Solutions for BUSBAR PROCESSING NPC. CNC busbar cutting - punching - bending solution BOSCHERT 420 CNC-WP. Internal document for training

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1 CNC busbar cutting - punching - bending solution BOSCHERT Internal document for training 420 CNC-WP 1

2 Overview Professional busbar processing: Punching machine CU-Profi Punching machine CU-WKII Bending machine 220 CNC-WP 420 CNC-WP 2

3 Overview Same (one) programming system Punching machine CU-Profi Punching machine CU-WKII Bending machine 220 CNC-WP 420 CNC-WP BOSCHERT BOSCHERT 3

4 The power combination High quality from Switzerland BOSCHERT Own production Big know-how Support in your country Longtime partnership Boschert - Stierli Best references Both companies are specialists in their field and do what they do best. STIERLI and BOSCHERT have been known for decades in the market as machine tool builders with great experience and the highest quality machines. 4

5 The power combination Absolut specialist for bending since 1936 High quality from Switzerland BOSCHERT Absolut specialist for punching since

Machine view 420 CNC-WP Programming with the

the machine Complete enclosed and robust

Sturdy and solid machine construction for

High quality from Switzerland 420 CNC-WP

vee-bloc - Vee-block with measuring system -

6 Machine view 420 CNC-WP Programming with the programming system or dialog control directly at the machine Complete enclosed and robust guidance system for a long-lasting precision Autom. CNC-back gauge with L = 1000, 2000 or 3000 mm Sturdy and solid machine construction for precise bending results Practical tool boards High quality from Switzerland 420 CNC-WP Toolings for busbar processing: - Standard vee-bloc - Vee-block with measuring system - Edgewise bending - Step forming tool - Z- step forming tool - Twisting tool Big working table, expandable with additional tables ready! 21

7 36.6 Liter/min Motor 132 M8 B5 3.0 kw / 720 Upm 3x400 V / 50 Hz 7.1 A NG10 6,0 cm³/u Oil filling Oil filling = approx. 600 Liter Ölqualitiy = BP Energol HLP 32 ISO 5,0 cm³/u 270 bar NG10/6 Filter MPF 180 Q = 340 Liter / min. Cylinder ø 100/70-33 A = 78,5 cm² Cylinder ø 100/70-33 A = 78,5 cm² 25,0 cm³/u 300 bar 3/8" G 3/8" G 3/8" G 3/8" G Pomp Pomp QX / R QX / R Q1 = 3.6 Liter / min Q3 = 46.9 Liter / min Q2 = 4.3 Liter / min Q4 = 36.6 Liter / min 3/8" G 3/8" G 1" G 1" G p = 320 bar p = 320 bar 32,0 cm³/u 100 bar ø12 S 3/8" G Cylinder ø 100/70-33 A = 78,5 cm² 3.6 Liter/min ø12 S 3/8" G ø12 S 3/8" G NG4 Motor 180 L4 B kw / 1470 Upm 3x400 V / 50 Hz 40.8 A 3/8" G 3/8" G 300 bar 300 bar ø12 S 3/8" G 80 bar 3/8" G 3/8" G ø12 S 3/8" G ø12 S 3/8" G 3/8" G 3/8" G ø12 S 3/8" G ø12 S 3/8" G 3/8" G 3/8" G 3/8" G 3/8" G Cylinder ø 100/ A = 78,5 cm² Temperatur indicator On => 65 C Off => 50 C Cylinder ø 80/56-33 A = 50,3 cm² 3/8" G 3/8" G 60 bar 46.9 Liter/min NG10 ø12 S 3/8" G 3/8" G 3/8" G 100 bar Cylinder 100 bar Cylinder 100 bar Cylinder 100 bar Cylinder 100 bar ø 100/70-33 ø 100/70-33 ø 100/70-33 ø 100/70-33 A = 78,5 cm² A = 78,5 cm² A = 78,5 cm² A = 78,5 cm² Oil cooler Oiltech LOC D-B 0.75 kw Q = 40 Liter / min 0.26 kw / C 1" ND ø28 L Proportional axe control X 300 bar 300 bar 300 bar (Installation in steel metal sheet front 4mm) 285 bar 270 bar Proportional axe control Y 1" G 1" G 4.3 Liter/min Cylinder ø 320/ A = 804,2 cm² Hybrid hydraulic system The HYBRID hydraulic system is characterized by: Pressure tension P4 Cylinder 1 & 2 Cylinder 3 Cylinder 4 Cylinder 5 Cylinder 6 Cylinder 7 Pressure tension P2 Energy on demand (save energy) ø25 S 3/4" G ø28 L 1" G ø12 S 3/8" G Pressure P1 Clamping Pressure bending P3 ø18 L 1/2" G ø16 S 1/2" G Bending ø12 S 3/8" G Feed Less machine noise M ø12x1.5 Stierli-Bieger AG Made with quality components Speed continuously adjustable, Advantage for long busbars HYBRID Technology 22

