volume 19 - issue 2 - Finn-Power International, Inc.

finnpower.com

volume 19 - issue 2 - Finn-Power International, Inc.

FABTECH 2009

ZAPHIRO & FAST BEND

Take Center Stage

at FABTECH

See Page 8

Prima ZAPHIRO

5 kW CO2 Laser

A New Higher Range

2D Laser

See Page 7

Tech Tips...

Upforming

Techniques

Tips and Techniques to

Maximize Upforming

Performance

See Page 2

Volume 19 Issue 2 December 2009

Improving Productivity... See Page 12

Flexibility to Redesign... See Page 4

Enhanced Quality... See Page 18

Customer Profiles Highlight

Prima Finn-Power’s

Productivity and Flexibility

A Prima Finn-Power Publication

Americas Edition

FAST BEND

New Bender & Mike Stock

Prove to be Ready for

Canadian Prime Time TV

See Page 20

New Resonator

Video Available

Highlights How Prima

Designs and Builds Lasers

In the News…

See Page 14

Website offers customer

profile articles and videos

See Page 22

Tooling Articles…

Wila USA See Page 10

Wilson Tool

International See Page 15

Mate Precision

Tooling See Page 23


TECH TIPS

Upforming Techniques in

the Finn-Power Turret Punch Press

With the introduction of the 12 Series machines, indexing capability

was added to the fixed upforming option first introduced in the

10.5 series machines. This enabled multiple large, accurate high

forms up to 16 mm / 0.62” to be formed from both below and above the

sheet, at any angle in a full tonnage 3.5” thick turret D Auto Index upform

station or Nova G Index upform station.

The ability to retract and index this station

independently of the forming stroke using the

DIE_LIFT commands in the 12 Series enables this

station to be used with wheel technology tools which

generally sit higher than regular punching dies and,

thus can catch in the sheet when not in use.

Even with the introduction of the Indexable

upform stations, the original fixed D upform station can be used in the same

turret layout when large forms are required up to 4.75” that exceed the 3.5”

size of the Index upform station. A special modified fixed upper D station

tool holder is used along with a modified 2-piece D station tool assembly

with the 4.75” louver.

Special Commands

The special commands available in the 12 Series allow both full-bottom

mechanical upforming with delay, using the FORMING (0/1) commands

and programmable depth forming, using the P value

with a variable bottom delay, using the

DEEP_DRAW (1-320 millisecond delay) in the same

station. This allows both a full mechanically

upformed louver – one 90 degree and one 75 degree –

using the P value with coining dwell (DEEP_DRAW

(10-320) in the same part, which is an oversize

(4.75”louver) utilizing a specially-modified fixed

upform D station upper and 2-piece tool assembly.

The independent DIE_UP function allows for fast

forming, compared to the precision full mechanical

upform stroke, which must cycle both the upper and

lower rams. It still has the advantage of allowing the

use of high-form tools up to 16 mm and the advantage of retracting the tool

afterward to the same height as the punching dies by using the mechanical

forming command with programmable dwell (BOTTOM_STROKE (10-

2000) combined with the DIE_UP command.

Non-Adjustable Form Tools

For nonadjustable form tools that require the use of

P value or programmable depth setting in the

upform stations in the 12 Series and up machines,

fast forming can be achieved by using the

The FINN-ISH LINE is a publication distributed to PRIMA 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@primafinnpower.us

Technical Editor Lutz Ehrlich lehrlich@primafinnpower.us

Contributing Editor Andrew McCarlie mccarlie@primafinnpower.us

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

2

by Andrew McCarlie, Applications Engineer

DEEP_DRAW(10-320ms) combined with the DIE_UP function.

This can be faster, however the accuracy of the form is not as

consistent as the mechanical forming command with mechanically

adjustable forming tools.

For 12.2 Series and newer machines, forming both up and down

using only the P value is now available using the FORMING (2)

FORMING (3) commands.

To use all these commands seamlessly without having to edit

NC code, you must select the correct forming mode, which is

available in the NC Express programming software with the DIE

LIFT function, e.g., DEEP_DRAW/BOTTOM_STROKE with die

lift, wheel with die lift, or FORMING (3) (4).

The standard 20-station turret punch has five full-tonnage index

upform-capable stations and the new 24-station Shear Brilliance turret

punch press has every station Index upform capable.

As in the case of most forms, what is required of the turret

punch press and tooling is to produce a form in sheet metal in the

most accurate and precise manner. The maximum size of the form in

the upform station is limited by the physical area available between

the two adjacent stations only.

■ Typically, form tooling dies sit much higher in the turret,

depending on their design, and so tend to scratch the material as

well as require the carriage moving the sheet to be run at much

slower speeds to avoid collisions under the turret. Larger form

tooling tends to exacerbate these problems.

■ Another issue is how close to the part edge you can place a large

form if the sheet must ride up onto a large high form die in the

first place. Typically, use of the two adjacent stations in a

machine without the Upform option is limited.

Upform Options

With the upform option, which can form from both the top or

bottom side of the sheet, the die or punch forms only after the sheet

is in position. The die retracts after the large form is made to the

same height as the other dies in the turret, leaving no high dies.

Greater flexibility is possible because these large form tools are

not permanently fixed in one or more stations that can be used for

only that purpose.

Special large form tools are available in both thick turret and

Nova tool styles from either Mate Precision Tooling or Wilson Tool

International.


MANAGEMENT CORNER

“I Can’t Change the

Direction of the Wind...But

I Can Adjust My Sails”

–Unknown Author

Recessions force all companies to make

adjustments. Sometimes these

adjustments translate into the painful

process of eliminating employees or product

lines. Other times this adjustment process

can take a more positive approach, such as

searching for cost savings by becoming more

energy efficient, more productive, and a

leaner manufacturer. It is these positive steps

that some companies take which will build

the foundation for future growth and

prosperity when the economy recovers.

And there appears to be better times

ahead. A recent CNN economic report

indicates that the manufacturing sector has

grown for the last four months after

contracting in 17 of the previous 18 months.

Business inventories are currently at bare

bones, suggesting the manufacturing bounce

will continue.

Prima Finn-Power has helped our

customers adjust their manufacturing sails

for more than 25 years. Our goal is, and

always has been, to improve our customers’

productivity and profitability by giving

them a competitive edge. Our combined

product range is by far the widest of any

fabrication machine manufacturer in the

world: 2D and 3D laser cutting and welding,

laser drilling, punching, and integrated

punching and laser cutting, integrated

punching and shearing, bending, paneling,

and Flexible Manufacturing Systems.

Our design engineers in Finland and

Italy are continually either introducing new

technology or making major enhancements

to existing technology. Most recently these

new products include:

ZAPHIRO – A new high-range 2D laser, is

designed to reach high dynamics and to

provide excellent cutting quality. The linear

motors and the rigid structure allow a

combined speed of 240 m/min, drastically

reducing production time and cost. A highly

innovative and unique feature of this

machine is the new Perfect Cut system,

granting a zero-defect, zero-waste production,

which is essential for intensive, unmanned

production. (see page 7)

FAST BEND – While technically part of the

bender product line, the FAST BEND

fulfills many of the needs of today’s

fabricators regarding the press brake

operation. (see page 21)

In the Words of our Customers

This issue of the FINN-ISH Line features

several customer profile articles that

highlight how Finn-Power’s flexibility and

technological advantage have helped

customers increase their quality,

productivity, and profits:

Orion Energy Systems, Plymouth, WI

(see page 4) By the early 2000’s, the company

began to develop its diverse line of energyefficient

products that provided an

alternative to the inefficient, old technology,

high-intensity discharge fixtures. With this

increased

demand for its

product, came

increased

pressures for

just-in-time

manufacturing.

And utilizing

job shops for

its sheet metal

fabrication was no longer a viable option for

Orion management.

