

assembled to within one day. Finn-

Power provided the solution.


FOCUS ON TOOLING

by Jeff Paulson, Marketing Manager, Wilson Tool International

Improve Punch Press Performance

with Lean Tooling Innovations

Tightening budgets and rising costs are leading punch press

fabricators worldwide to develop lean manufacturing processes.

Choosing more efficient tooling can play an important role in

reaching such lean goals as faster setups, higher productivity and reduced

waste. Wilson Tool offers a number of innovative tooling solutions that

drastically improve punch press performance and help our customers

achieve their lean manufacturing goals.

Multi-Tool or Multiple Tools? You Decide.

Perhaps more than any other tooling available, the Multi-Tool

exemplifies all the benefits

that contribute to “lean”

tooling advances for the

punch press. Using a single

Multi-Tool, punch press

fabricators are able to

produce the same part in less

time and for less money than

with several individual tools.

With our Multi-Tools

for Finn-Power machines,

fabricators are able to load

the equivalent of 3, 8, or even

20 smaller tools in a single

station to increase turret capacity. So, instead of loading punches

individually, fabricators can load multiple punches simultaneously and

perform several punching operations with one set-up. This reduces the

number of tool changes operators make in the course of a run and results

in significantly less downtime.

Our R-Series Multi-Tool ® for

Finn-Power machines adds further

dimension to the flexibility offered

by multi-tools by allowing high

capacity fabricators to select not only

the punch but also the angle with a

single Multi-Tool. Using indexing, each

individual tool in a Multi-Tool is able to

achieve 360° punching operation. This flexibility

eliminates the need to purchase multiple tools shaped

at a variety of angles to meet specific production needs

thereby reducing overall tooling costs.

Unlike conventional multi-tools, our engineers created an innovative

drop-in design that allows punches to be loaded quickly and easily. They

also made sure to limit the number of moving parts, meaning our multitools

are more reliable and require less maintenance.

Bound to be the most functional tool on your punch press, the

Wilson Tool Multi-Tool increases turret capacity, reduces tool changes,

speeds run times and means less tooling to purchase and maintain.

Get Rolling with Wilson Wheels.

In pursuit of greater speed and performance, sheet metal fabricators

worldwide are discovering the Wilson Wheel ® family of products. These

revolutionary tools are unlike any other style of punch press tooling,

allowing fabricators to create unique forms and shapes at unbelievable

speeds.

Wilson Tool Helps Fabricators Reach Lean Goals

16

Each forming tool is specially designed for high-speed

production of slits, ribs, offsets, knurls, flares and logos

on a wide range of materials with virtually no burrs

or nibble marks. Faster cycle times and high

quality production help fabricators achieve

higher output with less waste.

Fabricators wanting the flexibility to

quickly create offsets in any contour

starting or ending anywhere on the sheet

should try the Hydraulic Rolling Offset.

Creating ribs in contours can be done

just as easily with the Hydraulic Rolling

Rib. The Hydraulic Rolling Shear

makes it possible to create straight line

cuts or contours from anywhere on the

sheet. Each of these can be produced

using Auto Index.

For easy, clean separation of parts,

the Hydraulic Rolling Pincher is ideal.

The Rolling Logo tool makes it

easy to produce more visible logos.

Logos can be produced larger

than stations size (e.g. 100 mm

long logo in a C station) on a

wide range of material. Logos

can be started or ended

anywhere on the sheet. Tonnage

is reduced compared with single

hit stamping.

Our Rolling Knurl tool

creates a grip like effect on the

sheet metal for rapid

production of knurls. Highspeed

production is equal to

programmed table travel speed.

The innovative Rolling

Flare tool enables production

of large diameter flares, even

larger than station size

normally allows, as well as

other shapes. Each Rolling

Flare is designed to suit

specific customer requirements.

Wilson Wheel technology from Wilson Tool cuts cycle times, reduces

waste and produces higher quality products to support lean manufacturing

goals.

For more information, please contact:

Wilson Tool International

12912 Farnham Avenue

White Bear Lake, MN 55110 USA

Tel: 800.328.9646

Fax: 800.222.0002

marketing@wilsontool.com


PRODUCT REVIEW

Discover the Unique

Versatility of Servo-Electric Punching

Finn-Power introduced the servo-electric E series turret punch press

in 1998. Since then, we have continued developing and applying

this modern, highly productive technology so that today the range

of servo-electric Finn-Power solutions is the widest in the world market, and

our experience in this technology is the most extensive. The most recent

addition is the new E5 series turret punch press.

