“Finn-Power is the only machine builder that took a position on the ...

World Cup,
Fabrication
and Teamwork
Technological Advances
Help Level Playing Field
Through Unmanned
Operation and Increased
Production See Page 3
Euros Zoned
in on Competing
Metal Fabricating
Doesn’t Have to
D<strong>is</strong>appear in Western
Societies… See Page 6
A Bridge to
Higher Productivity
Argentina’s FIMAQH
Showcases X5 Turret
Punch Press See Page 25
Laser
Automation
Sparks Productivity
Volume 16 Issue 1 July 2006
<strong>“Finn</strong>-<strong>Power</strong> <strong>is</strong> <strong>the</strong> <strong>only</strong>
<strong>machine</strong> <strong>builder</strong> <strong>that</strong> <strong>took</strong> a
<strong>position</strong> on <strong>the</strong> front end of
material management…” See Page 4
A Finn-<strong>Power</strong> Publication
Americas Edition
A Breath of
Fresh Air for Sheet
Metal Fabrication
Venmar Sets Industry
Standard for Ventilation
Innovation with Finn-<strong>Power</strong>
Shear Brilliance See Page 14
NC Express ®
Software
CNC Programming
Software Manages
Finn-<strong>Power</strong> Equipment in
<strong>the</strong> Most
Efficient
Manner
See Page 10
In <strong>the</strong> News… Making
Headlines
with <strong>the</strong>
Trade
Press
See Page 18
Tooling Articles…
Mate Prec<strong>is</strong>ion
Tooling See Page 12
Wilson Tool
International See Page 20
Wila USA See Page 24

TECH TIPS
Tips and Techniques for
Punching Thicker Materials
Punching thicker materials with modern high-speed punching
<strong>machine</strong>s – both stand-alone or combination units and with or
without <strong>the</strong> latest high-speed drive linear technologies – can be a
challenge if attention <strong>is</strong> not paid to certain critical aspects of <strong>the</strong> punching
process.
Most sheet metal shops are familiar with <strong>the</strong> problems <strong>that</strong> can be
encountered when punching 10GA HRS (0.135" /3.4 mm) material: Punches
sticking in <strong>the</strong> sheet, which <strong>the</strong>n precipitates <strong>the</strong> heavy sheet being torn out of
<strong>the</strong> clamps and often results in index/turret m<strong>is</strong>alignments along with o<strong>the</strong>r
<strong>machine</strong> damage – and often significant <strong>machine</strong> downtime.
The problems are compounded when large sheets (120" x60" /
3.0 m x 1.5 m) of th<strong>is</strong> material are run at <strong>the</strong> uppers limits of <strong>the</strong> fast
punching speeds of <strong>the</strong> new generation of <strong>machine</strong>s. A good analogy for th<strong>is</strong>
scenario would be running a brand new sports car with worn, low-speed rated
tires at close to maximum speed down a gravel road with potholes. While <strong>the</strong>
vehicle <strong>is</strong> capable of 200+ km/hr with high-speed rated tires with good tread
depth on a freeway it <strong>is</strong> almost certain to crash on <strong>the</strong> gravel road at those
speeds with worn inappropriate tires.
So it <strong>is</strong> with punching
thicker hard materials. The
tires are <strong>the</strong> tooling, which if
it <strong>is</strong> worn and has <strong>the</strong>
incorrect die clearance for <strong>that</strong>
material, will cause problems.
The speed of <strong>the</strong> ram should
be related to <strong>the</strong> thickness of
<strong>the</strong> material just like <strong>the</strong>
condition of <strong>the</strong> road <strong>is</strong>
related to <strong>the</strong> speed of <strong>the</strong> car
NC Express 11.0 series <strong>machine</strong> Punch Speed settings.
traveling on it.
Punch tooling can be
made for high-speed use, hence <strong>the</strong> term high-speed steel. Th<strong>is</strong> <strong>is</strong> an often used
term for M grade tool steels such as M2 and M4. When such punch tools
with <strong>the</strong> correct die clearances are used in a fully guided assembly with a
micro fine grind fin<strong>is</strong>h and <strong>the</strong> appropriate back taper (1 deg), <strong>the</strong>y are
enormously strong and res<strong>is</strong>t wear when punching in thicker abrasive material
such as 10 Ga HRS.
Combine th<strong>is</strong> with rooftop shear on <strong>the</strong> punch of at least 0.125" (3 mm)
which significantly reduces <strong>the</strong> tonnage required to punch through <strong>the</strong>
material and you have a tool capable of easily standing up to HRS.
Next you should utilize <strong>the</strong> electronic PUNCH_SPEED(*,*) command
The FINN-ISH LINE <strong>is</strong> a publication
d<strong>is</strong>tributed to Finn-<strong>Power</strong> customers,
prospective customers, employees, dealers,
suppliers, and friends.
The staff of <strong>the</strong> FINN-ISH LINE requests
article ideas and letters for future publication.
Editor
Robert J. Kolcz rjk@finnpower.com
Associate Editor
Tiina Alanko tiina@finnpower.com
Technical Editor
Lutz Ehrlich lehrlich@finnpower.com
Contributing Editor
Andrew McCarlie mccarlie@finnpower.com
Senior Correspondent
Timo Laurinen timo.laurinen@fcorp.com
available in <strong>the</strong> newer <strong>machine</strong>s
(which controls both <strong>the</strong> up
and down parts of <strong>the</strong> stroke
independently), or <strong>the</strong> H2=
command in older <strong>machine</strong>s to
reduce <strong>the</strong> ram speed to a value
appropriate for <strong>the</strong> material
being punched. (See <strong>the</strong> FINN-
ISH LINE <strong>is</strong>sue from December
2004 for <strong>the</strong> tool control
mechan<strong>is</strong>m Tech Tips article.)
Th<strong>is</strong> speed change value
can be set in <strong>the</strong> Controlink
software of <strong>the</strong> newer <strong>machine</strong>s
or <strong>the</strong> tool table of <strong>the</strong> older
<strong>machine</strong>s. However as th<strong>is</strong> must
be changed by <strong>the</strong> operator
every time <strong>the</strong> material <strong>is</strong>
All reg<strong>is</strong>tered trademarks in th<strong>is</strong> publication are property of
<strong>the</strong>ir respective owners. 2
by Andrew McCarlie, Applications Engineer
changed a quicker way <strong>is</strong> to utilize <strong>the</strong> setting of <strong>the</strong> Ram speed by
using <strong>the</strong> die clearance option in NC Express. Th<strong>is</strong> allows you to
output automatically in <strong>the</strong> code ram speeds <strong>that</strong> are tied to a
particular die clearance thus avoiding any operator intervention.
Several die clearances can be used if required.
Below <strong>is</strong> a table of suggested Punch speeds for different materials
when high speed punches combined with <strong>the</strong> correct die clearances
and rooftop shear on punches 1.0" / 25 mm square and larger.
Material Thickness Punch Speed Sheet Lube Rooftop Shear on Punch
CRS

PRESIDENT’S CORNER
World Cup, Fabrication
Equipment & Teamwork
While recently watching <strong>the</strong> World
Cup from Germany on telev<strong>is</strong>ion, I
was struck by <strong>the</strong> many similarities
between World Cup soccer (football) and <strong>the</strong> sheet
metal fabrication equipment industry. I should
clarify <strong>that</strong> I am not referring to <strong>the</strong> unfortunate
physical confrontation at <strong>the</strong> end of <strong>the</strong>
championship match between Italy and France –
although I guess in all of our careers we may have
felt like we’ve been “headbutted” at one time or
ano<strong>the</strong>r. Ra<strong>the</strong>r, I am talking about <strong>the</strong> game plan,
teamwork, and selfless play <strong>that</strong> often spells <strong>the</strong>
difference between victory or defeat in <strong>the</strong> game of
soccer…and <strong>machine</strong> tool sales.
While not extremely popular in <strong>the</strong> U.S., <strong>the</strong>
World Cup <strong>is</strong> <strong>the</strong> most <strong>the</strong> widely watched
sporting event in <strong>the</strong> world and has been held
every four years since 1930, with <strong>the</strong> exception of
<strong>the</strong> years during World War II. Talk about
globalization, 198 nations attempted to qualify for
<strong>the</strong> 2006 World Cup. Th<strong>is</strong> number was pared
down to <strong>the</strong> 32 nations <strong>that</strong> actually competed in
<strong>the</strong> World Cup.
In <strong>the</strong> sheet metal fabrication industry, Finn-
<strong>Power</strong> technological advances in punching,
forming, laser cutting, bending, and automated
material management have created a global market
for our <strong>machine</strong>s, cells, and systems. Many
companies are reaching outside traditional
geographic borders to attract international
Host team Germany, in <strong>the</strong> red jerseys, played one of <strong>the</strong> many
competitive matches of <strong>the</strong> 2006 World Cup against Argentina.
LUBRICATE (X1…X6)
X1 X-coordinate of lower left corner
X2 Y-coordinate of lower left corner
X3 X-coordinate of upper right corner
X4 Y-coordinate of upper right corner
X5 Ax<strong>is</strong> speed F (mm/min or in/min)
X6 Selection of sheet lubricator (1 or 2; extra option)
The subroutine sprays <strong>the</strong> rectangular area determined by parameters
X1…X4. The coordinates are given from <strong>the</strong> actual zero point (from
sheet corner if no zero point offsets have been made). Even after
re<strong>position</strong>ing (REPOSIT) <strong>the</strong> coordinates are given from <strong>the</strong> sheet
corner. Ax<strong>is</strong> speed <strong>is</strong> determined with parameter X5, and with th<strong>is</strong>
value you can regulate <strong>the</strong> amount of lubricant coming onto <strong>the</strong> sheet.
At <strong>the</strong> end of subroutine LUBRICATE, ax<strong>is</strong> speed <strong>is</strong> set to maximum.
business. And while some developing
countries have huge labor costs advantages,
Finn-<strong>Power</strong>’s technological advances have
helped level <strong>the</strong> playing field through
unmanned operations and increased
production.
Soccer Teams
The objective of <strong>the</strong> game of soccer <strong>is</strong> to
simply score more goals than your opponent
by putting <strong>the</strong> ball past <strong>the</strong> goalkeeper into a
net. Each team has 11 players on <strong>the</strong> field.
Even though <strong>the</strong> players on a team may have
different talent levels and styles, <strong>the</strong>
optimum <strong>is</strong> to have all 11 play as a team
with a game plan to defeat <strong>the</strong> opponent.
The player <strong>position</strong>s include:
Forwards (striker & wings) – players
<strong>that</strong> are usually <strong>the</strong> scorers.
Midfielders (halfbacks) – players <strong>that</strong>
are links for both offense and defense.
Defense (fullbacks) – players <strong>that</strong> are
defenders. Fullbacks prevent shots
from being taken, without blocking
<strong>the</strong>ir goalie’s view.
Goalkeeper – <strong>only</strong> player <strong>that</strong> can
touch, hold or bounce <strong>the</strong> ball in <strong>the</strong>
penalty area. The goalie’s main job <strong>is</strong>
to prevent <strong>the</strong> o<strong>the</strong>r team from
scoring.
Finn-<strong>Power</strong> Team
The Finn-<strong>Power</strong> team cons<strong>is</strong>ts of
R &D and design engineers, sales &
marketing personnel, service and
application technicians, and various
support groups. While our employees
have different levels of experience and
various styles, teamwork <strong>is</strong> <strong>the</strong> key
ingredient to our past, present, and
future success.
A short-term goal of <strong>machine</strong> tool
<strong>builder</strong>s <strong>is</strong>, of course, to sell more
<strong>machine</strong>s than its competitors.
However, Finn-<strong>Power</strong>’s game plan <strong>is</strong> not
so myopic. We believe <strong>that</strong> success in
today’s sheet metal fabrication industry
depends not <strong>only</strong> upon an equipment
manufacturer’s ability to meet its customers’
current needs, but also upon its v<strong>is</strong>ion and
strength to anticipate and respond to future
changes in <strong>the</strong> marketplace.
The new marketplace realities match
Finn-<strong>Power</strong>’s product line perfectly. For
many years, Finn-<strong>Power</strong> has added versatility
to individual work stages by integrating <strong>the</strong>m
with automated material management and
making automation as flexible as possible.
Our game plan has always been to improve
3
by Mikko Lindstrom, President
our customers’ productivity and profitability by
giving <strong>the</strong>m a competitive edge.
Today, we have proven globally
acknowledged solutions for any sheet metal
fabrication need with a variety of work stages
and methods. In addition, we not <strong>only</strong> have <strong>the</strong>
modules for optimal automating process
material flow, but also <strong>the</strong> application
engineering knowledge to specify <strong>the</strong> optimum
in each case. Our
product range <strong>is</strong>
wide enough so
<strong>that</strong> our customers
do not have to
comprom<strong>is</strong>e to
achieve Lean
Manufacturing in
<strong>the</strong>ir fabrication
facilities.
Integrating
<strong>machine</strong>ry to work
toge<strong>the</strong>r seamlessly
from part to part
and operation to
operation has been
resolved by Finn-
<strong>Power</strong>’s Night
Train Flexible
Manufacturing
System. In addition to punching, shearing,
and/or laser cutting, <strong>the</strong> Night Train allows <strong>the</strong>
addition of robotic press brakes or an in-line
panel bender to automate <strong>the</strong> bending process.
Th<strong>is</strong> system allows customers to bend <strong>only</strong> <strong>the</strong>
parts <strong>that</strong> are needed for today’s production
while allowing <strong>the</strong> parts to be bent in different
sequences than <strong>the</strong>y were punched to match
assembly needs. Th<strong>is</strong> eliminates extra work in
process while increasing throughput.
A Winning Message
There are several articles in th<strong>is</strong> <strong>is</strong>sue of <strong>the</strong>
FINN-ISH Line <strong>that</strong> present excellent examples
of how Finn-<strong>Power</strong>’s flexibility and
technological advantage have helped our
customers increase production and profitability.
One such article, starting on page 6, <strong>is</strong> a reprint
from <strong>the</strong> July, 2006 <strong>is</strong>sue of The FABRICATOR
<strong>that</strong> details last April’s Editor Technology Trip
to Finland and Italy. Executive Editor Dan
Dav<strong>is</strong> has written a very thoughtful and
intelligent report on what he saw as well as an
analys<strong>is</strong> of common challenges and solutions for
both European and North American fabricators.
Great team players, a proven game plan of
technological advances, and selfless teamwork
allow Finn-<strong>Power</strong> to successfully compete in <strong>the</strong>
daily World Cups of sheet metal fabrication.

CUSTOMER PROFILE
Laser Automation Sparks Productivity
at Great Lakes Manufacturing, Inc.
When Great Lakes Manufacturing,
Inc., Corry, PA, began operations
in 1998 as a prec<strong>is</strong>ion sheet
metal fabrication shop, its original function was
to be a supplier to s<strong>is</strong>ter company Great Lakes
Case & Cabinet. However, th<strong>is</strong> modest
objective was met and dramatically exceeded
thanks to a stellar performance by <strong>the</strong>
company’s management and employees.
“Currently, we have 102 employees and about
60% of our business <strong>is</strong> for our s<strong>is</strong>ter company
and 40% <strong>is</strong> for contract customers,” explains
Robert Low<strong>the</strong>r, owner.
According to Low<strong>the</strong>r, h<strong>is</strong> company’s
philosophy of investment in people and in <strong>the</strong>
latest technology helped to make Great Lakes
Manufacturing a leader in prec<strong>is</strong>ion sheet metal
fabrication. “Our manufacturing plant occupies
over 90,000 square feet in prime location along
<strong>the</strong> I-90 and I-79 corridors of northwestern
Pennsylvania,” says Low<strong>the</strong>r. “We’ve tried to
<strong>position</strong> ourselves as one of a handful of
fabricators <strong>that</strong> have our level of capabilities.
The latest technology combined with a
commitment to lean manufacturing are <strong>the</strong>
ways <strong>that</strong> we have attempted to differentiate
ourselves,” Low<strong>the</strong>r continues. “Automation,
robotics, information technology, and a high
level of employee skill allow us to be
competitive in a global economy. In <strong>the</strong>
past two years, we have invested more <strong>that</strong>
$3-million into our facility.”
Part of <strong>that</strong> investment was earmarked for
<strong>the</strong> procurement of a new laser in 2004. Fred
Cooke, director of engineering /MIS, was
chosen to search <strong>the</strong> marketplace for <strong>the</strong> latest
laser technology. Cooke began <strong>the</strong> search during
<strong>the</strong> second quarter. “I began with some of <strong>the</strong>
big traditional names in <strong>the</strong> laser industry,” he
explains. “I v<strong>is</strong>ited several companies and
thoroughly investigated <strong>the</strong> best lasers on <strong>the</strong>
market. I sent <strong>the</strong> same time study to each of
<strong>the</strong>se companies. I also came across <strong>the</strong> Finn-
<strong>Power</strong> L6 Laser Work Center. Finn-<strong>Power</strong> was a
name I first heard in Europe.
“I sent <strong>the</strong> same time study to Finn-<strong>Power</strong>.
When <strong>the</strong> time studies of <strong>the</strong> same nesting run
came back, Finn-<strong>Power</strong>’s time was 60% faster
than <strong>the</strong> next best time. It was a massive
production improvement. We also received
some parts back so we were able to check <strong>the</strong>
Great Lakes Manufacturing uses technology, like <strong>the</strong> Finn-
<strong>Power</strong> laser and automated material handling equipment,
to differentiate itself from competitors.
edge quality and everything worked out very
well. We selected <strong>the</strong> L6 with load/unload and a
10-shelve storing tower which was installed in
December, 2004.”
The Finn-<strong>Power</strong> L6 Laser Work Center
utilizes a flying optics/moving beam system
driven by a linear drive motor system to achieve
maximum speeds, even while cutting small
notches or narrow contours.
The L6 features a 4 kW fast axial flow CO 2
laser. Cutting speeds up to 60 m/min
(2.362" /min) are reached using nitrogen as
cutting ass<strong>is</strong>t gas. The L6 can process sheet sizes
“Over <strong>the</strong> last 1 1/2 years, we’ve had a heavy flow of lean
manufacturing – we’re not batch manufacturing
anymore. We are producing a lean flow with Finn-
<strong>Power</strong> automation.”
up to 60" x 120" and up to 0.78" in thickness.
Performance values include a <strong>position</strong>ing speed
of 11,811" /min., acceleration over 2 g, and
cutting speeds up to 2,363" /min. Unlike
conventional re<strong>position</strong>ing, where straight line
movements of <strong>the</strong> cutting head waste time,
Finn-<strong>Power</strong> optimizes <strong>the</strong> cutting head
movement with “Ping Pong” re<strong>position</strong>ing. Th<strong>is</strong>
smooth and efficient transition translates to
added production speeds – up to 1,000
holes/min are now possible. The patented L6
rigid frame design withstands all <strong>the</strong> forces of
high-speed <strong>position</strong>ing and provides a solid base
for stable beam delivery optics.
4
Robert Low<strong>the</strong>r, owner (left) and Fred Cooke, director
of engineering/MIS, report <strong>that</strong> <strong>the</strong> L6 laser has
allowed Great Lakes to fully embrace lean/flow
manufacturing.
Automation <strong>is</strong> Key
According to
Cooke, automation
was ano<strong>the</strong>r key
reason for choosing
Finn-<strong>Power</strong>. “With
o<strong>the</strong>r lasers, automation
involved taking down an
entire shelf of material and
working with <strong>that</strong>,” reflects
Cooke. “With <strong>the</strong> L6, we take
down one sheet at a time, so we
can nest and kit parts. I can run
a 13 gauge sheet and <strong>the</strong>n a sheet
of 16 gauge and <strong>the</strong>n a sheet of
aluminum…and build up kits <strong>that</strong>