■ “Finn-Power has given us quality and

flexibility in our product line. Without

flexibility in today’s market…you’re

sunk. That flexibility has allowed us to

do our own prototyping, and to get the

product through as fast as we can. For

development and design changes, the

Finn-Power equipment has been a huge

asset, even though we are using it daily

for production.”

Fantech Ltd., Bouctouche, NB (see page

18) Since its founding in 1987, Fantech Ltd.,

Bouctouche, NB, has manufactured products

that provide “ventilation solutions” to

improve air quality for residential and

commercial applications.

3

by John Rogers,

Chief Operating Officer

■ “Today, 99% of Fantech’s sheet metal

fabrication is processed through the

Shear Genius. Although demand has

decreased due to current economic

conditions,

the Shear

Genius has

increased

our

productivity

by 10%.

“The Shear

Genius is

much more

efficient than our previous presses. With

‘lights out’ operation, it has allowed us

to delay adding a second shift.”

Electric Equipment & Engineering Co.,

Denver, CO (see page 12) Nearly 65 years ago,

the company began manufacturing products

for the telecommunications industry and has

evolved into a fierce competitor in

manufacturing power distribution and

transfer systems in all shapes and sizes from

200 – 4,000 amps.

■ “We were

surprised by

the increased

accuracy of

the servodriven

punch. We

used to

outsource

the welding

of a line of outdoor boxes, and their

price tripled in 10 years. It is critical that

the parts fit perfectly together because

the box needs to be watertight. With the

increased accuracy of the E Compact

Express, we were able to redesign the

boxes to eliminate welding. We now

rivet the boxes together and the holes

must match perfectly – and they do.

Our cost of manufacturing these boxes

has dropped 50%.”

Happy Holidays from everyone

at Prima Finn-Power!


CUSTOMER PROFILE

The Future Looks

Bright at Orion

Energy Systems

What started as a small agricultural lighting

company in Plymouth, WI, has evolved into a

leader in energy-efficiency technology for the

industrial and commercial lighting industry.

Orion Energy Systems was founded in 1996 by Neal

Verfuerth with a focus in agricultural lighting sales and

compact fluorescent technology. Today, the company has

235 employees in a 266,000-square-foot facility in

Manitowoc, WI. To stress the impact its products have on

the environment, Orion management chose this past Earth

Day, April 22, to formally open a 70,000-square-foot

technology center. This new facility will serve as Orion’s

headquarters and operations center as well as a national

destination for educational institutions and businesses to

learn about energy efficiency.

In its early years, Orion used contract manufacturers

for all its sheet metal fabrication production for its small

product line. By the early 2000’s, the company began to

develop its diverse line of energy-efficient products that

provided an alternative to the inefficient, old technology,

high-intensity discharge fixtures. A broad range of creative

designs expanded use to a wide variety of applications:

■ High-intensity fluorescent fixtures – Orion literature

states that its innovative line of high-intensity,

fluorescent fixtures provide the most light possible for

the least amount of energy input. Proprietary

attributes, like aluminum frame side and front

ventilation and patented roll-formed reflector, optimize

the way heat is conducted and radiated, and the way

light is harvested.

■ Apollo Light Pipe ® – The Apollo Light Pipe utilizes the

lowest cost light available – the sun. Apollo can reduce

energy costs for lighting to zero for significant portions

of the day. Daylight is harvested through the dome and

travels through the sealed light pipe, allowing focused

daylight to enter the building. The Apollo Light Pipe is

designed to be a one-for-one daytime replacement of a

typical electrical lighting fixture. When used with

Orion’s InterLite controls and high-efficient lighting

systems, a company can easily measure and manage its

energy usage and immediately improve its bottom line.

Impressive Growth &

Increased Production Demands

Orion has installed its energy management systems in 4,796

facilities in North America, including 119 customers listed

in the Fortune 500. Since 2001, Orion technology has

displaced more than 460 megawatts, saving customers more

than $642-million and reducing indirect carbon dioxide

emissions by 5.6 million tons.

With this increased demand for its product came

increased pressures for just-in-time manufacturing, and

utilizing job shops for its sheet metal fabrication was no

longer a viable option for Orion management.

Ron Ernst, vice president manufacturing, (right) and Troy Johnson, business unit manager, display alarge

lighting fixture fabricated on the C5 Compact Express and formed on the E Series robotic press brake.

The C5 Express adds unmanned operation to the C5 turret punch press through highly compact

load/unload automation. The unit’s loading/unloading solution utilizes the space above and below

the machine, requiring only slightly more space than a turret punch press.

4


During the 4th quarter of 2004, Orion

purchased a Finn-Power C5 turret punch

press and a servo-electric E press brake.

“This was the first sheet metal fabrication

equipment that we purchased,” explains Ron

Ernst, vice president manufacturing. “Before

the Finn-Power equipment, everything was

produced by job shops. That same year, we

acquired our first roll former, and we began

making our own reflectors. A few months

later, we ordered our second exact set of

Finn-Power equipment to meet our growing

production needs.”

C5 Turret Punch Press

The 20-station, 33-ton C5 hydraulic turret

punch press has a maximum sheet capacity

of 50” x 100” and is available with either

Siemens or Fanuc controls.

Tooling flexibility is also important to

Orion. Up to 10 auto-index and Multi-Tool®

holders may be installed in a Finn-Power

turret. Orion has five auto-index stations and

one 24-station Multi-Tool in all the C5

turret punch presses. 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. “By the sheer volume of

parts that we nest on a sheet, the auto-index

station is a big benefit,” explains Troy

Johnson, business unit manager. Other

features include:

■ Upforming – 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

(0.62”), with the forms made by the die

moving upwards and then retracting,

allowing completely free sheet

movement, eliminating scratched or

jammed sheets.

“Before we had access to Finn-Power’s

upforming feature,” says Johnson,

everything on the ballast channel was a

screwed-together assembly with a lot of

hardware and fasteners. Today, the Finn-

Power upforming stations creatively do the

job with snaps and catches. We redesigned

the product to make it modular. We now

offer a removable power pack that can be

replaced without any tools. With the

reduction of hardware, our volume in

assembly has increased. We also eliminated a

metal cross member for a 6% savings in

aluminum. We’re able to save material and

labor while making it a modular unit…which

results in lower maintenance for our

customers.”

“Today, the Finn-Power

upforming stations creatively do

the job with snaps and catches.

We redesigned the product and

we’re able to save material and

labor while making it a

modular unit…which

results in lower

maintenance for our

customers.”

■ Easy loading – Four optimallypositioned

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.

Finn-Power turret punch presses and press brakes fabricate

200 different fixture models at Orion, and have given

quality and flexibility to the company’s product line.

■ 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 for simple and efficient logistics

and enables the machine to be

positioned anywhere on the shop floor

– even in a corner.

E Press Brake

The Finn-Power E Series servo-electric 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

5

Finn-Power’s design allows

forming heights up to 16 mm

(0.62”), with the forms made by

the die moving upwards and then

retracting, allowing completely free

sheet movement, eliminating

scratched or jammed sheets.

requirements. The frame concept makes it

possible to utilize the back gauge system

across the entire working length.

The patented servo-drive system is a

revolutionary concept offering many

advantages. When performing batch work of

any size, the rapid advance, programmable

working speed, programmable stroke

parameters, and rapid return speed of the

ram enables maximum cycling rates without

compromising control. The fast positioning

speeds ensures that the backgauge will be

ready when the part is presented for each

operation. The Power Belt System virtually

eliminates ram deflection and the need for

compensating bed crown. By using the

pulley principle – a system with fixed and

moving rolls spread over the total working

length of the upper beam with a belt – a

highly equal force transmission is achieved.

By applying servo-motors and regulators, an

extremely simple and secure construction is

obtained.

“We liked the E press brakes

because of their high accuracy

and sensitivity in forming thin

material. These brakes have

increased our overall

production speed. Cost and

timing were the reasons for

bringing the manufacturing inhouse.