8 Powerful tools T 12.1 A L W H Vermassung (A,M,I) A Abstand A Länge L Höhe H Biegewinkel W Angle measuring system for automatic angle correction. (Automatic springback compensation) Bending with standard veeblocks (narrow bends) Edgewise bending up to 100/10 mm Step forming tool up to thickness 10 mm, Special tools up to 20 mm Twisting tool up to 100x10mm Cutting (shearing) tool for busbars 23

9 Automatic angle correction Step 1 Step 2... Programming and inserting the... Start bending proces... busbar... 24

10 Automatic angle correction Step 3 Step 4... Small reversing of the cylinder with measuring of the effective angle Re-bending according the measured springback of material... 25

Automatic angle correction Vee-block with integrated measuring system: Very robust design for high numbers Bending without marks For various

11 Automatic angle correction Vee-block with integrated measuring system: Very robust design for high numbers Bending without marks For various thicknesses: MW 50 for 4-6 mm MW 65 for 5-10 mm for 12mm if R=5mm MW 90 for mm 220 CNC-WP: 150 mm tooling height 420 CNC-WP: 200 mm (250mm) height 26

programming system can also be used with standard

12 Bending with standard vee-blocks With standard vee-blocks are closer bends possible The angle programming system can also be used with standard veeblocks Hardened leading edges for long life With quick tool change system 27

13 Bending without marks 28

Standard narrow section punch Bending of narrow bends

support for high busbars + precision in bending Heights

CNC/WP: 220 mm (optional 250 mm) Replaceable, hardened

14 Standard narrow section punch Bending of narrow bends are possible Automatic centering Replaceable, hardened inserts radius R5 and R10 inclusive. More radii according to order Standard version with support for high busbars + precision in bending Heights of bending punch: (standard) 220 CNC/WP: 150 mm 420 CNC/WP: 220 mm (optional 250 mm) Replaceable, hardened inserts radius With support for high busbar bending + precision Bending without support 29

15 Support for punch 30

Bending of narrow bends Height 100 mm (without support) Heights are possible up to 200 mm (with additional support) Special punch

16 Narrow section punch for small bends < 65mm The largest part of the busbars can be bent with the standard tools For narrow bends, there is the possibility of special punches. Please tell us your requirements, we offer you your requested tool. Bending of narrow bends Height 100 mm (without support) Heights are possible up to 200 mm (with additional support) Special punch for busbars with thickness up to 10 mm and U Inside dimension = 50 mm (even smaller dimensions on request) Special milled punch for narrow bends 31

17 Busbars geometries Stierli-Bieger offers a solution for all common bus bars geometries. Send us your drawings, we will review your requirements and make your personal specification for the required tooling. Or do you want to check your busbars by yourselfs? We will send you the necessary tools - such as bending tables with minimum shortest lengths. We will gladly check [Alle Angaben in mm] your requirements! [Alle Angaben in mm] Sonderspitzstempel auf Anfrage. 32

18 Vee-block spacer Vee-block spacers can be used to increase the distance between the vee-block and the cylinder support plate. For long Z-bends, vee-block spacers can be necessary Vee-block spacer 33

Step forming tool No. 1 If the side lengths are too short, so as to bend with a standard vee-block, the step forming tool may be used. We distinguish between two different step forming tools.

19 Step forming tool No. 1 If the side lengths are too short, so as to bend with a standard vee-block, the step forming tool may be used. We distinguish between two different step forming tools. Step forming tool No. 1 (Y-Distance is variable) Y X (X-Distance is fix) X = fix, about mm (or according to customer) Y = adjustable with length of cylinder stroke, max. ca. 25 mm Important: Step forming tools need additional working force (2 bends are bent together). The WP-420 CNC bending is preferable depending on the task. The step distance Y will be adjusted with cylinder stroke length. 34

Step forming tool Nr. 2 This tool is variable in both directions. The step distance is set with spacer plates with different thicknesses. Step forming tool No.

20 Step forming tool Nr. 2 This tool is variable in both directions. The step distance is set with spacer plates with different thicknesses. Step forming tool No.2 (Y-Distance is variable) Y X (X-Distance is variable) X = adjustable with moving of one tool block Y = adjustable with spacer plates, max. ca. 25 mm Important: Step forming tools need additional working force (2 bends are bent together). The WP-420 CNC bending is preferable depending on the task. The step distance and the step width are adjustable 35

The tool will be made for one specific geometry with one thickness and the step width and step distance are

21 Z-Tool Your deductions are 90 and the leg lengths are too short to bend the bending vee-block. Our bending solution is the so called Z-bending tool. 2 bends to be performed in one stroke. The tool will be made for one specific geometry with one thickness and the step width and step distance are not adjustable This tool can be used for very narrow 90 Z-bends For one such tool, the prior examination of your drawing is necessary. 36