way. Over <strong>the</strong> last 1-1/2 years, we’ve had a
heavy flow of lean manufacturing – we’re not
batch manufacturing anymore. We are
producing a lean flow with Finn-<strong>Power</strong>
automation.”
“Prior to our purchase of <strong>the</strong> L6, we
compiled a matrix of all lasers <strong>that</strong> were
currently on <strong>the</strong> market,” adds Low<strong>the</strong>r, “and
<strong>the</strong> Finn-<strong>Power</strong> L6 was <strong>the</strong> most proficient for
our needs. When we started to take a look at
<strong>the</strong> o<strong>the</strong>r offerings from Finn-<strong>Power</strong>, <strong>the</strong>re was
one common denominator <strong>that</strong> kept jumping
forward: Finn-<strong>Power</strong> was <strong>the</strong> <strong>only</strong> <strong>machine</strong>
<strong>builder</strong> <strong>that</strong> <strong>took</strong> a <strong>position</strong> on <strong>the</strong> front end in
material management – for <strong>the</strong> o<strong>the</strong>r <strong>builder</strong>s it
looked like an afterthought.”
Thinking Thin
On <strong>the</strong> L6, Great Lakes runs anything from
24 gauge cold rolled steel to 1/4" hot rolled
steel; .060" - 3/16" aluminum; and 20 gauge -
13 gauge stainless. “The high productivity of
<strong>the</strong> L6 in thinner sheets <strong>is</strong> very important,”
explains Cooke. “That’s where <strong>the</strong> <strong>machine</strong>
comes into its own versus <strong>the</strong> competition.
O<strong>the</strong>r laser <strong>builder</strong>s make 5 kW resonators and
different laser beam shapes and styles <strong>that</strong> will
do beautiful jobs on big thick sheets – but we’re
not a thick sheet producer. We don’t do plate
work. We fabricated thin sheets. So high speed
and high quality in thin sheets <strong>is</strong> very important
for us.”
About 60% of <strong>the</strong> material Great Lakes
puts on <strong>the</strong> L6 <strong>is</strong> between 16 -14 gauge cold
rolled steel. Currently, <strong>the</strong> L6 <strong>is</strong> running 20
hours/day, 5 days per week. “We are at a stage
now where <strong>the</strong> operator <strong>is</strong> doing h<strong>is</strong> own
nesting,” explains Cooke. “So when we have
demand for parts, <strong>the</strong> paperwork for XYZ part
comes to <strong>the</strong> operator and <strong>the</strong> operator will
make h<strong>is</strong> own nests, because he knows how <strong>the</strong>
<strong>machine</strong> runs best. He knows where he wants to
put h<strong>is</strong> crop lines and h<strong>is</strong> scrap cuts…what
should be tapped, where, and how. We found
<strong>that</strong> by letting <strong>the</strong> operator do <strong>the</strong> nesting, it
brought a huge improvement on producing <strong>the</strong>
parts – we’re not relying on an
engineer in an office to
pump out nests.”
The L6 replaced
two older technology
turret punch presses
and has enabled
Great Lakes to
add 30 - 40% to its
output. “The biggest
impact has not been <strong>the</strong>
mass of parts <strong>that</strong> we’ve been
making…but <strong>the</strong> flexibility,” says
Cooke. “Now we can make one part
without a setup. We do a certain amount of
business in what <strong>is</strong> called design changes. We
sell a standard product – 19" rack mounts for
IT industry. If a customer wants a fan in a
certain spot on <strong>the</strong> door or <strong>the</strong>y
want a different networking coil,
and <strong>the</strong>y <strong>only</strong> want one or two of
<strong>the</strong>se parts, a traditional punching
sheet metal shop would have a
hard time making <strong>the</strong>se few parts
at a competitive price. But <strong>the</strong> L6
has enabled us to reduce setup so I
can make fewer parts for <strong>the</strong> same
price as doing a large batch. Th<strong>is</strong> helps in
customer sat<strong>is</strong>faction. We are able to turn <strong>the</strong>
one and two units instead of doing <strong>the</strong> 50’s and
100’s with <strong>the</strong> same net effect…and still
maintain profitability.”
Cooke continues: “With <strong>the</strong> laser, we are
able to do slots and tabs <strong>that</strong> you wouldn’t
normally do with some of <strong>the</strong> o<strong>the</strong>r punched
parts. You get a clean edge. We’re cutting with
nitrogen most of <strong>the</strong> time, and we <strong>only</strong> cut
oxygen when we are going 10 gauge and thicker
in cold rolled steel and some hot rolled steels.
By cutting with nitrogen, we’re not getting <strong>the</strong>
oxide layer on <strong>the</strong> parts – we are getting a nice
clean edge. The powder quality <strong>is</strong> excellent. So
you’ll see <strong>that</strong> we don’t have an up or a down on
<strong>the</strong> part when <strong>the</strong> parts are burr free. With a
punched part you’ll always have an up or a
down. There <strong>is</strong> a definite change in quality.
We’re not nibbling radius like we used to with a
punch press. The customer <strong>is</strong> getting a much
better part. We aren’t getting any scratches. The
sheet <strong>is</strong> brought down with vacuum on rollers.
There’s no movement of <strong>the</strong> sheet in <strong>the</strong>
<strong>machine</strong>. Parts are taken out and put on <strong>the</strong>
unload – so we aren’t getting scratches on <strong>the</strong>
parts. We don’t have to deburr or sand out deep
scratches <strong>that</strong> you get with high dies and a
punch press. It eliminates some of those
secondary operations.”
Results
Great Lakes reports <strong>that</strong> <strong>the</strong> L6 has allowed
<strong>the</strong>m to fully embrace lean/flow manufacturing.
“It has allowed us to reduce inventory of <strong>the</strong>
s<strong>is</strong>ter company by $1-million in <strong>the</strong> last 12
months,” says Cooke. “One of our primary
objectives was to allow Great Lakes
Great Lakes also
purchased additional
Finn-<strong>Power</strong> equipment:
a hydraulic robotic press
brake; a C5 Express
(load/unload turret
punch press); and an
automated panel
bender, <strong>the</strong> EB
(Express Bender).
5
The Finn-<strong>Power</strong>
L6 Laser Work
Center utilizes
a flying
optics/moving
beam system
driven by a
linear drive
motor system to
achieve
maximum speeds,
even while
cutting small
notches or
narrow contours.
Manufacturing to become a better vendor to <strong>the</strong>
s<strong>is</strong>ter company. We accompl<strong>is</strong>hed <strong>that</strong> because
our on-time delivery <strong>is</strong> running 98 - 99% and
our rate of return <strong>is</strong> probably less <strong>the</strong>n 2 /10 of
1% in terms of reject rate.”
Great Lakes also purchased additional Finn-
<strong>Power</strong> equipment: a hydraulic robotic press
brake; a C5 Express (load/unload turret punch
press); and an automated panel bender, <strong>the</strong> EB
(Express Bender). “The next step <strong>is</strong> to not <strong>only</strong>
remain a good vendor for <strong>the</strong> s<strong>is</strong>ter company
but to <strong>position</strong> <strong>the</strong> company for future growth
as a contract manufacturer,” says Low<strong>the</strong>r. “Our
goal will be to fur<strong>the</strong>r reduce scrap and
eliminate <strong>the</strong> costly material handling
throughout <strong>the</strong> facility.”
To accompl<strong>is</strong>h <strong>the</strong>se goals, <strong>the</strong> company <strong>is</strong>
currently looking at <strong>the</strong> Finn-<strong>Power</strong> Shear
Genius (punch/shear) flexible manufacturing
cell and <strong>the</strong> Night Train Material Management
System.

FEATURE ARTICLE
by Dan Dav<strong>is</strong>, Executive Editor, The Fabricator
Euros Zoned in on Competing
Ilinox’s Express Bender panel bending <strong>machine</strong>, which
features automated load and unload of sheet metal
blanks, <strong>is</strong> fed by its large Night Train storage system.
A tale of a fabricator, a contract
manufacturer, and a commercial
refrigerator-maker
Astrong independent streak ex<strong>is</strong>ts in
<strong>the</strong> American psyche. It helped
forge an industrialized nation out
of <strong>the</strong> wilderness and establ<strong>is</strong>h a democratic
society envied by many in <strong>the</strong> world.
But with an independent mindset comes a
stubborn streak. When a country has so many
natural resources, talented citizens, and open
space, it doesn’t worry too much about what <strong>the</strong>
rest of <strong>the</strong> world <strong>is</strong> thinking.
That’s changing, however. Technology has
brought <strong>the</strong> world closer toge<strong>the</strong>r, and
international trade policies are making everyone
a stakeholder in <strong>the</strong> global economy. The
challenges <strong>that</strong> European metal fabricators face
aren’t too different from those North American
fabricators face. In fact, <strong>the</strong>se European
fabricators have had to come to grips with lowcost
competitors and international trade <strong>is</strong>sues
much earlier than <strong>the</strong>ir North American
counterparts.
6
Independent thought and actions are still
valuable, but inspiration from outside sources –
in th<strong>is</strong> case European companies – can provide
important lessons. V<strong>is</strong>its to an Italian stainless
steel cabinet fabricator, a Finn<strong>is</strong>h electronics
contract manufacturer, and a multinational
commercial refrigeration-maker – sponsored by
metal fabricating equipment manufacturer
Finn-<strong>Power</strong> Inc. – show <strong>that</strong> metal fabricating
doesn’t have to d<strong>is</strong>appear in Western societies as
emerging economies become more adept at
manufacturing.
Stainless Steel Wonder
Nestled away in an industrial park in
Parma, Italy, behind a stainless steel fence <strong>is</strong>
Ilinox srl. The choice of stainless steel as <strong>the</strong>
fence material <strong>is</strong> noteworthy because <strong>the</strong>
company’s success <strong>is</strong> linked inextricably to <strong>the</strong>
metal. Ilinox manufactures stainless steel
cabinets for electrical and medical markets and
tanks for food and pharmaceutical processing
industries.
The cabinets represent a majority of its
business. Even though a large number of <strong>the</strong>
cabinets are standard shapes and sizes – and can
even be ordered from a catalog – Ilinox offers
engineering support for customers needing
tailored designs for specific applications. One
recent example was an electrical cabinet
fabricated from 2-millimeter (0.08-inch)
stainless steel <strong>that</strong> contained track controls for a
new high-speed railway being built near <strong>the</strong>
Ilinox facility. The cabinets had to be especially
sturdy because <strong>the</strong>y would be <strong>only</strong> a wh<strong>is</strong>ker
away from trains blazing down <strong>the</strong> track.
Claudio Allodi, Ilinox’s managing director,
said <strong>that</strong> in 2003 h<strong>is</strong> company began to explore
new laser cutting equipment and material
handling automation <strong>that</strong> could connect <strong>the</strong>
laser to a panel bender. The laser was a necessity
because <strong>the</strong> laser produced a nice, burr-free edge
<strong>that</strong> was just not possible with a shear. Also, <strong>the</strong>
laser could handle certain cuts without <strong>the</strong> need
for a tooling adjustment, which was always
necessary with a turret-type device. The material
handling made sense because Ilinox wanted to
take labor cost out of <strong>the</strong> fabricating process.
Load and unload options on some
semiautomated laser cutting devices didn’t make
too much sense, according to Allodi, because an

operator was still needed to set up raw material
to feed <strong>the</strong> semiautomated device.
Early explorations revealed <strong>that</strong> integrating
a panel bender with a laser cutting device, with
each made by a different manufacturer, might
prove problematic. In 2004 <strong>that</strong> concern led
Ilinox to Finn-<strong>Power</strong>, which supplied an L+P
laser/punch combination <strong>machine</strong> and an
Express Bender panel bending <strong>machine</strong>, both
connected to a Night Train flexible
manufacturing system.
The laser/punch combination has given
Ilinox <strong>the</strong> benefits of cutting with a 2.5-kilowatt
laser, but <strong>the</strong> speed and functionality of a turret
punch. The punch comes in handy for making
holes, countersinks, and ra<strong>is</strong>ed forms or
indentations on <strong>the</strong> stainless steel sheet.
The combination unit can accommodate
sheets as large as 3 meters (9.840 feet) by 1 m
(3.28 ft.) and requires <strong>only</strong> one operator and
Ilinox’s panel bender provides prec<strong>is</strong>e bends <strong>that</strong> are necessary for secondary
welding processes.
The panel bender can produce radial bends on Ilinox’s
stainless steel cabinet doors <strong>that</strong> o<strong>the</strong>rw<strong>is</strong>e might require
a roll bender or some o<strong>the</strong>r forming tool.
one programmer to run <strong>the</strong> device. Allodi said
<strong>the</strong> unit runs specialized production during <strong>the</strong>
first and second shift, but on <strong>the</strong> third shift it
runs unmanned because it <strong>is</strong> pumping out highvolume,
regularly scheduled components.
The Express Bender, which runs one shift
per day, handles <strong>the</strong> awkward bends <strong>that</strong> would
be difficult for one – or even two – press brake
operators to handle. The laser-cut blanks are
automatically delivered to <strong>the</strong> panel bender for
bending and unloaded when complete. The unit
can handle blanks as large as 2.5 m (8.20 ft.) by
1.5 m (4.92 ft.) and as heavy as 65 kilograms
(143.30 lbs.).
The panel bender <strong>is</strong> versatile enough to
handle a positive bend on one side of a blank
and a negative bend on <strong>the</strong> o<strong>the</strong>r side of <strong>the</strong>
blank without have to flip <strong>the</strong> blank. The
<strong>machine</strong> also can hem steel edges with a special
flat tool <strong>that</strong> comes down on top of a bend;
Allodi said th<strong>is</strong> comes in handy for fabricating
doors without sharp edges. One full-time
operator, who <strong>is</strong> involved in quality checks and
preparing bent components for delivery to
assembly, <strong>is</strong> dedicated to <strong>the</strong> panel bender.
About 30 seconds <strong>is</strong> all it takes an operator
to change <strong>the</strong> bending program. Allodi said <strong>that</strong>
before <strong>the</strong> Express Bender, every bend was made
on press brakes.
At <strong>the</strong> heart of <strong>the</strong> sheet metal production
area <strong>is</strong> <strong>the</strong> Night Train. Not <strong>only</strong> does it help
feed <strong>the</strong> automated equipment, <strong>the</strong> flexible
manufacturing system (FMS) also has proved to
be a great storage solution. Ilinox <strong>is</strong> now able to
manage its steel supply much better, and <strong>the</strong>
FMS created a lot of space because it utilizes
plenty of vertical storage.
The storage system has 300 cassettes, of
which 60 percent <strong>is</strong> dedicated to raw material.
A limited amount of cassettes <strong>is</strong> dedicated to
work-in-process because of <strong>the</strong> low-volume,
short-turnaround jobs. Some space actually <strong>is</strong>
dedicated to scrap because <strong>the</strong> leftover stainless
steel skeletons are valuable to metal dealers.
Ilinox still maintains a seasoned collection
of craftsmen-welders, press brake operators, and
metal fin<strong>is</strong>hers – among its 60 employees, but
plenty of <strong>the</strong> labor costs have been removed
from <strong>the</strong> metal cutting and bending operations.
For those jobs <strong>that</strong> require more labor content,
Ilinox has a s<strong>is</strong>ter company in a country with
lower labor costs. That’s in Hungary, however,
not China.
Manufacturing Mix
Nokia <strong>is</strong> one of <strong>the</strong> largest mobile phone
manufacturers in <strong>the</strong> world. One might figure
<strong>that</strong> plenty of Finn<strong>is</strong>h subcontractors do work
for <strong>the</strong> mobile-phone giant. He or she would be
right, but <strong>that</strong> doesn’t mean <strong>that</strong> those
fabricating shops are content being in Nokia’s
supply chain.
“We don’t want to be a telephone-maker,”
said Mikko Leidén, director of InCap’s Helsinki,
Finland, location. “There are bigger companies
than us <strong>that</strong> can do <strong>that</strong>.”
InCap, an electronics contract
manufacturer, has been around nearly 30 years
and boasted revenues of $76.7 million in 2005.
The company has multiple locations in
Scandinavia and central Europe and <strong>is</strong>
investigating starting operations in Asia.
The Helsinki operation has 60 employees
in its 5,700-sq.-m (61,354-sq.-ft.) facility. It
specializes in metal fabricating and assembly of
products, ranging from components for wea<strong>the</strong>r
balloons to laminations for power generators to
video amusement devices. The company,
overall, still does plenty of telecommunications
business, but it has reached out aggressively to
<strong>the</strong> health care, measurement, and process
manufacturing equipment industries.
The punching tools on Ilinox’s laser/punch combination <strong>machine</strong> are put to good use creating openings
in th<strong>is</strong> cabinet component.
7
continued on page 8