It took about a week to

get product from the job shops.”

continued on page 6


continued from page 5

“We liked the servo-electric E press brakes because of their high

accuracy and sensitivity in forming thin material,” explains Ernst.

“These brakes have increased our overall production speed. Cost and

timing were the reasons for bringing the manufacturing in-house. It

took about a week to get product from the job shops. In the early

years, we were changing product nearly every week with the design

changes. The Finn-Power machines helped us take control of our

own destiny.”

“The Finn-Power equipment has worked out great,” adds

Johnson. “We were able to start rapid prototyping of product. Then

the engineering and design phase really took off because we were able

to prototype everything we needed with the Finn-Power equipment

without going outside. We could switch ideas on the fly and not get

stuck with someone else’s lead times.”

“We decided to automate both the punching and

bending to eliminate the fatigue our operators

were experiencing from manually loading and

unloading the large sheets and enclosures.”

Automation

In the fall of 2006, Orion purchased the C5 Compact Express and the

robotic E press brake. “We decided to automate both the punching

and bending to eliminate the fatigue our operators were experiencing

from manually loading and unloading the large sheets and

enclosures,” says Ernst.

Orion decided to automate both the punching and bending to eliminate the fatigue the operators

were experiencing from manually loading and unloading the large sheets and enclosures.

Compact Express

The C5 Express adds unmanned operation to the C5 turret punch

press through highly compact load/unload automation. The unit’s

loading/unloading solution utilizes the space above and below the

machine, requiring only slightly more space than a turret punch

press. It is fast – with simultaneous loading and unloading during

processing – accurate, and it does not limit easy manual operation.

“When we got the first C5 Compact Express and robotic E press

brake, enclosures were only 10-15% of our business…today it is 50%,”

says Johnson. “We were producing 500 fixtures a day. Today, we

build 3,300 compact modules, 1,200 enclosures, and 5,000 fixtures in

an 8-hour shift. The second C5 Compact Express and robotic E press

brake were delivered in January 2009.”

6

When the Apollo Light Pipe is

used with Orion’s InterLite

controls and high-efficient

lighting systems, a company

can easily measure and

manage its energy usage and

immediately improve its

bottom line.

The Apollo Light Pipe utilizes

the lowest cost light available –

the sun. Apollo can reduce

energy costs for lighting to zero

for significant portions of the

day. Daylight is harvested

through the dome and travels

through the sealed light pipe,

allowing focused daylight to

enter the building. The Apollo

Light Pipe is designed to be a

one-for-one daytime

replacement of a typical

electrical lighting fixture.

Dramatic Growth

To be sure, Orion has attained an enviable record of technological

achievement and financial growth. The company’s energy-efficient

products have won numerous awards, including: Wisconsin’s

Manufacturer of the Year, Plant Engineering’s Product of the Year, Platts

Global Energy Award, etc. Orion was also recently recognized by the

White House for its advances in clean energy and energy

efficiency. And the company’s financial success has been equally

impressive. In 2005 Orion sales were $12-million, and rose to $80million

in 2008. The company went public on NASDAQ in

January 2008.

“Now that we have the Finn-Power turrets

and brakes, we make 200 different models.

Finn-Power has given us quality and

flexibility in our product line. Without

flexibility in today’s market…you’re sunk.”

“From 2001- 2004, we had only 10 models of fixtures,”

concludes Ernst. “Now that we have the Finn-Power turrets and

brakes, we make 200 different models. Finn-Power has given us

quality and flexibility in our product line. Without flexibility in

today’s market…you’re sunk. That flexibility has allowed us to do

our own prototyping, and to get the product through as fast as we

can. For development and design changes, the Finn-Power

equipment has been a huge asset, even though we are using it daily

for production.”


NEW EQUIPMENT SPOTLIGHT

Zaphiro – A New, High-Range 2D Laser From

Prima Industrie

The ZAPHIRO is a new high-range 2D

laser, designed to reach high dynamics

and to provide excellent cutting

quality. The linear motors and the rigid

structure allow a combined speed of 240

m/min, drastically reducing production time

and cost.

A highly innovative and unique feature

of this machine is the new Perfect Cut

system, providing a zero-defect, zero-waste

production.

Perfect Cut is an intelligent system

which allows real time detection of the

cutting quality and automatic correction of

parameters. The ZAPHIRO stores a sample

cutting piece for each material and thickness

on the machine’s CNC. This is used by the

system and can be set according to the

application and to the desired result. The net

result is zero defects and zero rejects.

Another important innovation of

ZAPHIRO is the laser head, a further

evolution of PRIMA INDUSTRIE 2D

heads. The new F axis, with higher dynamics

and longer stroke, allows substantial cycle

time reduction and superior cutting quality.

The new “cartridge design” lens change

system is extremely quick and easy-to-use.

With Beam Size Control (BSC), the laser

beam diameter is adjusted to the material and

thickness to be cut. Flexibility, productivity,

and quality are further improved.

ZAPHIRO is also equipped with the

new, robust sheet metal supporting table,

highly efficient fume exhaust, and with the

new, faster pallet changer.

ZAPHIRO is provided with P30L, the

latest generation numerical control

manufactured within the PRIMA Group.

Faster and more powerful, the new

numerical control is compatible with all

previous versions and with all PRIMA

INDUSTRIE 2D machines and has a new,

easy-to-use, slim console with a 17” touch

screen.

For off-line programming ZAPHIRO

takes advantage of the easy, fast, and smart

MAESTRO-Libellua system. Other features

include: the highly effective and accurate

Nesting Module, the Tables-on-Board

7

(TOB), the Integrated Virtual Machine, and

the detailed and precise reporting.

ZAPHIRO is equipped with CV5000

(5 kW) laser resonator, allowing cuts up to

25 mm thickness with quality and efficiency

and provided with magnetic support turbine,

solid state high voltage power unit, servocontrolled

gas mixing, and the new “zeroemission”

device.

As with all PRIMA INDUSTRIE flat

bed machines, ZAPHIRO can be integrated

with automation systems, from the simplest

sheet metal loading/unloading systems, to

the most complex FMS, such as the FINN-

POWER Night Train.


FABTECH TRADE SHOW

Prima Finn-Power

Makes an Impact at FABTECH 2009

Prima Finn-Power made a strong impact on FABTECH 2009,

held November 15-18 at McCormick Place, Chicago, IL.

Although total attendance was down slightly from recent

shows, hundreds of interested fabricators visited the booth each day

of the show to see the latest in bending and laser cutting technology.

8

Visitors were enthusiastic when they saw the FAST BEND, a new

servo-electric bending concept, capable of bending 5 different parts in

just 5 minutes, and the new Zaphiro, a new high range 2D laser in

operation. Also on display was the E servo-electric press brake, a fast

and accurate bending solution.


FABTECH OPEN HOUSE

Prima Finn-Power Hosts

Open House During FABTECH

For two nights during FABTECH,

Prima Finn-Power North America

hosted an Open House after show

hours at its showroom in Arlington

Heights, IL. Visitors were able to get a

close-up look at numerous laser and

fabricating machines, including:

PLATINO 2D Laser System

High-performance, user-friendly,

flexible, and compact flat laser cutting

machine, flexibility is the distinctive

feature of PLATINO, a machine

designed and developed for the needs of

the sheet metal processing industry.

PLATINO cuts a broad range of

materials and thicknesses with speed

and precision.

DOMINO 2D/3D Laser System

The most versatile 2D/3D laser

machine in the world with unrivaled

production versatility, the DOMINO

is a machine designed for today’s

industrial reality that dictates high

productivity, great efficiency, extreme

versatility, maximum accuracy, and

limited costs. A single machine cuts

and welds sheet and three-dimensional

parts, performs bevel cuts for the

weld preparation, and processes tubes

and pipes.