The new generation of Finn-Power’s servo operated E-series turret punch

presses offers versatile punching, nibbling, forming and bending capacity on a

single machine tool. Based on the ECOPUNCH ® concept, the E-series is an

astonishing money saver, featuring:

Low connection power

Low power consumption

Low maintenance costs

High speed

High accuracy

High repeatability

In addition, carefully planned ergonomics, low noise levels, and a

modern industrial design combine to make the E-series turret punch press a

truly state-of-the-art solution for flexible, productive fabrication.

Three Models for Different Sizes

Finn-Power E5 – small layout and convenient operation. Max sheet size

without repositioning 50" x 120" (2,530 mm x 1,270 mm). Punching speed of

800 hpm at 1mm.

Finn-Power E6 – higher range of automation and optional features. Max

sheet size without repositioning 60" x 120" (3,074 mm x 1,542 mm).

Punching speed 900 hpm at 1mm pitch.

Finn-Power E8 – Full support for large sheet sizes. Max sheet size

60" x 169" (4,300 mm x 1,565 mm). Punching speed 900 hpm at 1mm pitch.

17


FOCUS ON TOOLING

by Andy Spence-Parsons, Marketing Manager, Mate Precision Tooling

Multi Tools Eliminate Waste

and Expand Capabilities

The implementation of lean

manufacturing techniques demands

that fabricators continually seek out

and eliminate sources of waste.

One common source of waste is the time it

takes to change tools between jobs. This can be

particularly true for a job shop manufacturer

who may have less ability to standardize on

common sizes. Multi tools help eliminate this

source of waste by allowing multiple tools to be

installed into a single station. This capability

expands the number of tools that can be

installed in a single machine set-up, reducing, or

maybe even eliminating, the necessity for tool

changes.

Mate has partnered with Finn-Power for

more than twenty years to become the world’s

leading designer and manufacturer of multi tool

systems. This valuable design partnership

resulted in a comprehensive range of world class

Multi-Tool products designed and engineered as

an integral part of the high performance

machines in which they operate.

As part of this continued relationship, Mate

recently launched a new generation of Multi

Tool assemblies that combine the flexibility and

longevity of Ultra TEC ® tooling with quick

length adjustment, and robust construction.

Ultra Multi Tools expand the capacity of a

thick turret Finn-Power punch press by allowing

either 3 or 8 punch and die sets to be placed in

one of the 3-1/2" D auto-index stations.

Designed for use with Mate’s Ultra TEC ®

punches, strippers and Slug Free ® dies, these

new multi tools enhance the high performance

of today’s thick turret Finn-Power punch presses

with the following operating features:

Ultra TEC punches provide exceptional life

between regrinds. Ultra TEC strippers have

recess for added 0.118 inch (3.00 mm) punch

grind life while the Slug Free dies eliminate slug

pulling and increase piece part quality.

The Multi Tool Drop-In quick tool change

design allows changing tools in the upper

assembly without hand tools or disassembly.

Fast tool changes reduce machine downtime

while increasing productivity.

The integral punch length adjustment

feature ensures optimal punching performance

and efficient slug discharge across a wide

material range. Each punch is adjustable for

precise punch-to-stripper lead and die

penetration suitable for sheet thicknesses from

0.020 inch (0.50 mm) to 0.157 inch (4.00 mm).

0.004 inch (0.10 mm) minimum die

clearance ensures unprecedented punching

accuracy and cleanly punched edges for

materials as thin as 0.020 inch (0.50 mm). The

one-piece multi tool punch carrier eliminates

cumulative tolerances to ensure punching

accuracy.

Sheet marking protection eliminates sheet

marking while improving piece part quality. The

innovative multi tool holder is designed so that

each tool is individually activated while inactive

punches are prevented from moving, thus

protecting part surfaces from unwanted marks.

A replaceable multi tool face plate reduces

ongoing maintenance costs. Its simple, robust

design provides extended service life and is fully

compatible with slide-in Ultra TEC strippers.