Electronics contract manufacturer InCap installed th<strong>is</strong> laser/punch combination <strong>machine</strong> in 2005 and a punching/shearing
cell with an FMS for raw material and work-in-process th<strong>is</strong> year. Plans call for integrating <strong>the</strong> equipment into one
automated sheet metal fabricating line.
In Helsinki, InCap produces about 3.5
million different “units,” which range in volume
from 10 to 10,000, according to Leidén. The
facility has 10 primary customers.
“Mass product – I don’t think it’s possible
to do it in Finland anymore,” Leidén said. “But
when <strong>the</strong> product has a lot of variances and
changes, you need to be close to <strong>the</strong> customer.”
Speed <strong>is</strong> <strong>the</strong> name of <strong>the</strong> game at InCap,
but not <strong>machine</strong> speed. It’s <strong>the</strong> speed to get
things up and running and switch between jobs.
It keeps deliveries on time and helps <strong>the</strong>
company be more responsive to engineering
changes in products.
That was <strong>the</strong> main motivation behind <strong>the</strong>
purchase of a Finn-<strong>Power</strong> LP6 laser/punch
combination <strong>machine</strong> in 2005. As an example
of how <strong>the</strong> equipment has made a difference,
Leidén pointed to a 2-in. by 1-in. metal
component <strong>that</strong> used to be fabricated with 10
different tools on an older turret punch press.
On <strong>the</strong> laser/punch <strong>machine</strong>, <strong>only</strong> four tools
are needed for certain quick punch-outs, and a
2.5-kW laser handles <strong>the</strong> rest of <strong>the</strong> cut. The
use of fewer tools decreases <strong>the</strong> likelihood <strong>that</strong>
operators will have to make tooling changes in
<strong>the</strong> equipment, he added.
In 2006 InCap invested in a Finn-<strong>Power</strong>
SG6 punching/shearing cell with <strong>the</strong> Night
Train FMS. Th<strong>is</strong> equipment will replace three
older punching <strong>machine</strong>s, one of which will be
kept for prototype work and jobs involving
specialty materials.
The SG6 will handle <strong>the</strong> cutting jobs <strong>that</strong>
don’t require <strong>the</strong> complex curved cuts <strong>that</strong> are
possible of <strong>the</strong> laser. Meanwhile, <strong>the</strong> laser can
cut thicker material – up to .313 in. – than <strong>the</strong>
SG6, which can cut up to 0.160 in.
Leidén said <strong>the</strong> programming of <strong>the</strong>se
newer metal fabricating devices makes it
possible to get <strong>the</strong> most out of every cutting
job. For instance, he described how <strong>the</strong>
punching/shearing device can cut some very
large generator laminations and simultaneously
punch out smaller parts from <strong>the</strong> laminations’
midsection, which normally just might end up
in <strong>the</strong> scrap heap.
Once <strong>the</strong> Night Train <strong>is</strong> fully integrated
with both <strong>the</strong> LP6 and <strong>the</strong> SG6, Leidén said he
These giant laminations for a power generator are an example of
<strong>the</strong> diversified products <strong>that</strong> InCap fabricates for customers.
anticipates <strong>the</strong> equipment will run unattended
during <strong>the</strong> weekend.
“The flexibility <strong>is</strong> <strong>the</strong> key,” he said.
Hot Refrigeration Business
Costan SPA, Limana, Italy, produces
30,000 refrigeration and freezer units per year,
mostly in <strong>the</strong> form of horizontal d<strong>is</strong>play cases.
The products end up in supermarkets all over
<strong>the</strong> world, from Austria to China.
Th<strong>is</strong> doesn’t sound like it has much to do
with <strong>the</strong> business of a metal fabricating shop
<strong>that</strong> specializes in low-volume jobs, but Costan
<strong>is</strong> not a typical high-volume manufacturer. It
builds everything to order.
Such <strong>is</strong> <strong>the</strong> nature of <strong>the</strong> business. A
refrigeration/freezer style can be selected from a
catalog or a showroom, but every installation
has its own unique design parameters. No two
products are fabricated exactly alike.
More than 800 people work in <strong>the</strong> Limana
factory, and more than 2,500 work in Costan
Costan SPA has a showroom for its commercial refrigeration and freezer products, but <strong>the</strong> company does not have a
warehouse of product. Every unit <strong>is</strong> built specifically from <strong>the</strong> incoming order.
8

facilities worldwide. The Limana factory, more than
45,000 sq. m (484,376 sq. ft.) in size, has a sheet metal
department <strong>that</strong> works three shifts, while <strong>the</strong> assembly
line works mostly two shifts.
Costan <strong>is</strong> no stranger to automation of its metal
fabricating activities. The company purchased two
Shear Genius punch/shear combination <strong>machine</strong>s and
a Night Train FMS from Finn-<strong>Power</strong> in 1999. The
storage system has 200 storage cassettes for steel sheet
and <strong>is</strong> 50 m (164.04 feet) long. Two operators work <strong>the</strong>
line during <strong>the</strong> first and second shift, and one person
attends <strong>the</strong> system at night.
Giandomenico Pinotti, who <strong>is</strong> responsible for
Costan’s sheet metal production, said <strong>the</strong> line has
worked well for <strong>the</strong>m over <strong>the</strong> years, but it did not
meet all of <strong>the</strong>ir needs. Business has grown in recent
years, and <strong>the</strong> busy season, which used to be from May to
November, <strong>is</strong> now beginning sooner and sooner. Pinotti said
<strong>the</strong> factory has been hopping since January, and it has
remained <strong>that</strong> way even into <strong>the</strong> summer.
To help <strong>the</strong>m with <strong>the</strong> fabricating activity, Costan has a
new 60 m (196.85-ft.) long Night Train with 250 cassette
storage slots. It <strong>is</strong> connected to two new Shear Brilliance
punch/shear combination <strong>machine</strong>s and an Express Bender
panel bender. In <strong>the</strong> storage system, 150 slots are dedicated
to semipunched or fin<strong>is</strong>hed components and 100 slots to raw
material.
The Express Bender panel bender can handle large steel blanks <strong>that</strong> might
pose an awkward material handling dilemma if done on a press brake.
Eight people work <strong>the</strong> new line over three shifts: two on
<strong>the</strong> punch/shear equipment and one on <strong>the</strong> panel bender on
<strong>the</strong> first and second shifts and one on <strong>the</strong> punch/shear
equipment and one on <strong>the</strong> panel bender on <strong>the</strong> third shift.
The older punching/shearing line calls for two operators on
<strong>the</strong> first two shifts and <strong>only</strong> one on <strong>the</strong> third shift.
Costan’s products need a lot of bends. Pinotti estimated
<strong>that</strong> Costan produces at least 7,000 different components,
most fabricated 1-mm-thick (0.04-in.) sheet metal <strong>that</strong> need
to be bent in some way.
Pinotti added <strong>that</strong> all bending activity <strong>is</strong> done on a justin-time
bas<strong>is</strong>. No storage of bent components <strong>is</strong> required.
The Express Bender fits <strong>that</strong> manufacturing approach
because programs can be initiated in less than a minute. The
panel bender also <strong>is</strong> adept at handling long sheets of
aluminum, stainless, and cold-rolled steel sheet <strong>that</strong> might
prove difficult for a press brake operator to bend.
Some of <strong>the</strong> older, stand-alone press brakes are being
Costan has two Night Train FMSs <strong>that</strong>, if placed next to each o<strong>the</strong>r, are longer than a football field.
moved closer to <strong>the</strong> automated storage system and panel bender. The goal <strong>is</strong> to keep
material handling to a minimum in <strong>the</strong> just-in-time environment, Pinotti said.
Despite <strong>the</strong> presence of four punch/shear <strong>machine</strong>s, <strong>the</strong> Costan facility still keeps
its five stand-alone punching <strong>machine</strong>s. The volume <strong>is</strong> large enough to warrant running
<strong>the</strong> older <strong>machine</strong>s. To keep throughput high, each of <strong>the</strong> older punching <strong>machine</strong>s has
dedicated tooling and <strong>is</strong> used for <strong>the</strong> same type of jobs repeatedly. The low-volume,
high-mix fabricating activity <strong>is</strong> left to <strong>the</strong> punch/shear combos attached to <strong>the</strong> Night
Train.
Pinotti admitted <strong>that</strong> Costan was still in a learning curve with its newest
punch/shear/bending line. He hoped to be able to eliminate an entire shift from <strong>the</strong>
manual punching cell when <strong>the</strong> line <strong>is</strong> finally up and running seven days a week.
Lessons Learned
What can North American metal fabricators take away from <strong>the</strong>se three quick
glimpses into European fabricating operations?
To be competitive with <strong>the</strong> rest of <strong>the</strong> world, <strong>the</strong>se companies have done what
<strong>the</strong>y can to minimize labor related to material movement and storage.
These companies are involved in specialty markets <strong>that</strong> call for plenty of
engineering input. The products <strong>the</strong>y are manufacturing or <strong>the</strong> parts <strong>the</strong>y are
fabricating are constantly tweaked or redesigned. It pays to be responsive and, in
many instances, close to customers – whe<strong>the</strong>r in-house or in-country.
These companies bought equipment <strong>that</strong> solved a problem for <strong>the</strong>m. Flexibility
was a priority over speed or power.
Your grandmo<strong>the</strong>r will never be able to make gnocchi like <strong>the</strong>y do in Parma,
Italy.
That’s advice even independent thinkers will be hard-pressed to ignore.
Reprinted with perm<strong>is</strong>sion from <strong>the</strong> July 2006 <strong>is</strong>sue of The Fabricator.
For a copy, contact Tiina Alanko at 847-781-3287 or tiina@finnpower.com
9

SOFTWARE UPDATE
by Kyle Plass, Applications & CAD/CAM Coordinator
NC Express ® Programming Software
Finn-<strong>Power</strong>’s NC Express CNC
programming system <strong>is</strong> a user
friendly, integrated, and
automated tool for managing Finn-<strong>Power</strong>
equipment in <strong>the</strong> most efficient manner
available. NC Express <strong>is</strong> a tooling, nesting,
and optimizing software package designed
to easily integrate into an ex<strong>is</strong>ting
manufacturing environment, taking full
advantage of <strong>the</strong> powerful CAM features
and <strong>the</strong> Finn-<strong>Power</strong> <strong>machine</strong> tool product
line.
NC Express <strong>is</strong> a scalable application –
<strong>the</strong> system may be used as a single part
drafting and tooling program or as a fullyautomated
<strong>machine</strong> tool management
system. Ei<strong>the</strong>r way <strong>the</strong> results are <strong>the</strong> 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 <strong>the</strong>
CAD database and processed by NC
Express for random part Just-in-Time (JIT)
production.
NC Express provides an easy-to-use
Windows-based Graphic User Interface.
Drop down menus and icons ensure easy
interaction with <strong>the</strong> system and immediate
productivity. Th<strong>is</strong> user interface, combined
with NC Express’ powerful automation
capabilities facilitates optimum production,
maximizes <strong>the</strong> computer-controlled features
of <strong>the</strong> <strong>machine</strong> tool, and simplifies <strong>the</strong>
effort required to design and program parts
for production.
With <strong>the</strong> r<strong>is</strong>e in material costs, labor,
and short-run jobs, today’s demanding
manufacturing market <strong>is</strong> focusing more on ways
to automate <strong>the</strong> fabrication of greater quantities
of parts in less time and with fewer people. NC
Express offers a complete programming package
for Finn-<strong>Power</strong> <strong>machine</strong>s <strong>that</strong> provides our
customers <strong>the</strong> ability to obtain high levels of
automation for less user interface and more
output.
Geometry
The first process in programming a
component file <strong>is</strong> <strong>the</strong> geometry creation. NC
Express offers a full CAD package for
component generation. Alternatively, geometry
can also be imported from a standard DXF file
format. Open contours within a component
file can be cleaned automatically according to
<strong>the</strong> set system tolerance. For open contours or
duplicate line segments outside <strong>the</strong> system
tolerance, NC Express will d<strong>is</strong>play where
problem areas ex<strong>is</strong>t for quick and easy
cleaning.
Automation of importing of <strong>the</strong> geometry
can be done when using <strong>the</strong> MRP database
(OMS). Through th<strong>is</strong> process, component files
can be generated from a DXF file or by using
parametric scripting. During th<strong>is</strong> process <strong>the</strong>
geometry, tooling, and storing of <strong>the</strong>
component file <strong>is</strong> accompl<strong>is</strong>hed.
Tool Placement
The NC Express Autotool will
automatically place optimal tool routines and
tool placement in accordance with <strong>the</strong> <strong>machine</strong>’s
capabilities. Additional automation of robot
placement and last hit orientation for unloading
<strong>is</strong> set properly for sorting of components. Any
section of tooling placed by <strong>the</strong> Autotool
function can be easily reorganized or replaced
manually. Tool placement features include:
Automatic and interactive tool placement
Automatic and interactive microjoint
creation
Automatic and interactive destruct
Interactive cycling
Machine intuitive tool placement
Nesting
Nesting within NC Express can be done
statically or dynamically. During <strong>the</strong> nesting
process parts can be quickly moved by dragging
and dropping to <strong>the</strong> necessary location. For
10
quick part rev<strong>is</strong>ions, a single component file can
be edited at <strong>the</strong> part level and once <strong>the</strong> nest
layout <strong>is</strong> reopened <strong>the</strong> change will be promptly
updated for each part in <strong>the</strong> nest.
True Shape Nesting
True Shape Nesting utilizes <strong>the</strong> true
boundary of <strong>the</strong> part as it appears in <strong>the</strong>
drawing. Th<strong>is</strong> 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 <strong>the</strong>
clamps
Nests in zones to guarantee part accuracy
Nests in holes to gain higher sheet yield
Rectangular/Shear Nesting
NC Express utilizes a rectangular nesting
algorithm to take advantage of <strong>the</strong>
manufacturing features of <strong>the</strong> Finn-<strong>Power</strong> Shear
Genius and Shear Brilliance punch/shear
Flexible Manufacturing Cell (FMC). Unique
features include:
Automatic notch tooling recognition for
dynamic or static common line
Interactive Nest Tooling
Interactive Grid Nesting
Optimization
Optimization <strong>is</strong> done automatically for all
Finn-<strong>Power</strong> <strong>machine</strong> types (punch, punch/
shear, laser/punch, and laser). The Optimizer
references a pre-establ<strong>is</strong>hed tool library verifying
<strong>that</strong> all of <strong>the</strong> necessary tools to produce <strong>the</strong>
parts are
available for
use in <strong>the</strong>
<strong>machine</strong>’s
turret. Once
confirmed,
<strong>machine</strong>
movement, punching
and forming operations,
tool changes and
sequencing are
optimized for efficient
<strong>machine</strong> operations and
throughput. Additional
optimization features
include:
Automatic Re<strong>position</strong>ing 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 <strong>the</strong>
programmer detailed information about how a
job will run at
<strong>the</strong> <strong>machine</strong>. A
full range of
reporting
options will
offer <strong>the</strong>
programmer and
operator ample
information on
how to set up <strong>the</strong> <strong>machine</strong>. The following are
some items l<strong>is</strong>ted within a report:
Tooling in a single nest or a run of nests
Nest layout
Part information
Time estimation per sheet
Key Features
The following <strong>is</strong> a description of a few
features <strong>that</strong> help obtain <strong>the</strong> high levels of
automation within NC Express.
Teach Cycles
Teach Cycles allow <strong>the</strong> ability to teach
tooling or cycled functions/routines to a specific
geometry. A Teach Cycle <strong>is</strong> applied when
Autotool <strong>is</strong> in operation. Teach Cycle works off
a given tolerance, material thickness, and
symmetry type. If geometry ex<strong>is</strong>ts <strong>that</strong> has a
Teach Cycle libraried, <strong>the</strong> same pattern or
tooling will be applied. The use of Teach Cycle
can vary with <strong>machine</strong> type.
A Teach
Cycle <strong>is</strong> created
to apply a cycled
order of hits for
a round punch –
extrusion – and
a tap (right).
Th<strong>is</strong> cycle will
<strong>only</strong> be used on
material thickness 0.5-1.5 mm. The tolerance <strong>is</strong>
0.03 mm for <strong>the</strong> hole sizes. When a part <strong>is</strong>
Autotooled with <strong>the</strong> same type of geometry, <strong>the</strong>
same tooling in <strong>the</strong> same order will be applied
throughout <strong>the</strong> part. Th<strong>is</strong> eliminates <strong>the</strong>
repetitive task of having to place each of <strong>the</strong>
tool hits for each hole on <strong>the</strong> part.
Automatic Form Avoidance
During punching process, NC Express
knows when a form ex<strong>is</strong>ts within a nest to avoid
smashing <strong>the</strong> form by a non-form tool. Form
protection areas can be set for a special tool to
inform NC Express
of <strong>the</strong> formed area
on <strong>the</strong> nest. If a
non-form tool will
cross <strong>the</strong> path of a
formed area within
a nest, NC Express
will optimize <strong>the</strong>
tool path so <strong>that</strong>
<strong>the</strong> ram will completely ra<strong>is</strong>e <strong>the</strong> tool and <strong>the</strong>n
cross over <strong>the</strong> formed area, avoiding <strong>the</strong>
possibility of smashing <strong>the</strong> form. No additional
ax<strong>is</strong> moves are made in order to avoid <strong>the</strong> form.
In addition to <strong>the</strong> form avoidance settings,
NC Express allows <strong>the</strong> setup of an exit angle
path to provide for automatic ordering of a
special tool when optimizing. Th<strong>is</strong> <strong>is</strong> especially
useful for a louver tool: Time <strong>is</strong> saved during
part preparation and during optimization
because no additional work <strong>is</strong> needed to
manipulate <strong>the</strong> tool path within <strong>the</strong> optimized
nest.
Orders Management System (OMS)
NC Express comes standard with an
MRP/ERP interface to allow customers to
control and track parts <strong>that</strong> have processed
within NC Express to be sent to <strong>the</strong> <strong>machine</strong>.
The Orders Management System (OMS) <strong>is</strong> 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, <strong>the</strong> OMS can benefit
<strong>the</strong> end user taking orders from <strong>the</strong> MRP/ERP
and processing <strong>the</strong>m into nests.
Automatic Common Line Cutting
For punching, punch/shear, and standalone
laser <strong>machine</strong>, NC Express offers fully
automatic
common
line cutting
features.
Common
line <strong>is</strong>
COMING SOON…
NC EXPRESS NEW RELEASE V6.1
Finn-<strong>Power</strong> will soon be releasing updated software
for NC Express…Version 6.1. Some of <strong>the</strong> new features
include:
Networking (Sharing) of nest folders
New nesting features:
– Automatic mirroring
– Coil line nesting
– Increased functionality for interactive editing
Optimization settings per tool to enhance <strong>machine</strong>
efficiency
Improved laser optimization
– More functionality for automatic common line
– Scrap cutting – crop lines in both X and Y
New feature for automatic scripted part generation
11
activated in <strong>the</strong> nesting phase and will help to
reduce <strong>the</strong> scrap rate between parts. Once a nest
<strong>is</strong> created with parts and tools in a common
line, <strong>the</strong> Optimizer will remove excessive hits in
order to avoid double punching hits or double
laser paths. Within <strong>the</strong> punch/shear
environment <strong>the</strong> nesting engine will common
line symmetrical parts, ignoring tooling
overlapping from notches. For non-symmetrical
parts in <strong>the</strong> punch/shear environment, <strong>the</strong> nest
engine will check <strong>the</strong> tolerance set and ignore
tooling extending less than <strong>the</strong> grid nesting
tolerance.
Component Stacking Management
For <strong>machine</strong> types requiring stacking of
components
on a cassette,
NC Express <strong>is</strong>
capable of
automatically
configuring
<strong>the</strong> stacking
layout of <strong>the</strong>
components
on <strong>the</strong>
cassette.
During <strong>the</strong>
nesting
process <strong>the</strong>
user has options to determine <strong>the</strong> layout of <strong>the</strong>
cassette. The nesting engine will nest parts based
upon stacking. Th<strong>is</strong> allows for NC programs to
be loaded within <strong>the</strong> <strong>machine</strong> and requires
minimal setup of cassettes by <strong>the</strong> operator when
queuing <strong>the</strong> NC files. The overall outcome of
th<strong>is</strong> feature offers less setup time by <strong>the</strong>
operator.
For even more automation and time savings
for <strong>the</strong> programmer, if a robot ex<strong>is</strong>ts on <strong>the</strong>
<strong>machine</strong>, <strong>the</strong> user can take advantage of <strong>the</strong>
automatic robot suction cup setup via Autotool
to automate more of <strong>the</strong> process.