22 Edgewise bending Depending on the dimension of the busbar requires a different clamping: Edgewise bending tool No.1 Edgewise bending tool No.2 Edgewise bending tool No.3 up to 30 x 10 mm without clamping up to 60 x 10 mm with hand clamping up to 100 x 10 mm with hyd raulic clamping 37

23 Twisting tool Twisting of the busbar with the twisting tool by 90 Moviesequenz Max. Dimensions: 100 x 10 mm. 38

24 Powerful control system It is a robust industrial control, which brings the following benefits: Graphic display Busbar shape library with Bending simulation dialog programming 39

25 Single bend mode Angle programming Stroke programming 40

Bending program mode Angle and length programming: Angles and

animation: The programmed busbar will be automatically designed.

animations shows, how to insert the busbar for the next bending

26 Bending program mode Angle and length programming: Angles and length can be directly entered for every bending step Graphic animation: The programmed busbar will be automatically designed. Bending animation: After every bending step, the bending animations shows, how to insert the busbar for the next bending step Zoom mode: In seperate screen, the bending animation can be zoomed 41

27 Shape library mode Choose a predefined shape and fill in the angles and length in dialog programming 42

Tooling and material library The punch and

Total length will be automatically calculated

28 Tooling and material library The punch and vee-blocks are registered in the tooling library In the bending programm, you can choose the tooling and material for the busbar. Total length will be automatically calculated according this tools and material. Incl. technology tables, with material library 43

29 Programm memory Programms can be load or saved with: - Internal machine memory ( programms) - USB Stick - Ethernet connection (company network) 44

30 Programming system METALIX Alternatively, a modern programming system are used: (same as Boschert) 45

31 Programming system METALIX The creation of the busbar geometry is dialog-driven as the machine programming. 46

32 Programming system METALIX The created busbar will be displayed graphically. 47

33 Programming system METALIX The flat pattern is created automatically, including bending lines and total lengths: 48

34 Programming system METALIX The busbar can be displayed in three dimensions 3D. (3D viewer) 49

35 Programming system METALIX With the same file / busbar the machines program for the punching machine CU Profi and CU-WKII can be created, as well as the bending program for the 420 CNC- WP Continue with punching processing 50

36 Programming system METALIX DXF Import (2D): 51

CAD Link Modul (Connection 3D) The 3D geometry can be

SolidEdge Solid Works Autodesk Inventor PTC

busbar, including holes in the 3D CAD system 2D

creation of the flat pattern with bending lines and

37 CAD Link Modul (Connection 3D) The 3D geometry can be passed to Metalix from the following programs: SolidEdge Solid Works Autodesk Inventor PTC Pro/ENGINEER eplan 3D 2D 3D Creating the complete busbar, including holes in the 3D CAD system 2D Export to Metalix or RADAN, with fully automatic creation of the flat pattern with bending lines and punching holes. Automatic creation of machine programs. CU-Profi CU WKII 420 CNC-WP 52

38 CAD Link Modul (Connection 3D) Create directly in 3D Radan system the busbar and use the CAD/CAM Modus to send the machine program to the machines. 3D CU-Profi CU WKII 420 CNC-WP 53

39 Large table surface The machines offer a standard large-sized work surface As an option, the table surface can be extended by additional tables. 54

The following options are available: Standard table mass available (see offer

40 Additional tables As an option, the table surface can be extended by additional tables. The following options are available: Standard table mass available (see offer Table according to customer request If the customer wants to produce the tables by themselves, Stierli has drawings which the customer can be given free of charge 55

Production advantages with Stierli 11 12 13 14 15 21

1 W H 41 42 43 44 45 A L Vermassung (A,M,I) A Angle

(Automatic springback compensation) Wide range of

Abstand A Länge L Höhe H Biegewinkel W Powerful

Connecting to Boschert punching machines.

41 Production advantages with Stierli T 12.1 W H A L Vermassung (A,M,I) A Angle measuring system for automatic angle correction. (Automatic springback compensation) Wide range of tools, developed for the rational busbar processing. Abstand A Länge L Höhe H Biegewinkel W Powerful control system with fast dialogue length- and angle programming High quality from Switzerland BOSCHERT ready! Connecting to Boschert punching machines. With programming system or directly programmable. Interfaces available to 3D Powerful and robust production machine - made with Swiss precision 56

42 References Large companies as well as smaller companies from around the world rely on the professional busbar processing solutions. Our customers need machine designs that can withstand the high demands of industrial applications. We have existing customers that manufacture in large production runs and those that require fast change-over for short run production, prototype and one-off parts. We have the world s best references. On request we can give you some references. Some of our references: GE Consumer & Industrial Power Protection 57

CNC SYSTEMS PUNCHING SHEARING MARKING. Trilogy Machinery, Inc.

CNC SYSTEMS PUNCHING SHEARING MARKING. Trilogy Machinery, Inc. The CNC Systems from SUNRISE are plate, angle and channel positioning systems with user-friendly interfaces. Many options are available factory-installed on Dual-Cylinder Ironworker or Punching Machines