EBe Servo-Electric

Express Bender

The EBe is a bending solution

specifically designed for each

fabricator’s production requirements to

achieve maximum productivity, quality,

and repeatability.

E Series Compact Express

The Finn-Power servo-electric E series

turret punch press offers versatile

punching, nibbling, forming and

bending capacity on a single machine

tool. The Compact Express adds

unmanned operation to Finn-Power’s

turret punch press line and versatility

through highly compact load/unload

automation.

Servo-Electric Press Brake

The E servo-electric press brake is a

fast, accurate bending solution.

By applying mechanics and electronics,

a unique patented “mechatronic” drive

was developed. The result is an even

distribution of forces in the top beam,

high accuracy, increased productivity,

high reliability, less energy

consumption, and fewer maintenance

requirements.

C6-LST–Compact Solution For

Loading and Component Sorting

The LST is a compact, automatic sheet

loading and part sorting and stacking

flexible manufacturing cell. The LST

loads sheets to the machine, picks up

the parts and sorts them to the

programmed unloading location.

Loading capacity is 6,615 lbs. (3,000 kg)

with a maximum stack height of 9.8

inches (250 mm).

9


FOCUS ON TOOLING

By David Bishop, Business Development Manager, Wila USA

Wila’s New “American Vintage” Tooling System

High Performance, Exceptional Value

Needless to say, times are tough. As we navigate

this difficult economy, most of us find ourselves

reaching for products that enable us to do more

with less. And getting the maximum value from

everything that we purchase is no longer an option.

In response to these needs, Wila® recently

introduced our new “American Vintage” line of press

brake tooling. This exciting new product line is

designed for fabricators that use press brakes made in

North America that utilize American style tooling. It

features a broad range of punches and dies that are

packed with many of the productivity enhancing

features that you have come to expect from Wila.

To start, all punches and dies are produced from a

tough 4140 alloy steel. We harden the working surfaces

to HRC-52 to provide long tool life and an equally long

period of retained accuracy. We precision grind all

critical dimensions to a tolerance of +/– .0008”

(.02mm). This provides you with the ability to order

various lengths of the same punch or die at different

intervals and know that they will match when used in

the same set-up. It also makes it possible to order

replacement pieces of sectionalized punches and dies and

with assurance that they will match the original set.

We also added our patented Safety-Clicks® to

punches weighing 28 pounds (12.5kg) or less, making it

possible to load and unload them vertically in a Wila

American Style Clamping System, or in the manual

ram clamps that your press brake came equipped with.

This makes it much faster to change punches and to

reconfigure set-ups involving sectionalized punches.

Press brake owners that want to upgrade their tooling

from basic low tolerance planer made tooling will enjoy

the fact that all punches in this product line are 4.750”

(120.6mm) tall, making them more versatile than the standard 4” (100mm) tall

punches that are common to American style tooling. All dies are 2.125” (54mm) tall,

which gives them slightly longer down flange capability than standard 2” (50mm) tall

American style dies.

If you’re accustomed to using American style tooling, you’ll also be glad to

know that all key dimensions are laser marked in imperial dimensions right on the

front face of the tooling. No more guesswork required when identifying punches

and dies.

Possibly the best feature of all is that our new American Vintage line of

tooling is attractively priced to make it affordable to all press brake owners!

If you rarely change tooling, are on a tight budget, or simply want the

benefits of Wila’s improved accuracy, durability, and the ability to order

matching replacement tooling sections, we have just the solution for you. It’s

called “American Vintage” and it’s available only from Wila, the company that

the world turns to for maximum press brake productivity.

For more information, please contact:

WILA USA

9135 Guilford Road

Columbia, MD 21046 USA

Tel: 888-696-9452

Fax: 301-490-3991

Press Brake Productivity Website: www.wilausa.com

10


CUSTOMER PROFILE

New Fabrication Technology Meets

Telecom Manufacturer’s Growing Needs

When Jim Morroni founded Electric

Equipment & Engineering Co.

(EEE), Denver, CO, in 1922, it

was just a small firm selling motors and

electrical systems. However, this fledgling

company soon earned the reputation of being

able to tackle the challenging jobs that

competitors couldn’t or wouldn’t attempt.

Today, this third-generation family business

would make patriarch Jim Morroni proud.

His commitment to innovation and

engineering excellence still exists through his

two sons, Dick and Tom, and grandsons Tim,

Greg, Craig, and Mike – all part of the current

EEE management team.

Nearly 65 years ago, the company began

manufacturing products for the

telecommunications industry and has evolved

into a fierce competitor in manufacturing

power distribution and transfer systems in all

shapes and sizes from 200 – 4,000 amps. “All

the products that we manufacture today have

been invented or pioneered at EEE,” explains

Greg Morroni. “We do not make what you

would call a ‘me too’ product.”

“We designed and introduced the very

first microprocessor-controlled transfer

switch,” adds Tim Morroni, Greg’s brother.

“Our larger competitors now manufacture this

product in much larger volume than we do,

but we can innovate quicker than they can.

We innovate constantly in order to compete.”

History of Increased Productivity

The first fabrication machines installed at EEE

were two single-station presses. These

machines served the company well for many

years, but fierce competition in the

telecommunications industry and rapidlygrowing

demand for just-in-time deliveries

forced EEE to look for more productive

fabrication equipment. In 1999, EEE chose the

Finn-Power P5 hydraulic turret punch press

to replace one of the single-station presses.

“We recognized that if we wanted to compete

more effectively, we had to upgrade our

fabrication equipment,” says Greg Morroni.

The P5 is still in production at EEE, and

this purchase began a 10-year relationship with

Finn-Power that covered several generations of

machines purchased to keep up with growing

demand. In 2000, EEE introduced another new

product that created a rapid increase in

production and prompted the company to add

an F5 hydraulic turret punch press.

In 2005, strong demand for another

product line, the integrated load center, once

again was responsible for adding new

fabrication automation technology from

Tim Morroni is part of a third-generation family business that is committed to innovation and engineering excellence.

Finn-Power fabrication equipment has been part of Electrical Equipment & Engineering’s success since 1999.

Prima Finn-Power – the C5 Compact Express.

This product added unmanned operation to

the C5 turret punch press through highly

compact load/unload automation. “Even

though we had short lead times and increased

demand, we didn’t have to add to the

workforce because of the machine’s

automation,” explains Tim Morroni.

Servo Electric Technology

The latest generation of Finn-Power

equipment to arrive at EEE was the E5

Compact Express in early 2009. This machine

has many of the same features as the C5, while

offering the advantages of servo-electric drives,

such as high precision and lower energy

consumption.

The Finn-Power E5 turret punch press is

a new generation, precision fabricating system

that features a servomotor-driven punch

mechanism and is both flexible and amazingly

accurate. In the E5, both the position and

speed of the punch and die are programmable,

which allows punching, nibbling, cutting,

forming, marking, bending, and tapping in

just a single setup.

This new approach to precision sheet metal

fabricating has the following features:

■ High accuracy and repeatability

■ Low connecting power

■ Low energy consumption

12

■ Excellent forming properties – .630" high

(16 mm) – with no die interference

■ Intelligent tool management technology

for easy settings

The punching process of this new technology

from Finn-Power combines servo-electric

technology with mechanical power

transmission, enabling strict punch control. A

“We were surprised by the

increased accuracy of the

servo-driven punch. With the

increased accuracy of the E

Compact Express, we were able

to redesign the boxes to

eliminate welding. We now

rivet the boxes together and the

holes must match perfectly –

and they do. Our cost of

manufacturing these boxes

has dropped 50%.”


servomotor, together with a lead screw, moves

a roll that in turn moves the ram by means of

a guiding surface.

The punching stroke is numerically

controlled by the CNC, which provides a

very fast and optimal punching stroke. The

stroke position and speed are controlled by

the CNC. With forming tools, you can

program a lower ram speed and use a lower

forming speed and a positioning tolerance.