FOCUS ON TOOLING
by Andy Spence-Parsons, Marketing Manager, Mate Prec<strong>is</strong>ion Tooling
Essential Tools for Improved Productivity
One of <strong>the</strong> cons<strong>is</strong>tent <strong>the</strong>mes demonstrated by Finn-<strong>Power</strong> <strong>is</strong>
enabling <strong>the</strong> fabricator to move from a flat sheet metal blank
to a fin<strong>is</strong>hed piece part on <strong>the</strong> punch press, while eliminating
time consuming secondary operations.
Innovative tooling solutions developed by Mate Prec<strong>is</strong>ion Tooling
continue to enable more operations to be completed on <strong>the</strong> punch press.
Examples include:
Mate Sheetmarker ®
Tool Makes Part
Traceability Easy
and Eliminates Labeling
Names, assembly codes,
serial numbers and etchings are
permanently imbedded in sheet
metal parts with <strong>the</strong> Mate
Sheetmarker Assembly.
Companies with quality programs requiring part traceability now can do
th<strong>is</strong> on <strong>the</strong>ir Finn-<strong>Power</strong> turret presses eliminating downstream labeling,
tagging and o<strong>the</strong>r forms of part identification. Using <strong>the</strong> turret press NC
program, part traceability data such as pallet numbers, sequential serial
numbers, time and date can easily and permanently marked into <strong>the</strong>
material at a specified location on <strong>the</strong> part.
Mate EasyTap Tooling
Produces Threaded Holes
Eliminating Secondary
Threading Operations
Add even more versatility to a
Finn-<strong>Power</strong> press with th<strong>is</strong> tool
system designed to produce
threaded holes in pre-punched
holes or extruded holes located on
<strong>the</strong> sheet. The tool uses <strong>the</strong> <strong>machine</strong> software to integrate prec<strong>is</strong>e ram
depth control and auto-index rotation to produce a range of threaded hole
diameters in materials such as stainless steel, mild steel and aluminum. It
uses standard roll taps and Bilz brand collets to make <strong>the</strong> threaded holes.
Not <strong>only</strong> does th<strong>is</strong> eliminate threading operations by hand or adjacent
<strong>machine</strong>s, it can be done using ex<strong>is</strong>ting taps and collets.
Mate EasyBend Tooling
Creates Bend Lines
Eliminating Press Brake
Operations
Fabricated metal parts often
require bending, an operation
most often done using press
brakes. Certain simple bending
operations, particularly on
smaller parts made of light, thin material, can be bent quickly and
accurately by hand after bend lines are produced using a tool called <strong>the</strong>
Mate EasyBend. The tool creates pre-programmed bend lines on <strong>the</strong>
material surface with CNC punch prec<strong>is</strong>ion and speed. Parts can be bent
by hand as <strong>the</strong>y come off <strong>the</strong> Finn-<strong>Power</strong> press without <strong>the</strong> need to use a
press brake.
12
Mate Snaplock Tooling
Fabricates Connecting
Joints Without Welding
The Mate SnapLock tool
produces self-locking, spring
loaded tabs <strong>that</strong> snap toge<strong>the</strong>r
securely into pre-punched holes.
No additional assembly
operations are needed. The tool
eliminates <strong>the</strong> need for welding
connecting joints in <strong>the</strong> fabrication of electrical boxes, for example.
Through pre-planning, multiple components can be reduced to a single
pre-punched component which folds up and locks toge<strong>the</strong>r. Th<strong>is</strong> tool also
allows use of pre-painted material for <strong>the</strong> fabricating which would
o<strong>the</strong>rw<strong>is</strong>e have to be painted following welding. The Mate Snaplock tool
<strong>the</strong>refore can also help eliminate additional fin<strong>is</strong>hing operations.
Ultra TEC ® Fully Guided
Slitting Assembly
Eliminates Secondary
Clean-Up
The final tool in th<strong>is</strong> group <strong>is</strong>
<strong>the</strong> Ultra TEC Fully Guided Slitting
Assembly. The assembly <strong>is</strong> designed
to produce piece parts with superior
edge quality <strong>that</strong> do not required
secondary cleaning operations.
The Ultra TEC Fully Guided
tool system overcomes <strong>the</strong> side load and tw<strong>is</strong>ting pressures comm<strong>only</strong>
experienced during slitting operations. By squarely and securely
controlling <strong>the</strong> punch point where it contacts <strong>the</strong> sheet, <strong>the</strong> punch can
accurately pierce a hole, even when punching partial hits or under side
load pressure.
Guiding <strong>the</strong> punch point <strong>is</strong> critical since <strong>the</strong> point <strong>is</strong> shaped as a long
narrow width and <strong>the</strong> point <strong>is</strong> where <strong>the</strong> greatest pressure <strong>is</strong> exerted. The
objective of punch point guiding <strong>is</strong> to prevent any lateral movement of <strong>the</strong>
punch. Th<strong>is</strong> <strong>is</strong> achieved by reducing <strong>the</strong> stripper opening to a total
clearance of 0.0015" (0.04 mm). Supporting <strong>the</strong> punch point prevents <strong>the</strong>
point from moving or deflecting under <strong>the</strong> side load pressures. By
eliminating <strong>the</strong> deflection, <strong>the</strong> resulting hole <strong>is</strong> punched more cleanly
which eliminates any overlap marks <strong>that</strong> require secondary clean-up.
Each of <strong>the</strong>se innovative tooling solutions <strong>is</strong> available exclusively from
Mate Prec<strong>is</strong>ion Tooling. They represent a continued demonstration of our
commitment to work closely with our fabrication industry partners to
improve productivity.
For more information of Mate products for Finn-<strong>Power</strong> presses, please
v<strong>is</strong>it us on <strong>the</strong> web at www.mate.com/finn-power.
Mate Prec<strong>is</strong>ion 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.

Shear Genius
FINN-POWER
EXPERIENCE
CAUTION: A ride on <strong>the</strong>
FINN-POWER EXPERIENCE
will permanently change your
concept of sheet metal fabrication.
FABTECH 2006 PREVIEW
Double <strong>the</strong> Excitement!
At FABTECH 2005 in Chicago,
we <strong>took</strong> over 2,000 v<strong>is</strong>itors on a
journey through a punch/shear
and ano<strong>the</strong>r dimension of increased
productivity, quality, and profits.
We’ve added a laser/punch reality
adventure to <strong>the</strong> marquee for
FABTECH 2006 in Atlanta.
Laser /Punch
FINN-POWER
EXPERIENCE
Finn-<strong>Power</strong> International, Inc. / 710 Remington Road / Schaumburg, IL 60173 / USA
Tel. 847 885 3200 / Fax 847 885 9692 / www.finnpower.com

CUSTOMER PROFILE
Shear Brilliance…A Breath of Fresh Air for
Sheet Metal Fabrication at Venmar Ventilation
Venmar Ventilation (H.D.H) Inc., Drummondville, Québec, was founded in
1978 as a roof ventilation d<strong>is</strong>tributor for pre-fabricated and mobile homes.
Through <strong>the</strong> years, investments and acqu<strong>is</strong>itions allowed <strong>the</strong> company to
manufacture its product line and rapidly grow to eventually set <strong>the</strong> industry standard for
ventilation innovation.
Today, Venmar <strong>is</strong> a div<strong>is</strong>ion within <strong>the</strong> Broan - NuTone Group, <strong>the</strong> largest div<strong>is</strong>ion
of Nortek. With over one million homeowners among its customers, Venmar continues
to manufacture a full range of products. From kitchen range hoods and attic ventilators
to filtration and ventilation systems, Venmar products are recognized as <strong>the</strong> industry
standard for quality, styling, reliability, and an optimally healthy indoor air environment.
The Drummondville plant specializes in <strong>the</strong> production of kitchen hoods,
specifically <strong>the</strong> professional style hoods. The hoods are mostly produced from stainless
steel and are low volume, high mix. There are several hundred different models of hoods
14
with more than 100 different options. Each year, <strong>the</strong> plant
produces tens of thousands of kitchen hoods for <strong>the</strong> North
American market.
In 2003, Venmar began a search for fabrication
equipment to process its stainless steel products. The
company was using a shear to make blanks for two standalone
turret punch presses. According to Eric Therrien,
production & project engineer, h<strong>is</strong> company was looking to
both increase productivity and decrease <strong>the</strong> amount of scrap
due to defects during <strong>the</strong> fabrication process. “We were
looking for a <strong>machine</strong> <strong>that</strong> could take a full-sized sheet,
punch it, shear it, and make fin<strong>is</strong>hed parts,” explains
Therrien. “We didn’t want to stay with <strong>the</strong> process of ‘shake
and break.’ We were cutting blanks on <strong>the</strong> shear and <strong>the</strong>n
putting <strong>the</strong> blanks on <strong>the</strong> standalone turret punch presses.
Because of <strong>the</strong> amount of handling, dents and scratches were
always a possibility. Our goal was to reduce th<strong>is</strong> damage as
much as possible.”
After a thorough search of <strong>the</strong> available fabrication
technology on <strong>the</strong> market, Venmar chose <strong>the</strong> Finn-<strong>Power</strong>
Shear Brilliance Flexible Manufacturing Cell. The Shear
Brilliance represents a new generation <strong>machine</strong> to provide
<strong>the</strong> fastest path in fabricating sheet metal parts. The
combination of a 6,400 mm X traverse, four clamps, and <strong>the</strong>
high <strong>position</strong>ing speed provided by linear drives means <strong>that</strong>
more functions – punching, forming, tapping, bar coding,
and shearing – can be performed as a single, multi-purpose
sheet metal fabrication center with a single clamping. Th<strong>is</strong>
saves time and increases accuracy, since re<strong>position</strong>ing <strong>is</strong> not
needed during <strong>the</strong> process and <strong>the</strong> same clamps <strong>that</strong> are used
for punching are also used for shearing. Utilizing one
<strong>machine</strong> for <strong>the</strong> various processes also protects <strong>the</strong> part from
defects during production. “We run 20 - 24 gauge stainless
steel and need <strong>the</strong> parts to be perfect,” says Therrien.
“Cosmetics are crucial for our professional style stainless
range hoods. Any small defects, such as a dent or scratch,
could be reason for rejection of <strong>the</strong> production. It was very
important to find a <strong>machine</strong> <strong>that</strong> could have all <strong>the</strong>se
functions in one process to produce excellent parts with
minimum scrap.”
Finn-<strong>Power</strong> Shear Brilliance utilizes linear drive technology
with <strong>the</strong> integrated shearing concept, surpassing all performance
values previously associated with traditional methods.

Speed, accuracy, and prec<strong>is</strong>ion are achieved
by both <strong>the</strong> linear drives and <strong>the</strong> coordinate table
construction, ensuring excellent repeatability of
each work stage performed. Th<strong>is</strong> Active
Synchronized Drive system ensures <strong>the</strong> highest
<strong>position</strong>ing accuracy of <strong>the</strong> coordinate table, even
when using maximum acceleration and
deceleration values.
However, faster punching speeds alone <strong>is</strong> not
<strong>the</strong> total answer to increased productivity. Finn-
<strong>Power</strong> found <strong>the</strong> greatest potential area for
productivity improvement in total manufacturing
time to be in <strong>the</strong> areas of axes movements.
Depending upon <strong>the</strong> program, axes movements
in typical fabrication systems can account for
50% of total processing time from loading <strong>the</strong>
sheet to stacking <strong>the</strong> fin<strong>is</strong>hed part. The X and Y
axes movements are <strong>the</strong> most time consuming
phase of <strong>the</strong> program. Finn-<strong>Power</strong> Shear
Brilliance utilizes linear drive technology with <strong>the</strong>
integrated shearing concept, surpassing all
performance values previously associated with
traditional methods.
O<strong>the</strong>r benefits of <strong>the</strong> Shear Brilliance
include:
Tool Holders – Finn-<strong>Power</strong> incorporates an
individual tool holder concept <strong>that</strong> allows
customers to design <strong>the</strong>ir own turret layouts.
Unlike o<strong>the</strong>r designs, specific tool stations are not
<strong>machine</strong>d into <strong>the</strong> turret. Finn-<strong>Power</strong> offers <strong>the</strong>
<strong>only</strong> flexible selection of tool holders in <strong>the</strong>
industry. Any tooling style from Mate Prec<strong>is</strong>ion
Tooling or Wilson Tool International can be
installed in a Finn-<strong>Power</strong> turret.
The Shear Brilliance turret has 30 tool
stations. Up to 15 Multi-Tool or auto index
stations can accommodate up to 200 tools
available in <strong>the</strong> turret in one set-up. “One of <strong>the</strong>
justifications for purchasing <strong>the</strong> Shear Brilliance
was reduction of set up times,” says Therrien.
“We <strong>only</strong> had 19 tools in each of our two turret
punch presses. We have 94 tools in <strong>the</strong> Shear
Brilliance and have reduced setup times from
35% to <strong>only</strong> 8%. Th<strong>is</strong> <strong>is</strong> a big advantage for us.”
Auto-Index – Finn-<strong>Power</strong>’s unique autoindex
system prec<strong>is</strong>ely rotates <strong>the</strong> punch and die
The Shear Brilliance turret has 30 tool stations. Up to
15 Multi-Tool or auto index stations can accommodate
up to 200 tools available in <strong>the</strong> turret in one set-up.
in <strong>the</strong>ir tool holders using a
single A.C. servo-motor
system. The system does
not need to match separate
servo-motors as in some
o<strong>the</strong>r <strong>machine</strong>s. Rotation
in .001 degree
programmable increments
gives <strong>the</strong> <strong>machine</strong> <strong>the</strong> ability to rotate beyond
360 degrees, thus allowing <strong>the</strong> system to
automatically select <strong>the</strong> shortest path to rotate
to a programmed angle input into <strong>the</strong> NC
part program with simplicity, speed, and
reliability. Peerless has four auto index stations.
Venmar has five auto-index stations.
Multi-Tool ® – Finn-<strong>Power</strong>’s Multi-Tool
stations increase <strong>the</strong> 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-
<strong>Power</strong> Multi-Tool offers 6, 8, 10, or 24
different punch/die combinations in <strong>only</strong> one
station – a turret within a turret. Venmar has
two 8-stations, three 10-stations, and one 24station
Multi-Tools.
Upward Forming System – Finn-<strong>Power</strong>’s
upward forming option provides more
accurate forming and greater forming heights
up to 16 mm (.63" ) and 5" in diameter.
Ano<strong>the</strong>r advantage <strong>is</strong> <strong>that</strong> all dies are at <strong>the</strong>
same height and <strong>the</strong>re are more high-forming
dies in <strong>the</strong> turret, thus, reducing r<strong>is</strong>k of
material damage and increasing <strong>machine</strong>
uptime. Venmar has two upforming stations.
FPS Storage
The level of automation can be
customized through Finn-<strong>Power</strong> flexible
modular solutions for raw material storage,
loading, unloading, sorting, and stacking.
These features can be added later as budget
allows and production demands increase.
Venmar chose <strong>the</strong> FPS double storage towers
to keep its line running efficiently. The FPS
has two storage blocks cons<strong>is</strong>ting of up to 19
cassettes in each. Material <strong>is</strong> stored by <strong>the</strong>
Input wagon or parts can be removed by <strong>the</strong>
Output wagon. Input/Output wagons are
used to transport <strong>the</strong> cassettes. Th<strong>is</strong> <strong>is</strong> done by
using a crane mechan<strong>is</strong>m with end telescoping
forks. For storage control and management,
<strong>the</strong>re <strong>is</strong> a computer unit located in <strong>the</strong>
electrical cabinet, which <strong>is</strong> located at <strong>the</strong> same
end as <strong>the</strong> motor of <strong>the</strong> vertical lifting device.
Material can be ordered straight with <strong>the</strong> cell
control and storage can be checked when
15
The Drummondville plant specializes in <strong>the</strong> production of
kitchen hoods, specifically <strong>the</strong> professional style hoods. The
hoods are mostly produced from stainless steel and are low
volume, high mix.
compiling a work queue. The wagons are
powered from <strong>the</strong> electrical cabinet and <strong>the</strong>
control buttons for movement are normally
located in <strong>the</strong> electrical cabinet.
“Since we are running very low volume and
high mix, it made sense for us to go with an
automated loading tower,” explains Therrien.
“At times we just use one sheet from a pallet
and <strong>the</strong>n switch to ano<strong>the</strong>r. The FPS storage has
been both productive and efficient for us.”
Performance
And how has <strong>the</strong> Shear Brilliance
performed at Venmar since its installation in
December, 2003? Venmar <strong>is</strong> currently operating
two shifts, seven days a week. The Shear
Brilliance <strong>is</strong> running unmanned part of th<strong>is</strong>
time. “During 2004, we increased production
by 50%,” explains Therrien. “Overall, <strong>the</strong> Shear
Brilliance has increased our capacity by 300%,
while reducing our cost of manufacturing <strong>the</strong>
part by 75%.”
“During 2004, we increased production by 50%. Overall,
<strong>the</strong> Shear Brilliance has increased our capacity by 300%,
while reducing our cost of manufacturing <strong>the</strong> part by 75%.”