Mate multi tools are compatible with

automatic tool lubrication delivery systems.

Lubrication is delivered via the punch ram

through the central shaft over all moving

surfaces within the multi tool punch holder

assembly. In addition, external spiral grooves in

18

Mate Ultra ®

Multi Tool 3

Punch and

Die Sets

Mate Ultra ®

Multi Tool 8

Punch and

Die Sets

the outside diameter of the holder reduce

friction between the machine and holder,

especially during high speed nibbling

operations.

“Extending the performance of today’s high

performance thick turret presses is every Finn-

Power user’s objective,” reports Andy Spence-

Parsons, Mate VP Operations. “Mate’s new

Ultra Multi Tools, incorporating Ultra TEC

tooling, accomplishes this cost effectively while

ensuring highest quality sheet metal parts. They

are another great tooling option for fabricators

looking for a competitive advantage.”

For more information on tooling systems to

suit Finn-Power machines, please visit

www.mate.com/finn-power.

Mate Precision Tooling

1295 Lund Boulevard

Anoka, Minnesota 55303

USA and Canada

1-800-328-4492

Fax 1-800-541-0285

Outside USA and Canada

1-763-421-0230

Fax 1-763-421-0285

Email: marketing@mate.com.


FOCUS ON BRAZIL

Finn-Power’s Punching & Bending Technology

Attracts Interest at Brazilian Trade Fair

Last May 13-17, Finn-Power International and its

Brazilian distributor ASAMAQ jointly participated in

the MECANICA trade fair at the Anhembi Park

Exhibition Hall, Sáo Paulo, Brazil. MECANICA is one of the

largest trade shows for all of South America. And this year,

there was record-setting attendance each day of the show.

On display were Finn-Power’s C5 turret punch press and

the servo-electric E press brake. “Brazil continues to be a very

important market for Finn-Power,” explains Ron Palick, vice

president South America. “We are very pleased with the

number of visitors to our booth. We sold several machines

during the show and obtained numerous excellent leads.”

Also representing Finn-Power were Lutz Ehrlich,

punching and automation product manager, Bob Kolcz,

director, marketing & corporate communications, and Jeremy

Caddick, applications engineer.

The Finn-Power C5 turret punch press and servo-electric E press brake were visitor magnets at the Mecanica

Trade Fair, held May 13-17 in Sao Paulo, Brazil. Record setting attendance was set each day of the show.

19


CUSTOMER PROFILE

Brazilian Oven Manufacturer Heats Up

Productivity with Finn-Power Turret Punch Press

Prática Technicook, Pouso Alegre, MG, Brazil, is a manufacturer

of professional ovens found in grocery stores, industrial

kitchens, and hotels. The company began operations in 1991 as

a shelving manufacturer for the supermarket industry with a three-person

staff. Soon the Prática management identified an opportunity in

producing energy-efficient baking equipment made from quality stainless

steel material, with a better design and in accordance with governmental

hygiene regulations.

Prática’s first entry into this market was the convection oven for

baking. By 1997, the company expanded into the Combi-Oven market,

which just had been introduced to Brazil. These products roast, bake, fry,

regenerate, grill, prepare “au gratin”, and defrost. Through the years,

Prática has earned a reputation for producing quality, well-crafted

equipment – growing 40% for each of the last five years. Today, the

company’s 150 employees work two shifts in producing oven products for

18 countries throughout Latin America.

Luiz Eduardo Rosa Rezende, diretor, (left) and Alberto Close, exports manager, inspect a

part produced on the Finn-Power C5 turret punch press.

The 20-station, 300 kN C5 hydraulic turret punch

press from Finn-Power has a maximum sheet capacity

of 1270 mm x 2500 mm and is available with either

Siemens or Fanuc controls.

Finn-Power’s patented automatic clamp setting PCS is a

standard C5 feature that automatically positions sheet

clamps according to the numerical program, virtually

eliminating dead zones.

20

In order to increase production and productivity to meet this growing

demand, Prática recently moved into a new manufacturing facility of

5,000 square meters. The company has also examined its fabrication

equipment and techniques in order to maximize its production.