“We were surprised by the increased

accuracy of the servo-driven punch,” says Greg

Morroni. “We used to outsource the welding

of a line of outdoor boxes, and their price

tripled in 10 years. It is critical that the parts fit

perfectly together because the box needs to be

watertight. With the increased accuracy of the

E Compact Express, we were able to redesign

the boxes to eliminate welding. We now rivet

the boxes together and the holes must match

perfectly – and they do. Our cost of

manufacturing these boxes has dropped 50%.”

Other E5 features include:

■ 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. EEE has

five 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. Using a 40

station alpha/numeric Multi-Tool, part

identification programs are fast and easily

done. EEE has four Multi-Tool stations.

■ Upforming system – Finn-Power’s

upforming 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. “Louvers are used to pull air

through many of our products,” explains

Tim Morroni. “Before Finn-Power, we

used a single-station louver punch. It was

much slower and more expensive than

our upforming solution today.”

■ Large work chute – A large work chute

capable of removing large parts up to

19.6" x 19.6". These parts are then

The C5 Compact Express added unmanned operation through highly compact load/unload automation. The unit’s

loading/unloading solution utilizes the space above and below the machine, requiring only slightly more space than a

turret punch press.

dropped onto a conveyor to be exited out

the end of the machine, thereby reducing

shaker parts and eliminating skeletons.

“Today, we try to send as many parts as

possible down the work chute,” Tim

Morroni continues. “It eliminates the

labor of shaking parts out and the parts

are ready to bend. In addition, with no

micro joints, I don’t have to worry about

deburring or having them bump on the

back gauge of the press brake.”

■ Tapping – The tapping feature of the E5

has also paid a large dividend to EEE.

The company chose a six-station, servodriven

tapping unit. “On one motor base

part, we have 40 tapped holes in three

different sizes,” says Tim Morroni. “On

our old machine it would take 2 1 /2 hours

to make 24 parts. On the E5, we can

make 48 parts in just 25 minutes.”

The E5 features a large work chute capable of removing

large parts up to 19.6" x 19.6". These parts are then

dropped onto a conveyor to be exited out the end of the

machine, thereby reducing shaker parts and eliminating

skeletons.

13

■ Vacuum scrap conveyor – This optional

feature ensures secure and effective slug

removal after punching.

Green manufacturing

According to Finn-Power International, recent

tests have proven that by using a creative

combination of servo-electric technology and

mechanical power transmission, the E5

consumes less than 1/3 the amount of

electrical power of a comparable hydraulic

turret punch press. More specifically, the E5

concept is an astonishing money saver in

terms of energy consumption. It uses breaking

energy in the acceleration of the following

movement. The operating economy is best

described by analyzing what happens energywise

during each sequence consisting of a

punching stroke and the sheet movement that

precedes and follows it.

Servo-electric press brake

The final piece of Finn-Power equipment that

EEE installed was the E Series servo-electric

press brake. This 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

“The repeatable precision

of the E brake is amazing.

It forms our parts quicker

and the increased precision

dramatically reduces

assembly time.”

continued on page 14


continued from page 13

distribution of forces in the top beam, high

accuracy, increased productivity, 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

repeatable precision of the E brake is

amazing,” says Greg Morroni. “It forms our

parts quicker and the increased precision

dramatically reduces assembly time.”

“The Finn-Power machines

have given us the

opportunity to integrate

products in a way that our

competitors either can’t do or

won’t do. Our products are

helping to improve our

customers’ bottom line…and

Finn-Power is helping us

produce these products.”

Future growth

EEE management is optimistic about the

future. “Our outlook is pretty good,”

concludes Greg Morroni. “The

telecommunications marketplace has

dwindled, with fewer customers and fewer

vendors. However, there are plenty of doors

open to us, due to our ability to innovate and

manufacture flexibly for tight deadlines.”

“Whatever comes down the pike,” adds Tim

Morroni, “with our Finn-Power equipment,

we are not going to worry about our capacity

to produce quality products. The Finn-Power

machines have given us the opportunity to

integrate products in a way that our

competitors either can’t do or won’t do.

Our products are helping to improve our

customers’ bottom line…and Finn-Power is

helping us produce these products.”

The final piece of Finn-Power

equipment that EEE installed

was the E Series servo-electric

press brake. This press brake is

a fast, accurate bending

solution. The frame concept

makes it possible to utilize the

back gauge system across the

entire working length.

New Video Available on Prima Laser Production

Prima Finn-Power North America, Inc.

has produced a new informational

video – The Single Source Solution –

featuring the stringent production processes

and premium components that go into every

Prima laser system. Prima has been an

innovator of state-of-the-art 2D and 3D

systems for laser sheet metal fabrication and

drilling of parts used in a broad range of

industries worldwide since 1977.

The video highlights include how Prima

Convergent lasers are designed and built by

Prima in the US for exclusive use in Prima

machines with in-house design, development,

multi-lab testing, clean-room assembly, extensive

performance testing, construction, installation,

customer support, and customer service.

14

The tapping feature of the E5 has also paid a large

dividend to EEE. The company chose a six-station, servodriven

tapping unit.

To receive your DVD copy of The Single

Source Solution, contact Diana Vazquez,

diana.vazquez@primafinnpower.us


FOCUS ON TOOLING

The Best Keeps Getting Better

Wilson Tool continues to raise the

bar for tooling performance and

durability. Not only does the

company lead the industry in innovation,

regularly introducing new tooling solutions,

they continuously strive to build on their

successes and improve the technology of

even their most groundbreaking tooling.

Here we profile several upgrades to

popular punch press and press brake tooling

lines, as well as introduce a few new helpful

accessories designed to improve accuracy,

increase efficiency and ultimately reduce

production costs.

A New Twist on Punch Tooling

Wilson Tool is helping punch press

fabricators further increase productivity,

precision and durability with significant

upgrades to the company’s popular High

Performance® (HP) product line.

The new HP punch tooling will retain

all of the features and benefits of the original

HP series, including tool-free removal of

guide assemblies and quick release stripper

plates, with several impressive

improvements.

Wilson’s new HP2 spring packs make

punch length adjustments faster and easier

than ever before. Simply twist the punch

head to adjust the punch length .005 inch per

click. There’s no need to snap the guide off,

use any tools or push any buttons. This also

enables length adjustments to be made in the

machine now, instead of having to take the

tool out of the machine.

Additionally, modifications were made

to the punch tips to ensure that the

maximum grind life of each and every

Wilson HP punch matches or exceeds all

other competitors. Enhancements were also

made to WB tool steel to ensure that

Wilson’s tooling is the toughest, most

durable in the industry.

A Groovy New Press Brake Tooling

Wilson Tool now offers American-style

press brake tooling featuring industry

standard groove on its tang. Available in all

the same profiles as Wilson’s standard

American tooling, the new "G-style" tooling

is fully compatible with all clamping systems

on the market today that require a groove in

the tooling.

Best of all, the new G-style tooling

continues to feature all the benefits of

Wilson American Precision press brake

tooling, including push button tool changes,

staged bending and unmatched durability.

“V” is for Versatile

New V-Series press brake dies from Wilson

Tool incorporate rolling inserts to decrease

friction and enable better performance on

certain tough-to-bend applications.

Wilson V-Series dies make it much easier

to produce small flanges, small bend radii

and bends closer to holes. V-Series dies also

make it possible to bend a wide range of

materials using the same die – reducing setup

time and the amount of tooling required.

V-Series dies include built-in blades that

rotate to minimize lateral movement

between the sheet and the die, thus reducing

friction and minimizing sheet marking.

The rotating blades are available in either

metal or composite material. Metal blades

are the most durable, while composite blades

are ideal for minimizing sheet marking. Both

blade types are interchangeable within the

same die base.