EDITOR TECHNOLOGY TRIP
The Latest Sheet Metal Fabrication Techniques
Demonstrated on Technology Trip
Last April, Finn-<strong>Power</strong> International, Inc. sponsored an Editor Technology Trip to Finland
and Italy. The participants included Dan Dav<strong>is</strong>, executive editor, The FABRICATOR;
John Mullally, editor, MODERN APPLICATIONS NEWS; and Dan Pelton, editor,
CANADIAN METALWORKING.
Hosted by Bob Kolcz, director, marketing & corporate communications and Tiina Alanko,
marketing coordinator, Finn-<strong>Power</strong> International, and numerous Finn-<strong>Power</strong> employees in both
Finland and Italy, <strong>the</strong> editors v<strong>is</strong>ited Finn-<strong>Power</strong> facilities and customer locations to see firsthand
<strong>the</strong> latest breakthroughs in sheet metal fabrication technologies. The v<strong>is</strong>its to Finn-<strong>Power</strong>
customers included both large and small companies and dramatically demonstrated <strong>that</strong> Finn-
<strong>Power</strong> had <strong>the</strong> flexible manufacturing cell or system for companies of any size or budget.
HALTON OY
Halton Oy manufactures air-handling
products for air d<strong>is</strong>tribution, airflow
management and fire safety. Markus
Helineva, production development
manager, hosted <strong>the</strong> company tour at
Halton’s two facilities in Lahti &
Kausala, Finland.
INCAP OY
The group v<strong>is</strong>ited an electronics
contract manufacturer Incap Oy
in Helsinki. The company has
manufacturing operations in both
Finland and Estonia.
16
MECANOVA OY
Mecanova Oy, a contract manufacturer of mechanical components for electronics
industry, <strong>is</strong> located in Harma, Finland.
OY LAINE TUOTANTO AB
Oy Laine Tuotanto AB –
Vaasa, Finland. Jukka
Porkkala demonstrates
manufacturing process to
<strong>the</strong> editors.
A v<strong>is</strong>it to a Russian restaurant with folk music entertainers
was on <strong>the</strong> agenda for Helsinki.

Tiina Alanko, marketing coordinator, made excellent Finn<strong>is</strong>h cu<strong>is</strong>ine
suggestions at ano<strong>the</strong>r Helsinki restaurant.
FINN-POWER
ITALIA
Finn-<strong>Power</strong>’s bending products
manufacturing facility <strong>is</strong> based
at Finn-<strong>Power</strong> Italia, located
in Cologna Veneta, (VR).
COSTAN
Costan SPA <strong>is</strong> a manufacturer
of commercial refrigeration
and freezer products in
Limana, (BL) Italy.
Finn-<strong>Power</strong> Italia’s Roberto DeRossi (third from right) was <strong>the</strong> group’s host
during <strong>the</strong> Italy segment of <strong>the</strong> trip.
EUROSTEEL
Eurosteel Italia s.r.l, located in Parma,
<strong>is</strong> a producer of metal components for
home and office furn<strong>is</strong>hings.
ILINOX
Ilinox manufactures of electrical
cabinets located in Parma, Italy.
Claudio Allodi, managing director,
explains company’s manufacturing
process to editors.
17

IN THE NEWS
Finn-<strong>Power</strong> in <strong>the</strong> Spotlight
Finn-<strong>Power</strong> sheet metal fabrication technology and its
customers continue to attract a great deal of attention
from trade publications throughout North & South America
CNC WEST – (January)
Th<strong>is</strong> 3-page article highlights a C5 Compact Express
installation at Red Dot Corporation, Seattle, WA. “We
had faith in Finn-<strong>Power</strong> equipment and service from past
experience, and
we were quite
confident with
<strong>the</strong> C5 Compact
Express as <strong>the</strong>
<strong>machine</strong> of
choice.”
TOOLING & PRODUCTION – (January)
Th<strong>is</strong> short article contained information and a photo
on <strong>the</strong> Finn-<strong>Power</strong> Experience reality ride <strong>that</strong> was
exhibited at FABTECH 2005 in Chicago. Th<strong>is</strong>
imaginary ride through a Finn-<strong>Power</strong>
Shear Genius Flexible Manufacturing
Cell was said to permanently change
<strong>the</strong> v<strong>is</strong>itors' concept of sheet metal
fabrication.
METALWORKING
PRODUCTION & PURCHASING – (January/February)
Th<strong>is</strong> <strong>is</strong>sue featured a full-tabloid sized page article on
<strong>the</strong> Shear Brilliance installation at Canadian
manufacturer Venmar Ventilation (H.D.H.) Inc.,
Drummondville, QC. “During 2004,
we increased production by 50%.
Overall, <strong>the</strong> Shear Brilliance has
increased our capacity by 300%, while
reducing our cost of manufacturing <strong>the</strong>
part by 75%.”
18
MODERN APPLICATION NEWS – (March)
A 3-page article on an installation of a Finn-<strong>Power</strong> L6
Laser at Great Lakes Manufacturing, Inc., Corry, PA,
<strong>that</strong> has allowed <strong>the</strong> company to fully embrace
lean/flow manufacturing. “When we
started to take a look at <strong>the</strong> o<strong>the</strong>r
offerings from Finn-<strong>Power</strong>, <strong>the</strong>re was one
common denominator <strong>that</strong> kept jumping
forward: Finn-<strong>Power</strong> was <strong>the</strong> <strong>only</strong>
<strong>machine</strong> <strong>builder</strong> <strong>that</strong> <strong>took</strong> a <strong>position</strong> on
<strong>the</strong> front end in material management –
for <strong>the</strong> o<strong>the</strong>r <strong>builder</strong>s it looked like an
afterthought.”
MANUFACTURA – (April)
Th<strong>is</strong> leading Mexican trade publication featured a fullpage
editorial on <strong>the</strong> E Series servo electric press brake
with robot.
CANADIAN INDUSTRIAL MACHINERY – (April)
LC Bakery Equipment Services Ltd. in Brantford,
Ontario, <strong>is</strong> highlighted in th<strong>is</strong> 3-page article on <strong>the</strong> H-
Series servo hydraulic press brake from Finn-<strong>Power</strong>.
“The H press brake has performed very
well at our company. It has given us
flexibility and versatility. That was <strong>the</strong>
sole reason for going with Finn-<strong>Power</strong>.
We wanted <strong>the</strong> best equipment and <strong>the</strong>
ability for all <strong>the</strong> <strong>machine</strong>s to talk and
integrate with each o<strong>the</strong>r.”

NE MANUFACTURING NEWS – (April)
Th<strong>is</strong> cover article contains two tabloid pages of
editorial on <strong>the</strong> Finn-<strong>Power</strong> LPE laser punch
combination installation at Resh, Inc., Franklin, MA.
“Our LPE has over 4,000 hours of
operating time. I believe <strong>that</strong> it <strong>is</strong> one
of <strong>the</strong> best <strong>machine</strong>s <strong>that</strong> I’ve ever run.
We have run periods of 24/7 since it
was installed. We just load it, turn it
on, and go home.”
FF JOURNAL – (May)
Finn-<strong>Power</strong>’s L6 flying optics laser <strong>is</strong> featured in th<strong>is</strong>
industry roundup article.
CANADIAN METALWORKING – (June/July)
Canadian fireplace manufacturer Montigo Delray
Corp.’s Finn-<strong>Power</strong> E5 Work Center <strong>is</strong> featured in th<strong>is</strong>
2-page article. The E5 Work Center <strong>is</strong> a 6-axes
prec<strong>is</strong>ion
fabricating
system featuring
a servo-motordriven
punch
mechan<strong>is</strong>m and
<strong>is</strong> both flexible
and amazingly
accurate. “The
Finn-<strong>Power</strong> E
<strong>machine</strong> has
really increased
our efficiency and accuracy. We also noticed less tool wear on <strong>the</strong> servo electric
press compared to <strong>the</strong> hydraulic models.”
19
THE FABRICATOR – (July)
Executive Editor Dan Dav<strong>is</strong> participated in <strong>the</strong> Editor
Technology Trip to v<strong>is</strong>it Finn-<strong>Power</strong> facilities and
customers in Finland and Italy last April 22 - 29. The
net result <strong>is</strong> a
4-page very
thoughtful and
intelligent
report on what
he saw as well
as an analys<strong>is</strong>
of common
challenges and
solutions for
both European
and North
American fabricators. “The challenge <strong>that</strong> European metal fabricators face
aren’t too different from those North American fabricators face. In fact, <strong>the</strong>se
European fabricators have had to come to grips with low-cost competition and
international trade <strong>is</strong>sues much earlier than <strong>the</strong>ir North American
Counterparts.”
To obtain copies of any of <strong>the</strong>se articles,
contact Tiina Alanko at 847-781-3287 or tiina@finnpower.com
FINN-POWER’S DISTRIBUTOR OF
THE YEAR 2005 ANNOUNCED
DURING APRIL MEETING
Last April, Finn-<strong>Power</strong> announced its annual recognition for
D<strong>is</strong>tributor of <strong>the</strong> Year at its Schaumburg, IL facility. Finn-<strong>Power</strong>’s
president Mikko Lindstrom presented <strong>the</strong> 2005 award to CNC
Accessories Company. The award was accepted by John Pekny and
Dan Cokinos. Congratulations to CNC Accessories Company for a
great success!

FOCUS ON TOOLING
Get Full Rotation with
New Multi-Tool R-Series
Multi-Tool technology and
indexing capability have long
been cornerstones of Finn-
<strong>Power</strong>’s modular engineering tradition. Now
Wilson Tool International has collaborated with
Finn-<strong>Power</strong> to enhance <strong>the</strong> capabilities of <strong>the</strong>se
two technologies and develop <strong>the</strong> new R-Series
of indexable multi-tools.
The R-Series reaches new heights in tooling
versatility, providing <strong>the</strong> first fully indexable
Multi-Tool for Finn-<strong>Power</strong> <strong>machine</strong>s. Now you
can punch with any tool, at any angle, with one
easy setup. The result <strong>is</strong> a significant increase in
<strong>machine</strong> and tool optimization. The R-Series <strong>is</strong>
available in both three punch (MT3Ri) and
eight punch (MT8Ri) versions.
Greater Tooling
Capacity and Versatility
Turret capacity gives subcontractors <strong>the</strong>
competitive edge, eliminating non-productive
set-up time and allowing more work to move
through <strong>the</strong> <strong>machine</strong>. The R-Series increases <strong>the</strong>
maximum index tool capacity of a <strong>machine</strong> to
80-eight times better than <strong>the</strong> previous
maximum. In addition, up to 31.75 mm (1.25" )
tools can be used with no limitations to
nibbling.
Flexibility <strong>is</strong> also vital to subcontractors
who must contend with continually changing
requirements of individual jobs. R-Series Multi-
Tools maximize <strong>machine</strong> flexibility by utilizing
<strong>the</strong> <strong>machine</strong>’s standard D indexing station,
allowing <strong>the</strong> fabricator to configure <strong>the</strong> turret as
needed for each job.
For example, one job might need <strong>the</strong> D
indexing station with eight punches loaded in
an MT8Ri. The next job might utilize <strong>the</strong> same
The R-Series reaches new heights in tooling
versatility, providing <strong>the</strong> first fully indexable
Multi-Tool for Finn-<strong>Power</strong> <strong>machine</strong>s.
D indexing station with a single 5 mm x 80 mm
rectangle. And <strong>the</strong> next job might require three
punches loaded in an MT3Ri. All of <strong>the</strong>se tools
can be indexed by <strong>the</strong> <strong>machine</strong> to any required
angle, and each of <strong>the</strong>se changes <strong>is</strong> easily made
by <strong>the</strong> <strong>machine</strong> operator in a matter of seconds.
Easier Setup
Given <strong>the</strong> increased flexibility offered by
<strong>the</strong> R-Series Multi-Tools, additional set-up and
configuration time might be expected. However,
Wilson Tool engineers have designed an
innovative product <strong>that</strong> <strong>is</strong> not <strong>only</strong> more
flexible, but also easier to use. Compared to
conventional multi-tools, <strong>the</strong> unique drop-in
style allows punches to be loaded and unloaded
quickly and easily. And because <strong>the</strong>y have fewer
moving parts, R-Series Multi-Tools require less
maintenance.
Long Lasting
Durability and Performance
Every R-Series Multi-Tool <strong>is</strong> made from <strong>the</strong>
strongest, most durable standard tool steel. Each
assembly <strong>is</strong> hardened and prec<strong>is</strong>ion ground for
longer life and greater reliability, resulting in
fewer alignment problems and less downtime.
Targeted lubrication <strong>is</strong> provided by an internal
lubrication system. The MT3Ri utilizes Wilson’s
HP Thick Turret B-size punches and
incorporates punch length adjustment to
increase tool life.
Improve Wear
Res<strong>is</strong>tance with Optima ®
R-Series Multi-Tool inserts are available
with Optima coating for maximum wear
res<strong>is</strong>tance and greater reliability. Optima <strong>is</strong> a
With <strong>the</strong> R-Series, you can punch with any
tool, at any angle, with one easy setup.
20
by Glen Shuldes, Application Engineer, Wilson Tool International
The R-Series increases <strong>the</strong> maximum index
tool capacity of a <strong>machine</strong> to 80 – eight times
better than <strong>the</strong> previous maximum.
proprietary version of TiCN tool coating <strong>that</strong>
has proven extremely effective in maximizing
<strong>the</strong> life of punching tools in a variety of
applications. Surpassing o<strong>the</strong>r coatings in several
performance categories, Optima improves
productivity and reduces tooling maintenance
costs.
Applying Optima coating drastically
improves surface hardness and substantially
increases tool wear res<strong>is</strong>tance. Optima coated
punches can pierce up to ten times as many
holes as o<strong>the</strong>r coated and uncoated punches.
Material adhesion (galling) <strong>is</strong> reduced up to four
times, and punch tip corner wear <strong>is</strong> decreased
by as much as five times <strong>that</strong> of o<strong>the</strong>r coated or
uncoated punches. Optima also greatly increases
<strong>the</strong> number of hits achieved before <strong>the</strong> first
punch sharpening <strong>is</strong> required.
Slug Retention
Dies for R-Series Multi-Tools are available
in Slug Hugger ® style for positive slug retention.
Slug Hugger dies allow for less galling and slug
packing when punching softer material such as
aluminum and galvanized steel. Slug Hugger
also reduces scrap, costly downtime, and
possible <strong>machine</strong> and tooling damage caused by
slug pulling.
For more information about Wilson Tool’s
industry-leading products and services, 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
Every R-Series Multi-Tool <strong>is</strong> made from <strong>the</strong>
strongest, most durable standard tool steel.

FOCUS ON CANADA
Bienvenue Montreal…
Customer Technology Tour 2006
Finn-<strong>Power</strong> recently hosted a technology trip to Montreal for its North American
customers. Last May 7-10, <strong>the</strong> tour group v<strong>is</strong>ited seven sheet metal fabricator facilities
in <strong>the</strong> Montreal region. Leading <strong>the</strong> tour were Lou<strong>is</strong> Pellin, sales engineer, and Lutz
Ehrlich, punching /automation project manager.
“These trips give customers a better understanding of
how Finn-<strong>Power</strong> equipment works in a real production
environment,” explains Ehrlich. “It also allows <strong>the</strong>m to see
<strong>the</strong> many features and benefits of Finn-<strong>Power</strong> <strong>machine</strong>s,
systems, and cells. It <strong>is</strong> important to show <strong>the</strong> customer <strong>that</strong>
automation has become a reality in North America – not
<strong>only</strong> in Europe.”
FINN-POWER’S
COMPACT EXPRESS AND
E SERIES PRESS BRAKE
DISPLAYED AT MONTREAL SHOW
The Montreal Fabricating & Machine Tool Show was held May
15 -17 at Place Bonaventure, Montreal, Quebec. On d<strong>is</strong>play were
Finn-<strong>Power</strong>’s C5 Compact Express and E Series servo-electric press
brake.
“The big buzz at
<strong>the</strong> show was <strong>the</strong>
compact footprint of
<strong>the</strong> C5,” explains Lou<strong>is</strong>
Pellin, sales engineer of
Finn-<strong>Power</strong> Canada.
“We had many v<strong>is</strong>itors
each day of <strong>the</strong> show
interested in <strong>the</strong> C5
and E press brake.”
21
E-SIZE TOOL HOLDER
Finn-<strong>Power</strong> has introduced an E-size tool holder for our latest
models. E-size holders are available for cluster and forming tools.
With cluster, more holes per punch can be achieved for a faster
punching process. Also longer forms can be made using E-size tools
and bottom stroke.
Finn-<strong>Power</strong> tool holder accepts E-size tools by Mate Prec<strong>is</strong>ion
Tooling and Wilson Tool. O<strong>the</strong>r makes must be checked case by case.
E-size stations are not available with indexing or upforming.
They can be used with cluster tools up to 118 mm diameter punching
area.
With normal punching tools <strong>the</strong>y can be used up to 89 mm, i.e.
<strong>the</strong> same diameter as a D-station.
Tools are available <strong>only</strong> for new <strong>machine</strong>s, retrofitting for E-size
tool holder <strong>is</strong> not available.
Special tool holder must
be specified to <strong>the</strong> export
secretary always immediately
because of extra delivery
time.
E-size tool holder can be
replaced afterwards by a
standard or indexing
D-size as well as a
Multi-Tool ® station.
E-size tool holder
requires changes to be
made in <strong>the</strong> <strong>machine</strong>
and CAD/CAM system
for protection areas.