Fabrication Equipment

In its early days, Prática’s fabrication equipment consisted of a hand

shear and mechanical press brake. In 2001, the company purchased its

first punching machine – a pneumatic, one-station punch. As its market

grew, Prática added five-station hydraulic machines. By 2006, the

“The C5 has not only supplied what we

needed but has taken the job of our two

older presses. We not only increased our

production but lowered our labor costs.”

company had outgrown its fabrication equipment and needed to add more

capacity…and chose the C5 hydraulic turret punch press from Finn-Power

which was installed in January 2007.

The 20-station, 300 kN C5 hydraulic turret punch press from Finn-

Power has a maximum sheet capacity of 1270 mm x 2500 mm and is

available with either Siemens or Fanuc controls. According to Luiz

Eduardo Rosa Rezende, diretor, the C5 has proven to be highly

productive, fast, and durable. “When we purchased the Finn-Power C5

turret punch press,” explains Rezende, “our hope was to just supply our

needs with the other punch presses still in operation. However, the C5 has

not only supplied what we needed but has taken the job of our two older

presses. We not only increased our production but lowered our labor

costs.”

Features and benefits of the C5 include:

Super fast servo hydraulic punching – Nibbling speeds up to 1100

hpm. The servo-controlled ram, stroke speed, and position are fully

and individually adjustable in both directions. Another benefit is

different punching modes (punch, Quiet Punch, downforming,

and marking).

Easy loading – Four optimally-positioned gauge pins allow easy

loading of blanks or full-sized sheets. Sheet loading is performed

with a simple push and always close to the table edge. Sheet

supports rise from the table to allow easy positioning of heavy

material.

The C5 delivers the processed components to a freely

programmable position on the table, increasing the

operator’s efficiency.


Efficient unloading – The C5 delivers the processed components to

a freely programmable position on the table, increasing the

operator’s efficiency. The entire material flow on the C5 can be

conducted from just one side. This allows simple and efficient

logistics and enables the machine to be positioned anywhere on the

shop floor – even in a corner.

Other unique features of the C5 turret punch press include:

Tool Holders – Finn-Power incorporates an individual tool holder

concept that allows customers to design their own turret layouts.

Unlike other designs, specific tool stations are not machined into

the turret. Finn-Power offers the only flexible selection of tool

holders in the industry. Any major tooling style can be installed in

a Finn-Power turret. Up to 10 auto-index, forming, or Multi-Tool ®

stations may be installed in a Finn-Power turret.

Auto-Index – Finn-Power’s unique auto-index system precisely

rotates the punch and die in their tool holders. Rotation in .001

degree programmable increments gives the machine the ability to

rotate beyond 360 degrees, allowing the system to automatically

select the shortest path to rotate to a programmed angle input into

the NC part program with simplicity, speed, and reliability. Full

tonnage can be used in any station, with any tool size, and at

maximum material thickness. Prática has four auto-index stations.

Multi-Tool ® — Finn-Power’s Multi-Tool stations increase the

number of tools available in a turret, thus reducing set-up and

increasing productivity. The Multi-Tool system allows multiple

tools to be put in one station. Finn-Power Multi-Tool offers 6, 8,

10, or 24 different punch/die combinations in only one station – a

turret within a turret. Prática has four Multi-Tools – two 8-station

and two 10-station. The company also utilizes the Roller Ball tool

from Mate Precision Tooling. “Finn-Power’s Auto-Index and Multi

Tool are very important features for us,” says Rezende. “We have

been able to dramatically reduce our set up time with the additional

tools in the turret.”

Automatic Clamp Setting & Movement – Finn-Power’s patented

automatic clamp setting PCS is a standard C5 feature. It

automatically positions sheet clamps according to the numerical

program, virtually eliminating dead zones. When changing

Pratica’s 150 employees work two shifts in producing oven

products for 18 countries throughout Latin America.

The C5 provides nibbling speeds up to 1100 hpm.

The servo-controlled ram, stroke speed, and position

are individually adjustable in both directions.

Finn-Power’s NC Express CNC programming system is a user

friendly, integrated, and automated tool for managing Finn-

Power equipment in the most efficient manner available.

21

production from full size to small sheets, clamp settings can be

made automatically without wasting operator time.

Optional features on the C5 include:

Optional Work Chute – Finn-Power’s work chute is not just a drop

door or a work chute in the ordinary sense. Its mechanism allows

the reception of several components to 500 mm x 500 mm in size

onto a level from which they subsequently exit from the machine.