15

By Jeff Paulson, Marketing Manager, Wilson Tool International

What a Square

Wilson Tool makes it easy to ensure accurate

angles time after time with two new costeffective

press brake tooling accessories.

The first of these accessories is Wilson’s

new Magnetic Squaring Arm. This flexible

tool is easy to use and will help bend more

parts with greater accuracy. The arm

attaches to the press brake die with a

powerful magnet –no screws to tighten or

fastening tools required.

The angle of Magnetic Squaring Arm

can be adjusted from 0 to 90 degrees to

match the part, ensuring the bend is

consistently in the correct location and can

also be used as a shelf for small parts. This

handy tool also helps accurately square

tricky Z-bends after the first bend by

positioning the angle bar on the opposite

side of the slide arm.

The second helpful accessory is the

Wilson Digital Protractor set. Lightweight

and easy-to-use, these highly accurate

protractors measure angles from 0 to 360

degrees with digital precision.

Wilson Digital Protractors include a

strong magnetic locking system, a hold

function to prevent losing the reading and a

reverse reading

capability to

simplify hardto-calculate

angles. Each set

includes a four,

eight and

twelve-inch

protractor.

Tooling Around YouTube

For demonstrations and information about

these and other tooling solutions from

Wilson Tool, be sure to check out the

company’s channel on YouTube. New video

content is added often. To subscribe to the

Wilson Tool Channel, please visit

www.youtube.com/wilsontooltube.


CUSTOMER PROFILE

16

By Michael Bishop, Assistant Editor

New dimension, familiar direction

H.W. Metals invests in a laser cutter for jobs

where plasma doesn’t cut it

H.W. Metals, Tualatin, Ore., processes

high-strength steel for transportation

equipment manufacturers and other

applications. The company began operating

in 1979 as the fabrication division of a local

service center, which would provide

materials and contract out work. Jack Suter

and Howard Wolfe both were with the

company in October of ’79 when it shipped

its first product: a 48-foot-long, grade-70

truck trailer frame.

When the service center closed the

fabrication division, Suter and Wolfe took

over a back bay, where they operated a large

press brake that was two tandem 24-ft., 750ton

machines. Since then H.W. Metals has

expanded its offerings with punching,

shearing, and arc welding. The company also

added high-definition plasma cutting with

the purchase of an 80-ft.-long by 10-ft. wide,

two-torch system and standard plasma

cutting with the acquisition of two fourtorch

systems—one measuring 80 ft. by 12 ft.

and the other 90 ft. by 12 ft. And it acquired

press brakes in 14-ft., 350-ton; 20-ft., 350-ton;

and 60-ft., 2,500-ton models for additional

forming capacity.

Suter now owns the company, along

with Wolfe and both of their sons: Vice

President/Sales Manager Josh Suter and Vice

President/General Manager Brian Wolfe.

H.W., which historically has maintained a

work force of about 75, currently employs 65

in a 140,000-sq.-ft. facility. It runs two shifts

per day, with the exception of certain

machines that run all the time. Even though

its large number of machines and its variety of

operations keep it reasonably busy, the

“The system allows the

company to cut a 60-ft. part

in a single section. It also cuts

small parts as quickly and

efficiently as a small laser. As

a result, the company didn’t

need to purchase both a large

and a small laser—it bought

one machine with a small

footprint.”

H.W. Metals processes high-strength steel for many different applications, including transportation equipment manufacturing.

company found that there was more and more

work it couldn’t do for its customers because

some jobs required laser-cut parts. The

company didn’t have laser technology, which

automatically excluded it from these jobs.

Taking those customers into account, as

well as new work and the evolution of the

way steel is cut, the company decided to

purchase a laser. Managers didn’t want to go

into new markets, but they wanted to

expand capabilities in their current markets

by offering an alternative to plasma cutting,

Suter said.

“It was a direction we had to go to

ensure our future,” he said.

First in North America

In October 2008, the company installed a

Prima Maximo laser cutting system, the first

of this model to be installed in North

America, according to Suter. The system

allows the company to cut a 60-ft. part in a

single section. It also cuts small parts as

quickly and efficiently as a small laser. As a

result, the company didn’t need to purchase

both a large and a small laser—it bought one

machine with a small footprint.

“I think that we’re the only job shop that

can plasma, high-def plasma, laser-cut, form,

and weld a 60-foot piece in a single section,”

Suter said. “We don’t cut 60 foot parts that

often, but we have the ability to do so.”

At first, Suter worried about bringing a

laser into a carbon steel, heavy-industry shop

environment because he didn’t know if the

laser would be affected by carbon dust and

vibration. Visits to shops in Italy that work

under similar conditions convinced him that

H.W. could install and use the laser without

problems.

Preparing for the installation required

work on the foundation, plumbing, and gas

lines. The foundation had to be isolated

from the rest of the shop floor to eliminate

the possibility of vibration and shock

problems. The gas lines needed to be run

from bulk tanks to the laser, a project that

the company contracted out. H.W. Metals

didn’t have to rearrange the shop at all; the

company just had to figure out the right

place to put the machine and clear enough

floor space. To assuage the worries about

carbon dust and vibration, technicians

installed it away from high-traffic areas and

the main work flow of the shop.

The introduction of the businesses’s first

laser required significant training to prepare

workers to operate the machine, Suter said.

“None of our people here had run a

laser, so we had to hire an operator who was

experienced in operating a fairly large laser,”

he said. “We trained a couple of our plasma

operators as well. And we trained two people

internally in the programming aspect.”


Streamlining the Operation

Early operations have met the company’s

expectations since the installation. The first

item the shop processed on the laser was

3/16 DOMEX®, 110,000-minimum-yield, 53ft.-long,

as-rolled steel for agricultural trailer

rails. The company also cut 1/2-in., abrasionresistant

track pad, which is heat-treated, 4ft.-long,

plate for mining applications. The

pads required holes that plasma couldn’t cut

correctly. So before the company installed

the laser, this was a two-stage operation in

which operators would plasma-cut the part

and then punch or drill holes. The process

since has been consolidated into a single

“Handling the material is

always a crucial issue, and the

fewer times you have to move

product from machine to

machine, the more time

you save, and then you can

allocate manpower more

efficiently.”

operation—operators now laser-cut the

perimeter and the holes. The laser also has

helped eliminate the need for customers to

have to prepare cut edges for welding.

“Handling the material is always a crucial

issue, and the fewer times you have to move

product from machine to machine, the more

time you save, and then you can allocate

manpower more efficiently,” Suter said.

The new laser is helping H.W. Metals provide new services to its current customers.

The company installed a Prima Maximo laser that allows the company to cut a 60-ft. part in a single section.

Anecdotal Engineering

H.W. Metals isn’t known for making just

one product. According to its Web site,

applications for its fabricated parts include

marine, railcar, truck trailer, dump truck

body, motor home, transit bus, crane boom,

military vehicle, and mining equipment. The

company also fabricates poles for light

structures and components for bridges,

buildings, conveyors, signs, and tanks.

The company, which also uses the laser

for some in-house art projects, continues to

train plasma operators on how to run the

machine. Suter believes the company

eventually will purchase another laser. But

because H.W. is a job shop, customer needs

17

will dictate goals for the future, he said. One

goal for the new laser is to provide new

services to current customers. Now, for

example, a customer that previously

requested plasma-cut parts from H.W., but

had to seek laser-cut parts from another job

shop can turn to H.W. for both.

In addition to its work with

transportation equipment manufacturers, the

company has gotten involved with the

military in parts for armament, cutting

components with both plasma and the laser.

The company also has been involved, to a

certain extent, in architectural and building

applications, and expects the laser to open up

new markets in these areas. This will prove

especially important, because H.W. depends

on manufacturers more than any industry

segment for business, and its work with

manufacturers cycles in ways that business

with fabricators and the construction

industry doesn’t, Suter explained. Because of

this, expanding into new markets with the

help of the laser may prepare the company

to work through slowdowns in the

manufacturing industry.