CUSTOMER PROFILE
Canadian Manufacturer Fills Bending Needs
with Finn-<strong>Power</strong> Servo Hydraulic Press Brake
In 1984, Luigi Casasanta Sr. establ<strong>is</strong>hed LC Bakery Equipment Services Ltd. in Brantford,
Ontario, Canada, to provide 24/7 maintenance service on all types of bakery equipment. As its
well-deserved reputation for reliable service and quality workmanship grew, <strong>the</strong> company moved
into a 6,300 square-foot-facility in 1988. In order to meet <strong>the</strong> equipment demands of h<strong>is</strong> customers,
Casasanta purchased some fabrication equipment and began manufacturing bakery equipment on a
small scale.
In 1998, LC Bakery Equipment moved to its present location were it now occupies a 35,000
square-foot facility. Joining Casasanta and h<strong>is</strong> wife Ernesta in <strong>the</strong> family business were <strong>the</strong>ir three
sons – Robert, Vice President of Engineering; Vic, Vice President of Operations; and Luigi Jr., Vice
President of Engineering. With many
years of experience in manufacturing
and maintenance of bakery equipment,
LC Bakery Equipment began <strong>the</strong>
development its own line of highquality
bakery equipment.
Today, <strong>the</strong> company has evolved
from its humble beginning as a service
oriented company in southwestern
Ontario, to a full-fledged
manufacturing company. According to
Robert Casasanta, Vice President of
Engineering, while service <strong>is</strong> still a vital
part of <strong>the</strong> company operations, LC
Bakery Equipment <strong>is</strong> focused on <strong>the</strong>
manufacturing of custom bakery
equipment, including ovens, proofing
systems, flour silo systems, racks, etc.,
for <strong>the</strong> Industrial/Commercial
international market. “We will always
maintain our service div<strong>is</strong>ion due its
importance as a valued resource to our
customers,” he explains.
The Casasanta family management team includes (from left to right):
Robert, vice president of engineering; Luigi Sr., president; Luigi Jr., vice
president of engineering; and Vic, vice president of operations.
Fin<strong>is</strong>hed product of industrial proofing system.
Fabrication
As production increased, it became
apparent <strong>that</strong> <strong>the</strong> current press brake
was becoming a limitation for <strong>the</strong>
company in terms of quality, speed and
flexibility. The company focused on <strong>the</strong>
purchase of a new Servo Hydraulic
Press Brake in order to alleviate th<strong>is</strong>
problem. “Our focus was to find a high
quality press brake, designed and
manufactured to help automate our
rapidly growing manufacturing
process,” he adds.
In order to meet <strong>the</strong>ir current and
future requirements, several key
features were considered as important.
It was imperative <strong>that</strong> <strong>the</strong> press brake
be more technologically advanced, be
designed and manufactured to provide
increased manufacturing flexibility,
have higher tonnage and bend length
abilities, have superior bend
repeatability and accuracy and allow for
rapid manipulation of press brake setup
with respect to tooling and
programming changes.
22
The press brake also needed to integrate
into <strong>the</strong> company’s flexible manufacturing
environment, which utilizes 3 dimensional
design software to design and manufacture all
components. These 3D parts are directly
imported into <strong>the</strong> press brake off-line software
which uses <strong>the</strong> 3D format to create a bend
program. Th<strong>is</strong> program <strong>is</strong> <strong>the</strong>n sent to <strong>the</strong> press
brake via network communication where <strong>the</strong>
operator can <strong>the</strong>n access and view <strong>the</strong> 3D
program to produce a fin<strong>is</strong>hed part.
Servo Hydraulic Press Brake
LC Bakery Equipment did an extensive
1-1/2 year search for <strong>the</strong> ideal press brake.
In August, 2005, <strong>the</strong> company purchased
<strong>the</strong> H Series servo hydraulic press brake from
Finn-<strong>Power</strong>.
The Finn-<strong>Power</strong> H Series 240 metric ton
press brake <strong>is</strong> designed for prec<strong>is</strong>ion and high
productivity. By applying servo hydraulic drives,
independent measuring frames, and CNC
control to a rigid <strong>machine</strong> structure, <strong>the</strong> H
Series press brake provides high accuracy,
increased productivity, improved flexibility, and
a high degree of reliability and safety.
Productivity
The servo hydraulic system <strong>is</strong> designed to
maximize ram speeds. Ram approach can reach
speeds of 472 IPM (200 mm/sec) and ram
return can reach speeds of 283 IMP
(120 mm/sec). The unique design of <strong>the</strong> servo
hydraulic system and fast acting servo valve
circuits yield extremely short cycle times at very
low power and energy consumption. The
working speed <strong>is</strong> completely programmable to
ensure bending <strong>is</strong> made without loss of product
quality or operator safety. Fast <strong>position</strong>ing
speeds ensure <strong>the</strong> back gauge will be ready when
<strong>the</strong> part <strong>is</strong> presented for each operation.
Easy Setup
The H Series press brake supports all <strong>the</strong>
available tooling styles to provide <strong>the</strong> quickest
means of tool setup available regardless of <strong>the</strong>
users requirements. The ram <strong>is</strong> universally
<strong>machine</strong>d to accept a variety of optional
clamping systems for different style tooling. LC
Bakery Equipment selected <strong>the</strong> tooling from
Wila.
The lower beam top on <strong>the</strong> H Series <strong>is</strong> also
universally <strong>machine</strong>d to support a variety of
tables for manual or CNC crowning,
mechanical or hydraulic clamping, American,
Wila or European die setups and a CNC
hemming shelf.
Standard on <strong>the</strong> H Series press brake <strong>is</strong> <strong>the</strong>
Touch Screen (TS 1) Control. The Pentium PC

ased system runs under Microsoft Windows
with information presented on a 12.1" TFT
color d<strong>is</strong>play. An operator friendly Touch Screen
user interface leads to a significant improvement
of data input rates and a considerable reduction
in programming time. The multi-ax<strong>is</strong> control
capability and variety of available back gauges
systems can be selected to minimize or eliminate
setup requirements of <strong>the</strong> back gauge fingers.
A 20 GB hard drive, 3.5" floppy d<strong>is</strong>c drive,
and standard network (100mb E<strong>the</strong>rnet UTP)
connection provides for unlimited memory. A
large program storage capacity with a database
of 30 upper and 30 lower tools substantially
reduces <strong>the</strong> setup time on repetitive jobs.
Complete control of <strong>the</strong> ram and back
gauge ax<strong>is</strong> <strong>is</strong> available at <strong>the</strong> operator’s fingertips
with use of <strong>the</strong> standard hand wheel.
Programming operation <strong>is</strong> direct and straight
forward and <strong>the</strong> error message system will ass<strong>is</strong>t
in making even first time operators productive.
Management data <strong>is</strong> available for <strong>machine</strong> time,
product and stroke counters.
Easy Bend
Easy Bend <strong>is</strong> a mechanical angle
measurement system to guarantee <strong>the</strong> accuracy
of <strong>the</strong> angle during <strong>the</strong> bending cycle. It
The Easy bend mechanical angle measuring system ensures
<strong>the</strong> accuracy of <strong>the</strong> angle during <strong>the</strong> bending cycle. It
compensates for variations found in <strong>the</strong> material (both
thickness and tensile) and <strong>is</strong> fully programmable.
compensates for variations found in <strong>the</strong> material
(both thickness and tensile) and <strong>is</strong> fully
programmable. You can program its use for all
bends or <strong>only</strong> some of <strong>the</strong> bends in a program.
Its measurements can be shared from one bend
to ano<strong>the</strong>r. Its <strong>position</strong> along <strong>the</strong> bed <strong>is</strong>
programmable for each bend. And it <strong>is</strong> fast,
<strong>only</strong> adding approximately three seconds to a
bend cycle.
Accuracy
The <strong>position</strong> of <strong>the</strong> upper beam, in relation
to <strong>the</strong> lower beam <strong>is</strong> measured by dual Y1 and
Y2 linear encoders <strong>that</strong> are attached
independent of <strong>the</strong> <strong>machine</strong> frame and are bed
referenced. The Y1 and Y2 cylinders power <strong>the</strong>
upper beam independently using servo
hydraulic technology. Th<strong>is</strong> design <strong>is</strong>olates ram
<strong>position</strong>ing accuracy from any deflection in <strong>the</strong>
side frames under load and maintains accurate
<strong>position</strong>ing even during off center bending
The Finn-<strong>Power</strong> H Series press brake at LC Bakery Equipment
Services Ltd., <strong>is</strong> equipped with CNC crowning, bed referencing
Y1 and Y2 encoders, and an Easy Bend angle measurement
system for accurate bending along <strong>the</strong> entire length of <strong>the</strong> brake.
operations. Ram repeatability on <strong>the</strong> S Series <strong>is</strong>
+/-.0004" (0.01 mm) and bottom bending
tonnage <strong>is</strong> programmable to +/-1 ton.
Programmable control of <strong>the</strong> ram and back
gauge movements supports all bending
requirements in even <strong>the</strong> most demanding
applications to produce cons<strong>is</strong>tent accuracy and
product quality.
A programmable back gauge <strong>is</strong> standard on
all H Series press brakes. Two rigid fingers are
provided with manual adjustment along <strong>the</strong>
length of <strong>the</strong> gauge via LM-guides and quick
release clamps. Three stops are available to
maximize <strong>the</strong> target surface for <strong>the</strong> operator and
extend <strong>the</strong> back gauge range while providing
material support for deep flanges. CNC control
of additional ax<strong>is</strong>, i.e.: X1, X2, R1, R2, Z1, and
Z2, are optionally available in a variety of back
gauge models.
Flexibility
Whe<strong>the</strong>r you are air bending or bottom
bending; running small batches with numerous
setups each day or high production quantities;
using Wila, European or American style tooling;
require special operations such as hemming or
bump radius forming, <strong>the</strong> H Series press brake
<strong>is</strong> up to <strong>the</strong> challenge. A generous standard
open height and stroke length can be increased
even fur<strong>the</strong>r with relative ease to accommodate
<strong>the</strong> various tooling styles. Due to a unique
design for connecting <strong>the</strong> cylinder to <strong>the</strong> ram
<strong>the</strong> open height can easily be increased 3.94"
(100 mm) without delaying shipment
Operation of <strong>the</strong> H Series Servo Hydraulic
Press Brake
enables
programmable
control of all
ram cycling
parameters
such as
desired bend
angle, bottoming tonnage, top of material stop,
bottom dead stop dwell, Y1 & Y2 ram tilt, ram
working speeds, and ram return <strong>position</strong>. All
servo driven back gauge ax<strong>is</strong> <strong>position</strong>s are
programmable including desired flange length
and gauge retraction. The integrated PC control
and flexible <strong>machine</strong> design features enable <strong>the</strong>
H Series Press Brake to handle a variety of
product requirements while maximizing
productivity. Part programs can be linked into a
stream for production of parts in a kit or
sequentially.
Reliability
The H Series frame <strong>is</strong> one of <strong>the</strong> heaviest in
<strong>the</strong> industry with minimal deflection under
load. The construction of <strong>the</strong> H Series Press
Brake has advanced from decades of proven and
innovative servo-hydraulic design. Valves are
manifold mounted and easily accessible for
maintenance.
According to Casasanta, h<strong>is</strong> company chose
<strong>the</strong> Finn-<strong>Power</strong> H press brake because of its
following features:
Length – 4300 mm, 4.3 meters, 168"
long.
Rugged design & weight (240 metric
ton).
Servo-hydraulic design.
Hydraulic clamping top & bottom
(Wila) – allowing quick tool change and
<strong>the</strong>y quickly seat exactly where you need
<strong>the</strong>m. “With <strong>the</strong> old press brake we could
spend 2 - 3 hours on setup to bend just
three pieces. That was something we
could not live with.”
CNC crowing (Wila)
Touch screen – Ability to adjust as many
parameters as possible in order to achieve
results. The touch screen provides <strong>the</strong>
ability to program and achieve
repeatability.
Back gauge – a rigid 5-ax<strong>is</strong> back gauge.
Ability to offline program using <strong>the</strong> 3D
software which integrates with <strong>the</strong>
software at <strong>the</strong> <strong>machine</strong> and will let <strong>the</strong>
operator see <strong>the</strong> part in 3D version and
be able to rotate <strong>the</strong> part, show bends,
etc.
“The H press brake has performed very well
at our company. It has given us a great deal
of flexibility and versatility which has allowed
us to increase our overall productivity.”
23
Performance
“The H press brake has performed very
well at our company,” says Casasanta. “It has
given us a great deal of flexibility and versatility
which has allowed us to increase our overall
productivity. Th<strong>is</strong> prom<strong>is</strong>ed performance along
with Finn-<strong>Power</strong>’s commitment to flexible
manufacturing and total equipment automation
and integration, was <strong>the</strong> driving factor in
proceeding with Finn-<strong>Power</strong>. Finn-<strong>Power</strong> was
really <strong>the</strong> <strong>only</strong> company <strong>that</strong> was promoting
th<strong>is</strong> automation integration concept as <strong>the</strong>ir
past, present and future focus.”
“We also appreciated <strong>the</strong> personal aspect of
working with <strong>the</strong> Finn-<strong>Power</strong> team,” concludes
Casasanta. “We focus on working very closely
with our customers…we hope for <strong>the</strong> same in
return. The purchasing of equipment for us,
whe<strong>the</strong>r large or small, <strong>is</strong> always very personal.
We hope to be treated by our suppliers <strong>the</strong> same
way we treat our customers. We are happy to
have experienced th<strong>is</strong> with Finn-<strong>Power</strong>.”

FOCUS ON TOOLING
Selecting a Press Brake
Tooling System for <strong>the</strong> Future
In purchasing one of today’s highly productive CNC press brakes, <strong>the</strong>
buyer will have to make several important dec<strong>is</strong>ions. One of <strong>the</strong>m
involves determining which tooling system will be used in <strong>the</strong> new
<strong>machine</strong>. While it may seem logical to have <strong>the</strong> new <strong>machine</strong> equipped to
utilize <strong>the</strong> style of tooling <strong>that</strong> was previously used, making <strong>the</strong> dec<strong>is</strong>ion to
go with an older, possibly outdated tooling system could actually prove to
be very costly and might place severe limitations on <strong>the</strong> <strong>machine</strong>s
capabilities.
Due to its accuracy and speed of set-up, <strong>the</strong> European or
Promecam”style tooling system formerly represented <strong>the</strong> state of <strong>the</strong> art.
However, usage of th<strong>is</strong> tooling system <strong>is</strong> now in a fairly severe state of
decline worldwide due to <strong>the</strong> fact <strong>that</strong> most of <strong>the</strong> punches are fairly short
in working height, thus limiting <strong>the</strong>ir versatility. In addition, <strong>the</strong> working
surfaces of <strong>the</strong> punches and dies are often hardened to HRC-43 to 48,
which provides an inferior level of wear res<strong>is</strong>tance when compared to <strong>the</strong>
more advanced heat treatment processes <strong>that</strong> are currently available.
O<strong>the</strong>r problems include <strong>the</strong> fact <strong>that</strong> it requires a variety of costly die
holders and die rails to utilize most of <strong>the</strong> various die styles <strong>that</strong> are
common to th<strong>is</strong> tooling system. These die holders and rails must also be
removed from <strong>the</strong> press brake when using dies with large V-openings and
Hemming Dies.
North American style press brake tooling has long been <strong>the</strong> most
comm<strong>only</strong> utilized tooling in North America. While versatile and easy to
use, it too has its limitations. Th<strong>is</strong> includes <strong>the</strong> fact <strong>that</strong> <strong>the</strong> end user <strong>is</strong>
limited to a narrow range of punch and die heights, which limits versatility
when forming deep parts and parts with long down flanges, as well as <strong>the</strong>
capability of press brakes with large amounts of open height.
Most North American style tooling in use today <strong>is</strong> of <strong>the</strong> nonprec<strong>is</strong>ion
type and <strong>is</strong> produced on planer milling <strong>machine</strong>s to a tolerance
<strong>that</strong> <strong>is</strong> several times <strong>that</strong> of <strong>the</strong> press brake itself. Consequently, it
comprom<strong>is</strong>es <strong>the</strong> <strong>machine</strong>s accuracy, repeatability, and overall productivity.
It also makes it difficult to take advantage of <strong>the</strong> flexibility and low
tonnage requirements provided with prec<strong>is</strong>ion air bending. Due to its lack
of prec<strong>is</strong>ion, planer made press brake tooling cannot be reordered with any
assurance <strong>that</strong> it will match <strong>the</strong> original tooling <strong>that</strong> was purchased.
North American style tooling <strong>is</strong> offered with a variety of working
surface treatments. Much of it <strong>is</strong> soft, and subsequently, does not last very
long. As punch tip radii and die shoulder radii break down, accuracy
suffers and <strong>is</strong> most often overcome by shimming <strong>the</strong> dies. Th<strong>is</strong> leads to
reduced productivity, lower part quality, and longer set-up times. Options
available to combat tooling wear include flame hardening of <strong>the</strong> working
surfaces, which will provide longer tool life but can be very incons<strong>is</strong>tent,
coatings, which are <strong>only</strong> approximately .020" (0.5 mm) deep, and laser
hardening which <strong>is</strong> approximately .039" (1.0 mm) deep. These processes
work very well for so long as <strong>the</strong> treated area remains intact. However, any
breach of <strong>the</strong> coated or laser hardened area will lead to rapid deterioration
of <strong>the</strong> working surface in <strong>that</strong> area of <strong>the</strong> tool.
Today, <strong>the</strong> state of <strong>the</strong> art in press brake tooling technology <strong>is</strong> defined
by <strong>the</strong> Wila New Standard tooling system. Th<strong>is</strong> system <strong>is</strong> prec<strong>is</strong>ion ground
to a tolerance of +/-.0004" (.01mm), making it <strong>the</strong> most accurate press
brake tooling system available. Most punches are available in four different
24
by David B<strong>is</strong>hop, Business Development Manager, Wila USA
heights with <strong>the</strong>
tallest being 7.874"
(200 mm), enabling
<strong>the</strong> operator to take
maximum
advantage of <strong>the</strong>
<strong>machine</strong>s open
height and stroke
length. Most New
Standard dies are
available in heights
of 2.165” (55 mm)
and 3.937”
(100 mm).
Like all Wila
press brake tooling,
our New Standard
tooling <strong>is</strong> CNC
Deep-hardened on
<strong>the</strong> working
surfaces to HRC-
60 to a depth of
.118" (3.0 mm),
making it <strong>the</strong> most
durable line of
press brake tooling
available. When used with our New Standard clamping and crowning
systems with hydraulic clamping, all Wila New Standard tooling <strong>is</strong>
clamped, seated, centered, and aligned with <strong>the</strong> push of a single button,
and <strong>the</strong> need for die shimming <strong>is</strong> totally eliminated. Th<strong>is</strong> results in a
drastic reduction in set-up time and eliminates <strong>the</strong> need for cumbersome,
time consuming wrenches and levers.
All Wila punches are available with our patented Safety Clicks,
making it possible to load and unload <strong>the</strong>m vertically, eliminating <strong>the</strong>
need to slide <strong>the</strong>m in and out <strong>the</strong> end of <strong>the</strong> <strong>machine</strong>.
Finally, our taller more versatile tooling profiles are extremely flexible
making it possible for <strong>the</strong> end user to use less tooling to produce a much
wider variety of parts.
The purchase of a new press brake <strong>is</strong> a dec<strong>is</strong>ion <strong>that</strong> you will most
likely have to live with for at least <strong>the</strong> next ten years. The same <strong>is</strong> true with
<strong>the</strong> tooling, clamping, and crowning systems <strong>that</strong> will be utilized on th<strong>is</strong>
<strong>machine</strong>. When viewed from th<strong>is</strong> perspective it <strong>is</strong> easy to see just how
important it <strong>is</strong> for you to make <strong>the</strong> right dec<strong>is</strong>ions.
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 Web Site: www.wilausa.com