Optional Upward Forming System – The safe solution for sheet

metal forming is from below the sheet. Finn-Power’s upward

forming option provides more accurate forming and greater forming

heights up to 16 mm.

Unique to the C5 turret punch press, full tonnage indexable

upforming allows complex forming operations to be made quickly by

using a single forming tool. An index mechanism is used to turn the

forming tool into an NC programmed angle. Finn-Power’s upforming

feature provides a precise process for knock-outs, louvers, and other

forming. Finn-Power resolved the conventional problem of the die height

impeding free sheet movement. Finn-Power’s design allows forming

heights up to 16 mm with the forms made by the die moving upwards

and then retracting, allowing completely free sheet movement, eliminating

the risk of process instability.

“We have greatly increased our capabilities with the Finn-Power C5

turret punch press,” explains Rezende. “Before we installed the Finn-Power

C5, we had the capacity to make six ovens per day. With the C5, we now

produce 10 ovens plus four refrigeration units per day. We have more than

doubled our production…with less labor and less expense in tooling. 95%

of what we produce is stainless steel. Everything is fabricated on the C5,

which amounts to 45 metric tons of stainless steel per month.”

Establishing strong relationships

with its customers and vendors is

extremely important to Prática.

“The C5 is a very accurate and

strong machine,” concludes

Rezende. “We have had no

maintenance problems and have

experienced very good after-sales

support by Finn-Power’s dealer

ASAMAQ, Limitada. When the

need arises, we would certainly buy

another Finn-Power machine.”

Through the years, Prática has earned a reputation for

producing quality, well-crafted equipment-growing 40%

for each of the last five years.


FOCUS ON ARGENTINA

Finn-Power Displays X5 Turret Punch

Press at Argentina Trade Show

The FIMAQH 2008 exhibition was held May

28 - June 1 at Costa Salguero Center in Buenos

Aires, Argentina. Finn-Power International and

its Argentine distributor, Forsthuber y Sia, s.r.l. displayed

the Finn-Power X5 hydraulic turret punch press.

“While Argentina certainly has faced its share of

economic challenges in past years, the post-election

climate in Argentina is very encouraging,” says Ron

Palick, vice president, South America. “We had many

visitors each day of the show interested in updating their

fabrication technology. In fact, we sold a Shear Genius

flexible manufacturing cell during FIMAQH. The

exhibition was excellent exposure for Finn-Power in

Argentina and was proof that Finn-Power continues to

attract the South American market.”

Also representing Finn-Power were Lutz Ehrlich,

punching and automation product manager and Jeremy

Caddick, applications engineer.

Large crowd of visitors filled the Finn-Power booth each day of the FIMAQH 2008 exhibition. The point of interest

was the X5 hydraulic turret punch press that provides Finn-Power technology, performance, and reliability at an

affordable investment and operating cost.

22


FOCUS ON ROBOTICS

New Advances in

Material Handling Robotics

Robotic automation has come along way in terms of the

capability and flexibility in the last 25 years, with each year

bringing greater advancements. Some are profound, such as

Intelligent Vision Guided Robot Systems, which are dramatically changing

the way systems are being designed. Robots that can see and think.

Unheard of. Sometimes the changes are subtle but offer a huge advantage

to the customer.

The new M-10iA robot is an excellent example of how a small

improvement on an already great product can result in a large payoff for

the customer. The M-10iA is the next generation of FANUC Robotics

high-performing six-axis material handling product line. With a standard

payload of 10 kg, this robot is ideal for the quick and precise movements

required in the press brake market.

Hollow Wrist & Arm (Solution Arm)

The most impressive new feature of the M-10iA is the hollow wrist

and upper arm, also referred to as the Solution Arm. Automating a press

brake application requires a dress out or cables to be attached to the

robot’s wrist and arm. Dress-out cables are bulky when exposed and can

interfere with the robot, tooling or peripheral equipment especially when

the wrist is twisting. Complications range from damaged or twisted cables

to completely severed cables.

Failures in this area can lead

to downtime and loss of

production.