“We don’t make a product; we are an

extension of our customer’s shop and

consider ourselves a local outsource option,”

he said. “We don’t have an engineering staff.

We work off of customer drawings and

consider ourselves anecdotal engineers.”

Reprinted with permission from THE FABRICATOR.

February, 2009.


CUSTOMER PROFILE

Ventilation Manufacturer Clears

the Air on Higher Productivity

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.

Since its founding in 1987, Fantech Ltd.,

Bouctouche, NB, has manufactured

products that provide “ventilation

solutions” to improve air quality for residential

and commercial applications. In addition to its

modern 130,000-square-foot facility in New

Brunswick, Fantech has another manufacturing

facility in Lenexa, KS, and distribution centers

in Reno, NV, Lenexa, KS, and Mississauga,

ON. Fantech's parent company, Sweden-based

Systemair, has a global network of 50

subsidiaries on three continents, making the

Systemair Group one of the largest air

movement companies in the world.

Fantech’s product line includes:

■ Inline fans for bathroom exhaust, dryer

boosting and radon mitigation.

■ A full line of indoor air quality

equipment, such as heat recovery and

energy recovery ventilators, and whole

house HEPA filtration.

■ Larger CFM fans for commercial

applications such as inline centrifugal

fans for round, square and rectangular

duct, exterior mounted centrifugal fans

for wall and roof, multi-port centrifugal

fans, low-silhouette axial fans and air

curtains.

■ New rooftop enthalpic wheel units for

commercial applications.

According to Ron Caissie, Fantech’s

production manager, the company had

traditionally grown 15 - 20% per year, until

the recent dip caused by the current

recession. “The benefits of our products are

superior quality, high energy efficiency and

low power consumption,” explains Caissie.

“Our EBM motors are recognized as the best

in the world.”

Increasing Capacity

Prior to 2007, Fantech fabricated its sheet

metal with two stand alone hydraulic turret

punch presses. “We began running three

shifts during the summer and didn’t have

enough capacity to keep up with increased

demand,” explains Caissie. Fantech began its

search for new equipment and visited

FABTECH, where Caissie and his team first

saw the Finn-Power Shear Genius flexible

manufacturing cell. “We were familiar with

Finn-Power since our parent company,

Systemair, has three Shear Genius cells and a

Night Train material management system in

its plant in Sweden. However, we had the

final decision on which equipment to

choose. We looked at other machines, but

selected the Finn-Power because of the

quality of the Shear Genius.”

Punch/Shear Combination

With the Shear Genius concept, the objective

is to provide one machine capable of

transforming a full-sized sheet into finished

parts. These parts can be moved to final

production stages for immediate integration

directly into final product assembly. The

Shear Genius accomplishes all of this in less

18

floor space – approximately 30 feet (9

meters) of space to fabricate raw material

into finished parts on one machine. 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.

“We liked the punch/shear

combination concept. It has

improved our quality. Before,

we had to shake the parts and

contend with micro joints and

skeletons. With the Shear

Genius, the parts come out to

a bin sorted and go directly to

the bending operation.”

These features can be added later as budgets

allow and production demands increase.

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.

“We liked the punch/shear combination

concept,” says Caissie. “It has improved our

quality. Before, we had to shake the parts

and contend with micro joints and skeletons.

With the Shear Genius, the parts come out

to a bin sorted and go directly to the

bending operation.”

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.


“Today, we are down to six

stacks because the Shear

Genius can utilize 8 x 5

sheets. This has increased

our sheet metal utilization

by 10% and decreased our

metal inventory.”

Better Sheet Metal

Utilization & Flexibility

“To fabricate our products, we use six

different gauges of sheet metal”. Before the

Shear Genius, we needed 3 different sizes of

sheets for each gauge in order to try to

minimize waste. This meant that we had to

stock 18 different stacks of metal product.

Today, we are down to six stacks because the

Shear Genius can utilize 8 x 5 sheets. This

has increased our sheet metal utilization by

10% and decreased our metal inventory. It

has given us more options because we can

now nest the parts on a full-sized sheet.”

Fabrication at Fantech has also become

more flexible with the Finn-Power Shear

Genius. “We used to program parts for units

using various multiples,” continues Caissie.

“We would try to optimize the sheet

utilization by making a predetermined

multiple of the finished product. Unit

multiples varied from 6 to 63. This works well

with the high-volume items, but with lowvolume

products, sometimes we only needed

three units. The remainder of the parts for

With the Shear Genius concept, as loading, punching

(above), and shearing (below) of parts become automated,

the result is finished parts with a dramatic reduction in scrap

and manual labor while increasing profitability.

that unit went to inventory. With the Shear

Genius, if we need three units, we program

and make the parts for three units. This has

given us a lot more flexibility and has reduced

our finished parts in inventory. Now we only

build what we need for production.”

Other benefits of the Shear Genius 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 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.

“With the Shear Genius, if we

need three units, we program

and make the parts for three

units. This has given us a lot

more flexibility and has

reduced our finished parts in

inventory. Now we only build

what we need for production.”

■ 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. Fantech

has five 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. “We have

three Multi-Tools and they have helped

us dramatically cut set up times,” explains

Caissie. “With our old turret punch

presses, we were down 10-15 minutes

every hour for tool changes. With the

Shear Genius, we are down about 30

minutes per day for tool changes.”

19

Ron Caissie, Fantech’s production manager reports that

today, 99% of Fantech’s sheet metal fabrication is processed

through the Shear Genius. “The Shear Genius is much

more efficient than our previous presses. With ‘lights out’

operation, it has allowed us to delay adding a second shift.”

■ 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. Fantech

has four upforming stations.

■ Labor & tooling savings – Prior to

installing the Shear Genius, Fantech had

two CAD programmers and two machine

operators. Today, that number has been

reduced to just two employees who split

the programming and machine operator

duties. “Now the machine operator can

perform other duties while the Shear

Genius in running,” adds Caissie.

There has also been a substantial savings in

tooling costs. “We got only 30,000 hits per tool

before sharpening was required with the old

turret punch press,” says Caissie. “We get

about 300,000 hits per tool with the Shear

Genius. In addition, we had two employees,

one per shift, sharpening tools all day. Our

tooling cost was approximately $100,000 per

year. Now we do weekly maintenance of the

machine and sharpen maybe 10 tools per

week. The Shear Genius has dramatically cut

our tooling costs.”

Today, 99% of Fantech’s sheet metal

fabrication is processed through the Shear

Genius. Although demand has decreased due

to current economic conditions, Caissie says

the Shear Genius has increased Fantech’s

productivity by 10%. “The Shear Genius is

much more efficient than our previous

presses. With ‘lights out’ operation, it has

allowed us to delay adding a second shift.”


FOCUS ON CANADA

Prima Finn-Power Brings Laser and Bender to CMTS

The Canadian Manufacturing Technology Show was held

October 19–22 at the Direct Energy Centre in Toronto,

ON. Prima Finn-Power North America exhibited the

following equipment:

■ Platino 2D laser system featuring a new 3-lense cutting head

that greatly expands its cutting capabilities.

■ Fast Bend – a flexible, servo-electric bending machine that is

revolutionizing the world of press brakes.

■ E Series servo-electric press brake. This press brake is a fast,

accurate bending solution.

Prime Time Product

Ahighlight of the show was the appearance of Mike Stock, bending product

manager, on the popular Citytv Breakfast Television program. Mike taught the

Citytv reporter how to operate the Fast Bend on air and explained the number

of applications it can perform. The video can been viewed at www.finnpower.com

20


555 W. Algonquin Road, Arlington Heights, IL 60005

Tel. +1 847 952 6500 www.primafinnpower.us

New from Prima Finn-Power, the FAST BEND – a flexible, servo-electric bending

machine that will revolutionize the world of press brakes. The FAST BEND can bend

5 different parts with different thicknesses and alloys in just 5 minutes.