FOCUS ON SOUTH AMERICA
FIMAQH 2006…
A Bridge to Higher Productivity
The FIMAQH 2006 exhibition was held May 30 - June 3 at Centro Costa Salguero in
Buenos Aires, Argentina. Finn-<strong>Power</strong> International participated with its dealer
Deformaciones-Tecnologicas and exhibited <strong>the</strong> X5 turret punch press.
Finn-<strong>Power</strong>’s <strong>the</strong>me for th<strong>is</strong> exhibit was “Bridge to Higher Productivity”, which featured a
walk up bridge <strong>that</strong> served as an observation platform for <strong>the</strong> many guests who v<strong>is</strong>ited <strong>the</strong> Finn-
<strong>Power</strong> booth.
According to Bob Kolcz, Finn-<strong>Power</strong>’s
director of marketing and corporate
communications, <strong>the</strong> Argentina economy
continues to improve. “It <strong>is</strong> very encouraging
to see <strong>the</strong> amount of interest in <strong>the</strong> X5,” says
Kolcz. “We welcome <strong>the</strong> opportunity to
introduce Finn-<strong>Power</strong> technology to th<strong>is</strong>
important South American market.”
X5 TURRET PUNCH PRESS & E PRESS BRAKE
DISPLAYED AT MECANICA TRADE FAIR
Large crowds v<strong>is</strong>ited <strong>the</strong> Finn-<strong>Power</strong>/ASAMAQ
booth each day of <strong>the</strong> show to see <strong>the</strong> X5 turret
punch press and <strong>the</strong> E Series servo electric press
brake in action.
25
Finn-<strong>Power</strong>’s Bridge to Higher
Productivity served as an
observation platform <strong>that</strong> allowed
v<strong>is</strong>itors to see a close up of <strong>the</strong> X5
turret punch press in action. The X5
<strong>is</strong> available in Mexico and South
America.
Last May 23 - 27, Finn-<strong>Power</strong>
International and dealer ASAMAQ
jointly participated in <strong>the</strong> MECANICA
trade fair at <strong>the</strong> Anhembi Park Exhibition Hall, São Paulo, Brazil.
The X5 turret punch press and <strong>the</strong> servo electric E press brake
attracted large crowds each day of <strong>the</strong> show.
Finn-<strong>Power</strong> International’s bending products
manager Mike Stock (right) d<strong>is</strong>cusses <strong>the</strong> E
Series servo electric press brake with
ASAMAQ’s Edson Gregorio da Silva.

CUSTOMER PROFILE
Brazilian Freezer Manufacturer Warms Up to
Increased Productivity with Finn-<strong>Power</strong>
“We have increased our capabilities
with <strong>the</strong> Finn-<strong>Power</strong> C5 turret
punch press. It has allowed us to
improve <strong>the</strong> design of our cabinets.”
Kalten’s director Jose Paulo Carvalho (left) inspects a freezer in production with Gustavo
Borges Carvalho, gerente commercial.
26
Kalten Brasil Ind. e Com. Ltda. <strong>is</strong> a manufacturer of a complete
line of industrial refrigeration equipment for small, medium,
and large installations. The company traces its roots to 1977
when it began making complete assemblies for condensers and evaporators
under <strong>the</strong> trade name Iral in Brazil’s free trade zone of Manaus. To better
serve its growing customer base, in 1994 <strong>the</strong> company moved its facilities
to Boituva, São Paulo and changed its name to Kalten. Through <strong>the</strong> years,
Kalten has gained <strong>the</strong> well-deserved reputation for both quality and
innovation – Kalten <strong>is</strong> a pioneer in <strong>the</strong> “Plug-In” technology in <strong>the</strong> freezer
industry.
Today, <strong>the</strong> company’s product line has grown to more than 60 models
with capacities from +25° C to -35° C. Kalten sells to all <strong>the</strong> Latin
American markets with customers such as Nestle, Sadia, Perdigão, etc.
There are also corporate plans to expand into new markets. In order to
increase production and productivity, Kalten has recently moved into a
new manufacturing facility of 2,800 square meters. The company has also
examined its fabrication equipment and techniques in order to maximize
its production.
Kalten imports compressors and controls from Italy, Germany,
Denmark, and <strong>the</strong> U.S. Cabinets and assemblies are produced in Brazil.
Although <strong>the</strong> company has some older fabrication equipment, including
several single station presses, a mechanical stamping press, press brake,
etc., until recently, Kalten purchased most of its sheet metal parts from job
shops. Th<strong>is</strong> dependency on contract manufacturers has created problems
in <strong>the</strong> past in terms of reliable delivery. “Our company <strong>is</strong> expanding with
special products such as quick freeze and humidity-controlled units as well as
new markets. On-time deliveries are extremely important,” explains
Kalten’s owner/director Jose Paulo Carvalho. “We needed to eliminate our
dependency on job shops to become more self reliant in <strong>the</strong> fabrication of
our product in order to meet our growing production and quality
requirements.”
In addition to <strong>the</strong> new manufacturing facility, ano<strong>the</strong>r solution was to
purchase modern fabrication equipment to process carbon steel,
aluminum, and stainless steel in thickness from 1.08 mm - 3 mm <strong>that</strong> <strong>the</strong>
company uses in its freezer products. After researching several turret punch
presses on <strong>the</strong> market, Kalten chose <strong>the</strong> C5 hydraulic turret punch press
from Finn-<strong>Power</strong>.
Kalten Brasil Ind. e Com.
Ltda. <strong>is</strong> a manufacturer of a
complete line of industrial
refrigeration equipment for
small, medium, and large
installations. <strong>the</strong> company’s
product line has grown to
more than 60 models with
capacities from +25° C to
-35° C. Kalten sells to all
<strong>the</strong> Latin American markets
with customers such as
Nestle, Sadia, and Perdigão.

Finn-<strong>Power</strong>’s Multi-Tool stations increase <strong>the</strong> 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. Kalten has three Multi-Tools.
The 20-station, 300 kN C5 hydraulic turret
punch press from Finn-<strong>Power</strong> has a maximum
sheet capacity of 1270 mm x 2500 mm and <strong>is</strong>
available with ei<strong>the</strong>r Siemens or Fanuc controls.
According to Jose Paulo Carvalho, <strong>the</strong> C5 has
proven to be highly productive, fast, and
durable. “The C5 will reduce our production
costs,” says Carvalho.
Features and benefits of <strong>the</strong> C5 include:
Super Fast Servo Hydraulic Punching –
Nibbling speeds up to 1100 hpm. The
servo-controlled ram, stroke speed, and
<strong>position</strong> are fully and individually
adjustable in both directions. Ano<strong>the</strong>r
benefit <strong>is</strong> different punching modes
(punch, Quiet Punch , downforming,
and marking).
Easy Loading – Four optimally<strong>position</strong>ed
gauge pins allow easy loading
of blanks or full-sized sheets. Sheet
loading <strong>is</strong> performed with a simple push
and always close to <strong>the</strong> table edge. Sheet
supports r<strong>is</strong>e from <strong>the</strong> table to allow easy
<strong>position</strong>ing of heavy material.
Efficient Unloading – The C5 delivers
<strong>the</strong> processed components to a freely
programmable <strong>position</strong> on <strong>the</strong> table,
increasing <strong>the</strong> operator’s efficiency. The
entire material flow on <strong>the</strong> C5 can be
conducted from just one side. Th<strong>is</strong> allows
simple and efficient log<strong>is</strong>tics and enable
<strong>the</strong> <strong>machine</strong> to be <strong>position</strong>ed anywhere
on <strong>the</strong> shop floor – even in a corner.
O<strong>the</strong>r unique features of <strong>the</strong> C5 turret
punch press include:
Tool Holders – Finn-<strong>Power</strong> incorporates
an individual tool holder concept <strong>that</strong>
allows customers to design <strong>the</strong>ir own
turret layouts. Unlike o<strong>the</strong>r designs,
specific tool stations are not <strong>machine</strong>d
into <strong>the</strong> turret. Finn-<strong>Power</strong> offers <strong>the</strong>
<strong>only</strong> flexible selection of tool holders in
<strong>the</strong> industry. Any major tooling style can
be installed in a Finn-<strong>Power</strong> turret. Up to
10 auto-index, forming, or Multi-Tool ®
stations may be installed in a Finn-<strong>Power</strong>
turret.
Auto-Index – Finn-<strong>Power</strong>’s unique autoindex
system prec<strong>is</strong>ely rotates <strong>the</strong> punch
and die in <strong>the</strong>ir tool holders using a
single A.C. servo-motor system. The
system does not need to match separate
servo-motors as in some o<strong>the</strong>r <strong>machine</strong>s.
Rotation in .001 degree
programmable increments
gives <strong>the</strong> <strong>machine</strong> <strong>the</strong>
ability to rotate beyond
360 degrees, allowing <strong>the</strong>
system to automatically
select <strong>the</strong> shortest path to
rotate to a programmed
angle input into <strong>the</strong> 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.
Kalten has four auto-index
stations.
Multi-Tool ® – Finn-<strong>Power</strong>’s
Multi-Tool stations increase
<strong>the</strong> number of tools available
in a turret, thus reducing setup
and increasing productivity. The Multi-
Tool system allows multiple tools to be put in
one station. Finn-<strong>Power</strong> Multi-Tool offers 6,
8, 10, or 24 different punch/die
combinations in <strong>only</strong> one station – a turret
within a turret. Using a 40 station
alpha/numeric Multi-Tool part identification
programs are fast and easily done. Kalten has
three Multi-Tools. <strong>“Finn</strong>-<strong>Power</strong>’s Auto-Index
and Multi Tool are very important features for
us,” says Gustavo Borges Carvalho, Kalten’s
gerente commercial. “We have been able to
reduce setup times with a total of 69 tools in
<strong>the</strong> turret.”
Automatic Clamp Setting & Movement –
Finn-<strong>Power</strong>’s patented automatic clamp
setting PCS <strong>is</strong> a standard C5 feature. It
automatically <strong>position</strong>s sheet clamps
according to <strong>the</strong> numerical program, virtually
eliminating punching of <strong>the</strong> clamps. When
changing production from full size to small
sheets, clamp settings can be made
automatically without wasting operator time.
Optional features on <strong>the</strong> C5 include:
Optional Catch & Carry Work Chute –
Finn-<strong>Power</strong>’s “Catch & Carry” work chute <strong>is</strong>
not just a drop door or a work chute in <strong>the</strong>
ordinary sense. Its mechan<strong>is</strong>m allows <strong>the</strong>
reception of several components to
500 mm x 500 mm in size onto a level from
which <strong>the</strong>y subsequently exit from <strong>the</strong>
<strong>machine</strong> as a stack.
Optional Upward Forming System – The
safe solution for sheet metal forming <strong>is</strong> from
below <strong>the</strong> sheet. Finn-<strong>Power</strong>’s upward
forming option provides more accurate
forming and greater forming heights up to
16 mm. Ano<strong>the</strong>r advantage <strong>is</strong> <strong>that</strong> all dies are
at <strong>the</strong> same height and <strong>the</strong>re are more highforming
dies in <strong>the</strong> turret, reducing r<strong>is</strong>k of
material damage and increasing <strong>machine</strong>
uptime.
Unique to <strong>the</strong> C5 turret punch press, full
tonnage indexable upforming allows complex
forming operations to be made quickly by
using a single forming tool. An index
mechan<strong>is</strong>m <strong>is</strong> used to turn <strong>the</strong> forming tool
into an NC programmed angle.
Finn-<strong>Power</strong>’s upforming feature provides a
prec<strong>is</strong>e process for knock-outs, louvers, and
o<strong>the</strong>r forming. Finn-<strong>Power</strong> resolved <strong>the</strong>
conventional problem of <strong>the</strong> die height
27
From left to right, Antonio Roberto Pereira, director from
ASAMAQ, Maydi Carolina Garcia, Kalten’s programmer,
and Jose Paulo Carvalho inspect a part fabricated on <strong>the</strong>
Finn-<strong>Power</strong> C5 turret punch press.
Finn-<strong>Power</strong>’s NC Express CNC Programming Software <strong>is</strong>
a user friendly, integrated, and automated tool for
managing Finn-<strong>Power</strong> equipment in <strong>the</strong> most efficient
manner.
impeding free sheet movement. Finn-
<strong>Power</strong>’s design allows forming heights up
to 16 mm (0.62" ) with <strong>the</strong> forms made
by <strong>the</strong> die moving upwards and <strong>the</strong>n
retracting, allowing completely free sheet
movement, eliminating scratched or
jammed sheets.
“We have increased our capabilities with
<strong>the</strong> Finn-<strong>Power</strong> C5 turret punch press,” explains
Jose Paulo Carvalho. “It has allowed us to
improve <strong>the</strong> design of our cabinets. It also
allowed us to explore new markets, including
<strong>the</strong> job shop market to fill <strong>the</strong> excess production
time due to our improved productivity. We
recently purchased an automated paint line and
we intend to add a servo-electric press brake in
<strong>the</strong> near future <strong>that</strong> will allow us to make
additional product design enhancements.”

