Advanced hybrid technology punching-shearing center

Today companies have to cope with many challenges in order to remain competitive in a continuously developing market. These challenges include:

1. The need to automate information distribution, in order to create a lean, error-proof production environment, by integrating company ERP/MRP systems with process software for production management.
2. The growing need to increase the autonomy and efficiency of production systems by automating loading, unloading and sorting operations.
3. Finally, to prevent programming from becoming a bottleneck for production, the aim of implementing simple and quick office software solutions, able to make procedures leaner and improve overall efficiency.

For Salvagnini, punching is always a combined process of forming and separating parts, with the separation done either by shear or by laser. The Salvagnini S4.G4 punching-shearing machine is the ideal solution for businesses looking for productivity, flexibility, reactivity and efficiency. The S4.G4 performs all the part punching, forming and separation operations by subtraction, destroying the skeleton to ensure that the parts flow progressively downstream: this eliminates the need for regripping and rapidly feeds the next production step. Part separation integrates the punching machine in a modern and efficient production flow, able to feed the workstations downstream, such as the panel bender.

Part geometries, increasingly small batch sizes, cutting quality and expected productivity are all factors that make the investment in an S4.G4 more attractive than that in a traditional punching machine. High productivity is guaranteed because the S4.G4 is a single work center, able to automatically produce finished parts without the need for re-machining and/or retooling. It is the winning solution in production contexts in which lead times have to be minimized, because the integration of forming and separation processes drastically reduces throughput times. The S4.G4 is the ideal solution in sectors requiring parametric jobs: more flexible than a laser, it drastically simplifies programming and reduces overall process times, from product design to production.

The S4.G4 natively integrates the punching and separation operations and automatically manages the feeding, sorting and unloading cycles which, when possible, are performed in masked time. With the patented multi-press head, the tools are always available for nesting and multiple jobs. The proprietary Punch&Cut algorithm optimizes the integrated shearing cuts for separating the single parts of the workpiece in a fast, flexible and automatic sequence with no waiting times.

With conventional punching, productivity and flexibility depend on the number of tool changes in-cycle and the times for moving the sheet underneath the turret or single punch, and are influenced by the time required for the separation operations downstream. The S4.G4, on the other hand, natively combines productivity and flexibility. Helping to maximize productivity are the multi-press head, which requires no re-tooling in cycle, the modulated dynamics of the manipulator with 9 independent pincers and the integrated shear, which works in Punch&Cut mode. These unique solutions also improve the flexibility of the S4.G4 as – whatever the geometries and materials being machined – they produce large batches, kits or batch one with equal ease.

The multi-press head, a distinctive feature of Salvagnini punching machines, requires no re-tooling or tool changes in-cycle, reducing overall processing times.

Salvagnini has always worked to produce solutions with low environmental impacts, guaranteeing maximum operator safety and resource optimization. 

S4.G4 implements differentiating solutions that reduce consumption while guaranteeing the same performance and reliability, as they are based on successful applications borrowed from other product lines.

S4.G4 is equipped with advanced hybrid actuators: a proprietary solution used to reduce average consumption by up to 20% compared to the corresponding electrical solutions. This original solution has made it possible to eliminate mechanical parts, to the benefit of a structural simplification that eliminates maintenance due to worn moving parts in electrical actuators, and guarantees extremely stable performance and at 100% in stress tests. In addition, this solution does not require a cooling system, as there are no moving parts that could overheat, so further reducing consumption, today the lowest on the market for punching-shearing centers.

The head is extremely accessible for simple and agile tool change and extraction, meeting not only the user’s requests but also the ergonomic usage requirements set by the current standards.

The adaptive technologies, closed-chain controls, sensors and proprietary solutions assure that the materials are used in the best way, with zero waste by effectively reducing scrap.

The S4.G4 is a flow solution. In its basic configuration, it integrates feeding and unloading solutions that automate the production process and optimize each operation: at the infeed, a conveyor-centering device anticipates the loading of the sheet metal in masked time, positioning it correctly; at the outfeed, each part is automatically transferred to the next devices or the collection bins. 

In addition to solutions that optimize the efficiency of each operation, Salvagnini supplies automation and process software which, by suitably organizing the whole production flow, help to achieve greater autonomy for unmanned and lights-out jobs, reducing the impact of labor costs and the return-on-investment time.

The S4.G4 is easy to configure and can work stand-alone, in-line, integrated into a flexible cell or for lights-out manufacturing.

• The loading/unloading solutions allow unmanned operations, enhancing the productivity of the punchingshearing center.
• The modularity of Salvagnini's automation devices allows the production flow to be extended and/or modified, even after first installation.
• In addition to integrated automation, Salvagnini supplies a wide range of automatic loading/unloading and sorting devices which, coupled with a store, increase system autonomy and efficiency. These devices mean that different materials and thicknesses are always available for just-in-time jobs, minimizing waiting times for sheet metal feeding and reducing the risk of error or damage to the material resulting from human intervention.