17 21

The FAST BEND features include:

■ 3X faster than the fastest press brake

■ Automatic tool change

■ Eliminates setup time

■ Skilled operator free – operator’s only duties

are load, rotate, and unload the panel

■ Scan the bar code containing product

information to begin process

■ Perfect for single piece flow, high-mix / low

volume production orders

■ High accuracy, high quality

Increased bending flexibility

Can your press brake bend 5 different parts

in just 5 minutes? For a free brochure and

video, contact us today!


IN THE NEWS

Customer Profile Articles & Videos on the Web

Prima Finn-Power sheet metal fabrication technology and its customers continue to attract a great

deal of attention from trade publications throughout North America. Now these articles and select

customer profile videos are available on the Prima Finn-Power website.

These are just a few of the articles available on the Prima Finn-Power website. Prima laser customer

profile articles and videos will be added to this section throughout 2010. To access these articles and

videos, go to: www.finnpower.com/html/customer_profiles.html

WOODSTONE CORPORATION, Bellingham, WA

Finn-Power Equipment:

Laser Brilliance, Night Train, EBe automated bender, servo-electric E Brake with robot, two

stand alone servo-electric E Brakes.

Customer Comments:

“We outsourced $4-million of parts with sub-contractors in 2007. By the end of 2008 we should be doing

90% in-house. In five months, we are halfway to having the system pay for itself. It is already paying for

itself in better products and inventory reduction.”

Click for Article Click for Video

Click for Article

Click for Article

Click for Article

KING ELECTRIC MFG. COMPANY, Seattle, WA

Finn-Power Equipment:

C5 Compact Express.

Customer Comments:

“With the old method of production, our cost was $9/grille. With Finn-Power, our cost is $3/grille. We make

60,000 of these parts a year. In addition, the C5 Express has allowed us to bring all of the $250,000

outsourcing to job shops back in-house. That was a plus to the bottom line from the first day the C5 Express

was installed.”

JB RADIATOR SPECIALTIES, INC., Sacramento, CA

Finn-Power Equipment:

Shear Genius FMC, servo electric E brake.

Customer Comments:

“It was the productivity and flexibility of the Finn-Power Shear Genius that swung the deal for us. We

fabricate many square and rectangular parts…and you can’t produce then faster than on the Shear Genius.”

EPMP, INC., Sequin, TX

Finn-Power Equipment:

2 Shear Genius FMCs, Night Train, EBe automated bender, two hydraulic press brakes

with robots.

Customer Comments:

“In order to stay ahead of the competition, you have to automate. You have to take some additional risks that

perhaps the rest of the industry may not be willing to take. When we decided to automate, we raised the bar

for the rest of the industry in our area. We can now compete on fabricated parts from Mexico and China.”

22

Click for Video

Click for Video

Click for Video


FOCUS ON TOOLING

By John Galich, Marketing Manager, Mate Precision Tooling

Eliminate Secondary Operations at the Turret

Intoday’s economy, fabricators are

looking hard for opportunities to reduce

costs in their businesses. Secondary

operations are a great place to look because

they add cost, not value. Believe it or not,

your turret press can help you can eliminate

steps and enhance efficiencies. The most

obvious point to maximize value add is

when the part is manufactured in the press,

which can help streamline downstream

processes.

One good example are machined

countersinks, such as the one shown in the

picture above. Once the part is made, you

need to take the part to another work

station to machine the countersink, which is

non value-added time. You can skip the

entire machining step by making the

countersinks directly on the turrets using a

forming tool. Simply form them up or

down, as required by the job and take the

part to the next manufacturing station.

Mate offers a number of standard

solutions to make it easy for you to

eliminate such non-value added steps. You’ll

also get higher piece part quality, satisfied

customers and reduced costs. Let’s start with

our newest—Mate’s Rollerball Deburr tool

for thick turret punch presses.

Rollerball Deburr Tool

The punching process frequently causes

burrs on sheet metal parts. They’re

unavoidable. Removing them requires

secondary deburring operations that are

either performed manually or used

specialized equipment. Mate’s Rollerball

Deburr tool helps you eliminate these costly

secondary operations right at the turret!

The Mate Rollerball Deburr tool takes

advantage of Mate’s Rollerball technology,

which uses the extended programming

capabilities of turret presses that can operate

in the x and y axis with the ram down.

Rollerball Deburr pushes the burr away

and creates a radius on the side of the part.

Using a special ball in both the upper and

lower part of the tool, every possible part

contour can be processed—even small

corners. Mate Rollerball Deburr can be used

with mild steel, stainless steel and aluminum

materials. Rollerball Deburr comes complete

with everything you need, including three

springs that allow you to adjust the tension

appropriate to the material being punched.

Two more of Mate’s standard solutions

to eliminate secondary operations include:

■ HexLock, which provides a method of

retaining common hexagon fasteners in

sheet metal.

■ SnapLock, our ingenious solution to

making fabricated joints in sheet metal

without welding.

By using Mate’s HexLock tool, you can

retain common threaded fasteners and

eliminate pressed-in inserts. Mate HexLock

uses the CNC precision of the press to

assure accurate and reliable fastener

locations. The fastener is securely gripped

between the forms to prevent rotation. Since

conventional hexagon fasteners are less

expensive and more readily available than

self-clinching fasteners or weld-nuts, you’ll

save even more.

Mate’s SnapLock, which can be sized

and shaped for your specific requirements, is

23

our ingenious solution that replaces rivets

and welding. SnapLock allows the part to be

locked automatically when formed,

eliminating a secondary operation. The

assembly allows users to join materials, even

if they are of dissimilar type and/or

thickness, thus eliminating expensive

secondary operations such as spot welding,

riveting or fastening with threaded

hardware. With SnapLock, you can create

fabricated assemblies efficiently, effectively

and with CNC precision.

Other Cost-Saving Mate Products

Many other opportunities abound, too.

Operators often have difficulty removing

nested parts from a sheet. The number of

tabs, frequently thick, increase production

time and reduce quality. There is a better

way and that is Mate’s EasySnap scrapless

part retention system. EasySnap creates a Vline

stencil from both sides, creating a snapline.

This allows the components to be

snapped out of the sheet. EasySnap is

available for all tooling styles. Visit

mate.com/easysnap to see a video of

EasySnap in action.

Also available for all tooling styles is

Mate’s EasyBend, which makes complex

bending easy! The tool creates a V-line

stencil, which is a line of weakness. This

allows subsequent bending of the part

by hand.

If you have a secondary operation you

want to eliminate that is not covered by one

of Mate’s standard solutions, our team of

custom design engineers and applications

specialists has helped hundreds of customers

solve their issues. They can create a custom

solution for you quickly and affordably.

Standard or custom, all Mate products are

backed by world-class field support and

100% satisfaction guarantee.

For more information about Mate

tooling systems for Finn-Power punch

presses, please visit mate.com/finn-power.

If you want to learn more on how Mate’s

Custom Engineering group can help you,

please visit mate.com/sa and

mate.com/gallery.


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

PRIMA INDUSTRIE S.p.A

Via Antonelli, 32

10097 Collegno (To)

ITALY

Tel. +39 011 4103 1

Fax. +39 011 411 28 27

www.primaindustrie.com

PRIMA FINN-POWER

NORTH AMERICA, INC.

555 W. Algonquin Road

Arlington Heights, IL 60005

U.S.A.

Tel. +1 847 952 6500

Fax. +1 847 952 6530

www.finnpower.com

Happy Holidays...

Happy Holidays...

from all of us at Prima Finn-Power

PRIMA FINN-POWER

NORTH AMERICA, INC.

711, East Main Street

Chicopee, MA 01020

U.S.A.

Tel. +1 413 598 5200

Fax. +1 413 598 5201

www.prima-na.com

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