FOCUS ON ROBOTICS
by Mark Handelsman, Manager, Industry Marketing, FANUC Robotics America, Inc.
Advances in Robot Intelligence
According to <strong>the</strong> Robotic Industries
Association, <strong>the</strong> North American
robotics industry grew at an average
annual rate of 20% from 2003-2005. Taking
into consideration a relatively soft automotive
market and increased pressure from overseas
manufacturers, how has th<strong>is</strong> strong growth
occurred? An ongoing trend of cost reductions
has been a factor. The price for both robots and
overall turnkey systems has continued to
decline. Also driving <strong>the</strong> strong growth <strong>is</strong> <strong>the</strong>
continually improving performance of robots.
Robots can perform tasks today <strong>that</strong> were not
possible just a few years ago. Robots can also do
more in less time, providing higher levels of
productivity.
Perhaps <strong>the</strong> most important long-term
trend has been <strong>the</strong> increased advances in robot
intelligence. Since <strong>the</strong>ir initial inception, robots
have had some level of intelligence in making
dec<strong>is</strong>ions about part availability, checking if a
feature <strong>is</strong> present, detecting error conditions, or
related <strong>is</strong>sues. In most cases, th<strong>is</strong> intelligence
was based on a specific sensor detecting a
specific condition. For example, a photo eye <strong>is</strong>
used to detect <strong>that</strong> a part <strong>is</strong> present, and in <strong>the</strong>
correct orientation through <strong>the</strong> presence or
absence of a pin, detent or o<strong>the</strong>r feature. Th<strong>is</strong>
photo eye <strong>is</strong> <strong>the</strong>n wired to a PLC or directly to
<strong>the</strong> robot controller. At <strong>the</strong> appropriate time in
<strong>the</strong> robot program <strong>the</strong> robot checks th<strong>is</strong> photo
eye to confirm <strong>that</strong> <strong>the</strong> part <strong>is</strong> in <strong>position</strong> and
in <strong>the</strong> correct orientation before picking it up or
performing some o<strong>the</strong>r operation.
Using a photo eye or similar sensor for th<strong>is</strong>
example <strong>is</strong> a simple and reliable approach, and
<strong>is</strong> probably <strong>the</strong> right choice in th<strong>is</strong> instance.
However, opportunities for automation are not
always th<strong>is</strong> simple. Multiple part styles may
need to be handled. The means of
differentiating parts may be more complex.
Parts or <strong>the</strong> manufacturing process may not
lend itself to simple conveyors. For example,
parts located in bins, with layers separated by a
slip sheet are comm<strong>only</strong> used for metal parts.
Parts may have complex geometries, making
<strong>the</strong>m more difficult to locate without <strong>the</strong>
additional cost for fixtures to locate <strong>the</strong> parts.
Two Dimensional V<strong>is</strong>ion Location
Adding <strong>the</strong> means necessary to deal with
<strong>the</strong>se types of complexities has been a major
barrier to <strong>the</strong> increased use of robotics in some
industries. Recently th<strong>is</strong> has begun to change.
The technology <strong>that</strong> has had <strong>the</strong> most
significant short-term impact has been two
dimensional v<strong>is</strong>ion systems. 2D v<strong>is</strong>ion systems
cons<strong>is</strong>t of standard industrial cameras used to
take images <strong>that</strong> are processed by <strong>the</strong> robot to
make dec<strong>is</strong>ions on how parts should be handled.
Industrial v<strong>is</strong>ion systems have been available for
some time, but <strong>the</strong>y have reached <strong>the</strong> priceperformance-reliability
point <strong>that</strong> allows <strong>the</strong>m
to be used for applications <strong>that</strong> were not feasible
just a few years ago.
A good example <strong>is</strong> using a v<strong>is</strong>ion system in
conjunction with a robot to locate parts stacked
in bins separated by standard slip sheets. Th<strong>is</strong> <strong>is</strong>
a common means of transporting parts from
plant to plant or even to transport parts within
a plant. Without <strong>the</strong> use of a v<strong>is</strong>ion system,
manufacturers must use relatively expensive
formed plastic dunnage or some o<strong>the</strong>r means of
accurately locating parts within a bin. Th<strong>is</strong> type
of formed plastic dunnage <strong>that</strong> can be stacked
within a bin <strong>is</strong> relatively expensive with <strong>the</strong>
mold alone costing $60,000 to $100,000 to
design and manufacture.
2D v<strong>is</strong>ion systems are a good alternative to
formed dunnage or o<strong>the</strong>r relatively expensive
methods of locating parts within a bin. Until
recently, <strong>the</strong>re were many <strong>is</strong>sues <strong>that</strong> made using
a v<strong>is</strong>ion system difficult, including variations in
part color from batch to batch, variations in <strong>the</strong>
condition of <strong>the</strong> bins, or markings <strong>that</strong> are left
on reused separator sheets. With ongoing
advances in v<strong>is</strong>ion technology, <strong>the</strong>se <strong>is</strong>sues can
now be overcome with good success. Today’s 2D
v<strong>is</strong>ion systems can locate most parts <strong>that</strong> can
stack on top of separator sheets within bins.
The typical approach to th<strong>is</strong> application <strong>is</strong>
to use a camera mounted over <strong>the</strong> bin to locate
parts. The camera <strong>is</strong> mounted high enough so
<strong>that</strong> a robot can move underneath <strong>the</strong> camera
and into <strong>the</strong> bin. At <strong>the</strong> beginning of each layer,
<strong>the</strong> robot processes an image of a layer of parts
and determines where to pick up each part. If
more prec<strong>is</strong>e <strong>position</strong>ing <strong>is</strong> required, a camera
28
can also be mounted to a robot. The robot <strong>the</strong>n
moves <strong>the</strong> camera over a part or group of parts,
takes a picture, and passes th<strong>is</strong> information to
<strong>the</strong> robot to determine where to pick each part.
When all of <strong>the</strong> gears in each layer are removed,
<strong>the</strong> robot removes <strong>the</strong> separator sheet and starts
removing parts from <strong>the</strong> next layer.
With ei<strong>the</strong>r a fixed camera or a robotmounted
camera, <strong>the</strong> incremental investment to
add v<strong>is</strong>ion <strong>is</strong> significantly less than <strong>the</strong> cost to
develop a special dunnage or o<strong>the</strong>r alternatives
to locating parts. V<strong>is</strong>ion systems also provide
greater flexibility for handling different parts on
<strong>the</strong> same line, or adapting to a part change-over.
Automated de-stacking systems like th<strong>is</strong> were
cost prohibitive just a few years ago. Now, with
integrated v<strong>is</strong>ion, robots are feasible and
affordable.
Three Dimensional V<strong>is</strong>ion Location
2D v<strong>is</strong>ion systems are great for parts <strong>that</strong> lie
flat, but th<strong>is</strong> <strong>is</strong> not always possible. Within <strong>the</strong>
past few years, three-dimensional v<strong>is</strong>ion systems
have become feasible for some applications
where parts do not lie flat: For example, parts
<strong>that</strong> can stack upon each o<strong>the</strong>r, but may shift
from side to side as <strong>the</strong> parts stack up. A 2D
image does not provide enough information to
handle th<strong>is</strong> shifting.
A simple technique <strong>that</strong> has proven
effective <strong>is</strong> to use laser light strips in
conjunction with a 2D camera. An overhead
2D camera provides a rough location of parts in
a bin. Th<strong>is</strong> camera also identifies <strong>the</strong> next part
to be selected. A second camera mounted to <strong>the</strong>
robot works in conjunction with a laser
Tactile Feedback
Although v<strong>is</strong>ion systems are <strong>the</strong> most
common form of intelligent sensors for robots,
<strong>the</strong>y are not <strong>the</strong> <strong>only</strong> alternative. Six degree of
freedom force sensors are comm<strong>only</strong> used to
give robots tactile feedback. For high prec<strong>is</strong>ion
assembly, force sensors are used to guide tight fit
insertions such as for inserting shafts, with or
without keys, into holes. Robots with force
sensors can also be used for more complex
assembly tasks such as inserting gears into
housings such as transm<strong>is</strong>sions.
Beyond Today’s Solutions
Intelligent sensor technology has played a
critical part in <strong>the</strong> successful use of robots in a
variety of applications. As intelligent sensor
technologies continue to advance, robots will
have even greater capabilities in <strong>the</strong> future.
Nothing will ever replace <strong>the</strong> super computer in
each person’s brain <strong>that</strong> can make very complex
d<strong>is</strong>tinctions, but applications once thought to
be impractical are now common tasks for
intelligent robots.

Hydraulic Turret
Punch Press
= One <strong>machine</strong> capable of transforming a full
sized sheet into fin<strong>is</strong>hed parts
= Less scrap with material yields as high as 98%
= Unmanned operation
= Dramatic decrease in material handling
= Elimination of micro-joints, tabs, shaker parts
and skeletons
= Ability to punch, nibble, upform, tap, mark,
perform wheel technology operations, and
shear in one process
= Elimination of secondary operations
= Higher productivity and profits
= Higher quality
= Reduced manufacturing costs
= Faster return on investment
= Finn-<strong>Power</strong>’s 20 years experience in
punch/right angle shear technology with
proven field performance in hundreds of
fabrication shops throughout <strong>the</strong> world
IT ALL ADDS UP TO INCREASED PRODUCTIVITY,
QUALITY, AND PROFITS FOR YOUR COMPANY.
Contact us to learn how Finn-<strong>Power</strong> can add to your company’s bottom line.
Finn-<strong>Power</strong> International, Inc. / 710 Remington Road / Schaumburg, IL 60173 / USA
Tel. 847 885 3200 / Fax 847 885 9692 / www.finnpower.com
Integrated Right
Angle Shear

CUSTOMER PROFILE
Quality “Hot & Cold” Manufacturing
Red Dot Corporation Provides Worldwide Climate Control Solutions
For over 40 years, <strong>the</strong> Red Dot Corporation, Seattle, WA, has earned a well-deserved
reputation as a pioneer in designing and manufacturing heating and air conditioning
systems for <strong>the</strong> heavy-duty vehicle industry. Th<strong>is</strong> pioneer spirit began with Red Dot being
<strong>the</strong> first company to supply integrated Heat/Air Conditioning systems to Kenworth, Freightliner,
Mack and Peterbilt trucks.
Today, Red Dot supplies many of <strong>the</strong> world’s major OEMs of both On-Road and Off-Road
vehicles as well as many smaller companies in <strong>the</strong> development of durable HVAC units. To
manufacture its products for <strong>the</strong> world market, <strong>the</strong> company’s Seattle location has two buildings with
250,000 square feet of capacity and 450 employees. Red Dot also recently opened a 75,000-squarefoot
facility in Memph<strong>is</strong>, TN, with 18 employees, and a 25,000-square-foot facility, Red Dot
Europe, LTD., <strong>is</strong> located in <strong>the</strong> U.K. with 18 employees.
Red Dot’s manufacturing philosophy <strong>is</strong> one <strong>that</strong> incorporates “Lean Manufacturing Techniques”
to optimize its flexibility in <strong>the</strong> processing of component parts and assemblies, while maintaining
quality of workmanship and improving throughput. To achieve th<strong>is</strong>, Red Dot draws from <strong>the</strong>
following practices:
J.I.T. (Just In Time), to minimize inventory levels
Pre-cut width coil stock
The Finn-<strong>Power</strong> C5 Compact Express provides highly compact load/unload automation by utilizing <strong>the</strong>
space above and below <strong>the</strong> turret punch press.
“We had faith in <strong>the</strong> Finn-<strong>Power</strong> equipment
and service from past experience, and we were
quite confident with <strong>the</strong> C5 Compact Express
as <strong>the</strong> <strong>machine</strong> of choice for Red Dot.”
Jim Yantzer, Red Dot’s production systems manager
(right) and Jesse Smith, fabrication manager, inspect a
part fabricated on <strong>the</strong> C5 Compact Express.
30
Employee cross-training
Computer-aided forecasting systems
Manufacturing <strong>is</strong> involved in product
design
Building block sub-assembly
Kan Ban control systems to maximize
flow rate
Lean Techniques minimize cycle times
and limits waste
Low inventory of purchased materials
and components
Employee participation in “Kaizen”
events to continuously improve processes
and throughput
According to James R. Yantzer, production
systems manager, Red Dot attempts to keep
most manufacturing in-house. “We like to
control our own destiny in terms of quality and
deliveries,” explains Yantzer. “We are a vertically
integrated company <strong>that</strong> manufactures more of
<strong>the</strong> components used in its products than any
o<strong>the</strong>r HVAC supplier in <strong>the</strong> heavy-duty
industry. The manufacturing processes involved
in producing condensers, wire harness, tub
assemblies, evaporators, heater cores and sheet
metal components requires specialized
equipment.”
Red Dot has <strong>the</strong> equipment, <strong>the</strong>
technology, and <strong>the</strong> knowledgeable personnel
required to build <strong>the</strong>se components. Red Dot’s
fabrication equipment includes turret punch
presses, lasers, press brakes, tube benders,
stamping presses, and spot welders. “Our
strategy <strong>is</strong> to continually invest in equipment
and have <strong>the</strong> resources available <strong>that</strong> offer
tremendous flexibility to quickly and efficiently
build to customer specifications,” says Yantzer.

More Turret Punch Press Capacity
In 2004, Red Dot needed to increase its
turret punch press capacity to keep pace with
both double digit growth and a new
government contract <strong>that</strong> put increased demand
on <strong>the</strong> fabrication department. The U.S.
military dec<strong>is</strong>ion to armor plate all <strong>the</strong> Humvees
used in Iraq created a major challenge to keep
<strong>the</strong> vehicle’s cab temperature cool enough for
<strong>the</strong> soldiers and marines to operate effectively.
With <strong>the</strong> armor plating, temperatures up to
130F degrees were reg<strong>is</strong>tered inside <strong>the</strong> cabs. In
late 2004, Red Dot met <strong>the</strong> challenge and was
awarded <strong>the</strong> contract to retrofit 20,000 of <strong>the</strong>
armor-plated Humvees with upgraded air
conditioner units. The project was recently been
completed in November, 2005.
While <strong>the</strong> company looked at equipment
from several <strong>builder</strong>s, <strong>the</strong>y eventually chose <strong>the</strong>
Finn-<strong>Power</strong> C5 Compact Express. “We had
previous experience with Finn-<strong>Power</strong>,” says
Yantzer. “We purchased <strong>the</strong> Finn-<strong>Power</strong> TP
turret punch press 12 years ago and <strong>the</strong> F Series
<strong>machine</strong> about six years later. One of goals was
to standardize our equipment for benefits in
service and maintenance, tooling, software, etc.
We had faith in <strong>the</strong> Finn-<strong>Power</strong> equipment and
service from past experience, and we were quite
confident with <strong>the</strong> C5 Compact Express as <strong>the</strong>
<strong>machine</strong> of choice for Red Dot.”
In January, <strong>the</strong> Finn-<strong>Power</strong> C5 Compact
Express was installed at Red Dot. The C5
Express adds unmanned operation to <strong>the</strong> C5
turret punch press through highly compact
load/unload automation. The unit’s
loading/unloading solution utilizes <strong>the</strong> space
above and below <strong>the</strong> <strong>machine</strong> – requiring <strong>only</strong>
slightly more space than a turret punch press.
“The small footprint of <strong>the</strong> C5 Compact
Express makes it easier for one operator to run
two <strong>machine</strong>s,” continues Yantzer. “We
configured <strong>the</strong> <strong>machine</strong>s for <strong>that</strong> end and also
to maximize efficient part flow.”
The 20-station, 33-ton C5 hydraulic turret
punch press has a maximum sheet capacity of
50" x 100" and <strong>is</strong> available with ei<strong>the</strong>r Siemens
or Fanuc controls.
Tooling flexibility <strong>is</strong> also important to Red
Dot. Up to 10 auto-index and Multi-Tool ®
holders may be installed in a Finn-<strong>Power</strong> turret.
Red Dot has four Multi-Tool cassettes in <strong>the</strong> C5
– a 24 station, two 10-stations, and an 8
station. Red Dot also has six full tonnage autoindex
stations and two indexable upforming
stations. Unique to <strong>the</strong> C5 turret punch press,
full tonnage indexable upforming allows
complex forming operations to be made quickly
by using a single forming tool. An index
mechan<strong>is</strong>m <strong>is</strong> used to turn <strong>the</strong> forming tool into
an NC programmed angle.
Finn-<strong>Power</strong>’s upforming feature provides a
prec<strong>is</strong>e process for knock-outs, louvers, and
o<strong>the</strong>r forming. Finn-<strong>Power</strong> resolved <strong>the</strong>
conventional
problem of <strong>the</strong>
die height
impeding free
sheet movement.
Finn-<strong>Power</strong>’s
design allows
forming heights
up to 16 mm
(0.62" ) with <strong>the</strong>
forms made by
<strong>the</strong> die moving
upwards and <strong>the</strong>n
retracting,
allowing
completely free
sheet movement,
U.S. Marines on <strong>the</strong> Humvee <strong>that</strong> has been retrofitted with armor and a new air conditioning
unit from Red Dot.
eliminating scratched or jammed sheets. “We
use dimples on our parts for locating in spot
welding,” explains Yantzer. “It’s important for us
to have dimples <strong>that</strong> can go up or down –
sometimes both on <strong>the</strong> same part. We also use
louvers and flanges on our parts.”
O<strong>the</strong>r features of <strong>the</strong> C5 turret punch press
include:
Super fast servo hydraulic punching –
Nibbling speeds up to 1100 hpm. The
servo-controlled ram, stroke speed, and
<strong>position</strong> are fully and individually
adjustable in both directions. Ano<strong>the</strong>r
benefit <strong>is</strong> different punching modes
(punch, Quiet Punch, downforming,
and marking).
Easy loading – Four optimally-<strong>position</strong>ed
gauge pins allow easy loading of blanks or
full-sized sheets. Sheet loading <strong>is</strong>
performed with a simple push and always
close to <strong>the</strong> table edge. Sheet supports
r<strong>is</strong>e from <strong>the</strong> table to allow easy
<strong>position</strong>ing of heavy material.
Efficient unloading – The C5 delivers
<strong>the</strong> processed components to a freely
programmable <strong>position</strong> on <strong>the</strong> table,
increasing <strong>the</strong> operator’s efficiency. The
entire material flow on <strong>the</strong> C5 can be
conducted from just one side. Th<strong>is</strong> allows
simple and efficient log<strong>is</strong>tics and enable
<strong>the</strong> <strong>machine</strong> to be <strong>position</strong>ed anywhere
on <strong>the</strong> shop floor – even in a corner.
Automatic Clamp Setting & Movement
– Finn-<strong>Power</strong>’s patented automatic clamp
setting PCS <strong>is</strong> a standard C5 feature. It
automatically <strong>position</strong>s sheet clamps
according to <strong>the</strong> numerical program,
virtually eliminating punching of <strong>the</strong>
clamps. When changing production from
31
Three Finn-<strong>Power</strong> turret punch presses product most of <strong>the</strong>
sheet metal pans at Red Dot.
full size to small sheets, clamp settings
can be made automatically without
wasting operator time.
Catch & Carry Work Chute – Finn-
<strong>Power</strong>’s “Catch & Carry” work chute <strong>is</strong>
not just a drop door or a work chute in
<strong>the</strong> ordinary sense. Its mechan<strong>is</strong>m allows
<strong>the</strong> reception of several components to
19.7" x 19.7" in size onto a level from
which <strong>the</strong>y subsequently exit from <strong>the</strong>
<strong>machine</strong> as a stack.
And how has <strong>the</strong> C5 Compact Express
performed at Red Dot? “The Finn-<strong>Power</strong> turret
punch presses make most of <strong>the</strong> sheet metal
parts for our HVAC units,” explains Yantzer.
“We couldn’t have completed <strong>the</strong> military
project in-house without <strong>the</strong> addition of <strong>the</strong> C5
Compact Express. In addition, during C5
installation and training, <strong>the</strong> Finn-<strong>Power</strong>
technicians gave our engineers ideas on how to
design products to best use <strong>the</strong> features and
capabilities of <strong>the</strong> Finn-<strong>Power</strong> turret punch
press.”
“We couldn’t have completed <strong>the</strong> military project inhouse
without <strong>the</strong> addition of <strong>the</strong> C5 Compact Express.”

Global Headquarters & Manufacturing
Finn-<strong>Power</strong> Oy
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2244
www.finn-power.com
Finn-<strong>Power</strong> Group Sales & Service Units
Bending Technology Unit
Finn-<strong>Power</strong> 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-<strong>Power</strong> N.V.
Leenstraat 5
B-9810 Nazareth
BELGIUM
Tel. + 32 9 382 9030
Fax + 32 9 382 9031
Canada
Finn-<strong>Power</strong> 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-<strong>Power</strong>
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-<strong>Power</strong> Oy
P.O. Box 38
FIN-62201 Kauhava
FINLAND
Tel. + 358 6 428 2111
Fax + 358 6 428 2083
France
Finn-<strong>Power</strong> 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-<strong>Power</strong> GmbH
Postfach 54
D-85399 Hallbergmoos
GERMANY
Tel. + 49 811 55330
Fax + 49 811 1667
Spain
Finn-<strong>Power</strong> Iberica, S.L.
C/. Vapor 8
Poligono Industrial El Regás
08850 Gavá (Barcelona)
SPAIN
Tel. +34 902 302 111
Fax +34 902 302 112
United States
Finn-<strong>Power</strong> International, Inc.
710 Remington Road,
Schaumburg, IL 60173
USA
Tel. + 1 847 885 3200
Fax + 1 847 885 9692
www.finnpower.com