The sleek design of the

M-10iA hollow wrist and

upper arm eliminates the

need for complicated robot

dress outs and offers reduced

costs and improved reliability

in return. Dress outs, cables

and airlines are simply routed in the 50-mm hollow wrist and upper arm

and are protected. This design also brings benefits of simplified wiring of

electrical and pneumatic connections which saves integration costs. Simply

enclosing the dress out improves cable life and reliability. The hollow wrist

and arm is a unique feature of the M-10iA and is unmatched in the

robotic industry.

Doing More with the Allowable

Payload (Moments and Inertia)

Another key advantage to the M-10iA robot is that the allowable wrist

moments and inertias are significantly higher than the previous model as

well as similar class competitors’ products. The allowable wrist moment is

70% higher than the previous model and the allowable wrist inertia is

56% higher. In layman’s terms, these higher specifications allow users to

have much larger tools and allow them to have the 10kg payload offset

further away from the face of the robot. This is a key factor in the press

brake market, where the robots are required to pick and place large sheets

of sheet metal.

Long Arm Product Variant

Extremely versatile, the M-10iA is also available in a long arm version.

The benefit of the long arm requires a slight sacrifice in the payload. The

M-10iA payload decreases from 10kg to 6kg. However, if payload is not a

pressing issue, the long arm version provides a significant benefit in terms

by Kari DeSantis, Senior Marketing Analyst, FANUC Robotics America, Inc.

New M-10iA Material Handling Robot

23

of robot reach. The long arm version increases the reach from 1420mm to

1630mm. The larger work envelop can save costs by avoiding the use of

multiple robots in a cell. In addition, both the M-10iA can be mounted

on the floor, wall or ceiling at any angle.

Model Specifications

Robot Model Reach Payload

M-10iA 1420 mm 10 kg

M-10iA/6L 1630 mm 6 kg

The M-10iA represents a dominant product line with world-class axis

speeds that decrease cycle times and improve production.

Other High Performance Features & Benefits

Motion Speed Enhancements – World-class axis speeds which

result in reduced cycle times

Slimmer Arm – More compact arm for reduced interference zones

Smaller Footprint – Robot base more compact, particularly useful

for multi-arm systems

Rigid Arm – Results in improved path accuracy

Integrated iRVision – Allows visual guidance or error proofing

For more information regarding the FANUC Robotics Product line,

contact FANUC Robotics at www.fanucrobotics.com or by calling

248-377-7000.


Global Headquarters & Manufacturing

Finn-Power Group

P.O. Box 38

FIN-62201 Kauhava

FINLAND

Tel. + 358 6 428 2111

Fax + 358 6 428 2244

www.finn-power.com

Finn-Power Group Sales & Service Units

Bending Technology Unit

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

Benelux

Finn-Power N.V.

Leenstraat 5

B-9810 Nazareth

BELGIUM

Tel. + 32 9 382 9030

Fax + 32 9 382 9031

Canada

Finn-Power Canada, Ltd.

1040 Martin Grove Road, Unit 11

Toronto, Ontario

M9W 4W4

CANADA

Tel. +1 416 242 4431

Fax +1 416 242 7867

China

Finn-Power

Representative Office

1/F, Block 1,

Golden Dragon Ind. Centre

152-160 Tai Lin Pai Road

Kwai Chung, N.T.

Hong Kong, P.R. CHINA

Tel. + 852 2427 7991

Fax + 852 2487 5548

Finland

Finn-Power Group

P.O. Box 38

FIN-62201 Kauhava

FINLAND

Tel. + 358 6 428 2111

Fax + 358 6 428 2083

France

Finn-Power S.A.R.L.

13, Avenue Condorcet

91240 Saint Michel sur Orge

FRANCE

Tél. + 33 1 69 46 55 80

Fax + 33 1 69 46 55 81

Germany

Finn-Power GmbH

Lilienthalstr 2A

Isar-Büro-Park

Am Söldnermoos

D-85399 Hallbergmoos

GERMANY

Tel. + 49 811 55330

Fax + 49 811 1667

Spain

Finn-Power Iberica, S.L.

Crta. De Molins de Rey a Sabadell

km 13,5, Nave 5

08191 Rubi, Barcelona

SPAIN

Tel. +34 902 302 111

Fax +34 902 302 112

United States

Finn-Power International, Inc.

555 W. Algonquin Road

Arlington Heights, IL 60005

USA

Tel. + 1 847 952 6500

Fax + 1 847 952 6530

www.finnpower.com

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