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Panel Bending – Now Fully Automatic Processing With Top Part Flexibility

Panel bending with maximum part flexibility is now even faster – with the TruBend Center 7030, TRUMPF’s new and fully automatic bending cell.

The machine turns the parts automatically, freeing up the operator and increasing the productivity of the bending process. The usual benefits of TRUMPF panel bending are retained: short side lengths, small profiles and parts with formed sections, recesses, diverse radii or multiple negative bends – the machine reliably bends them all with precision. The laser-based ACB angle measurement system enables operators to work with greater precision and in conjunction with TRUMPF TecZone Fold (the fastest offline programming tool on the market), more efficiently than ever.

Fully automatic machine with top part flexibility

Using the new rotary part manipulator, the TruBend Center 7030 can bend parts fully automatically. The manipulator secures the sheet and rotates it as needed into the required position. Here, axis speeds of 3,000 millimeters per second make it possible to achieve significantly increased productivity compared to the semi-automatic TruBend Center 5030 panel bender.

When it comes to positioning smaller parts, the patented 2-axis part manipulator also comes into play. The synchronized interaction of rotary and 2-axis part manipulator allows what is for fully automatic panel bending an unusually large degree of freedom to shape components. With its TruBend Center 7030, TRUMPF is alone in the industry in offering a fully automatic panel bending machine with an additional vertical axis for the 2-axis part manipulator. This makes for unprecedented flexibility, since the gripper modules can fasten onto parts in a variety of positions, making it possible, for example, to secure narrow profiles on their edge or grip them with clamps and bend them. This benefit is offered only by TRUMPF. Without this additional feature, many parts would be impossible to manufacture. The vertical axis also ensures that the operator can easily remove parts with downward edges.

Using the new rotary part manipulator (highlighted in blue), the TruBend Center 7030 can bend parts fully automatically: the manipulator secures the sheet and rotates it as needed into the required position

The TruBend Center 7030 is designed to allow for a wide range of shapes and formats, including sheets of aluminum up to 4 millimeters thick, mild steel up to 3 millimeters thick, or stainless steel up to 2.2 millimeters thick. The machine handles extremely short side lengths, boxes up to 220 millimeters deep, small profiles, narrow or negative bends, and diverse radii. A single tool can be used to achieve these different bending radii very quickly – and that increases both creativity and productivity by allowing product designers to incorporate more curves in trim panels or create exceptional geometries. Because the machine operates with extremely high precision (the accuracy of repetition is precise to within hundredths of a millimeter) and uses bending tools that are mechanically stable, it can process with a minimum of tool marks – which is a great advantage in the case of stainless steel and painted sheet metal.

First angle measurement system for automatic panel bending Precise angles are essential for bending.

The TruBend Center 7030 is the only fully automatic panel bending machine with an additional vertical axis for the 2-axis part manipulator. This makes for unprecedented flexibility, since the gripper modules (highlighted in blue) can fasten onto components in a variety of positions.

The main threats to achieving this precision come from variations in material characteristics such as strength, spring-back and fluctuations in material thickness. To ensure precise angle measurement, the TruBend Center 7030 is fitted with TRUMPF’s tried and tested Automatically Controlled Bending (ACB) solution. This makes it the first fully automatic panel bending machine to have an angle measurement system, which means quality parts from the outset. The two ACB laser modules for negative and positive bends are placed with the additional bending tools and they automatically move into position for the measurement process. The laser then projects a line onto the sheet and a camera detects the position of the line and calculates the part angle in real time.

Another special feature of the TruBend Center 7030 is the extremely powerful TRUMPF programming software TecZone Fold. This is the fastest programming tool on the market and it has already won over users of the TruBend Center 5030. TecZone Fold automatically creates bending programs in a few seconds – as well as 3D-simulations complete with collision monitoring, which makes efficient workshop programming possible for the first time for panel bending. This operator-friendly software is included in the base model and it runs on the control unit as well as on the office PC (as an offline version). That makes the TruBend Center 7030 extremely economical even for manufacturing small batches or single parts.

For more information contact Retecon – Tel: 011 976 8600

Bystronic’s Award-Winning Xpert 40 Press Brake Mobile Bending Cell

Global fabrication is demanding an ever-greater variety of sizes and shapes of bent parts. Bystronic’s Mobile Bending Cell, which operates in tandem with Bystronic’s Xpert 40 press brake, provides a solution to this challenge with a remarkably compact design. In fact, the Xpert 40 was designed to be transportable by forklift, so that it can be easily moved for optimized deployment.

The Bystronic mobile bending cell.

With the combination of automation and press brake, it is still possible to bend oneoff components. Simply move the Mobile Bending Cell to one side and take manual control. When it is time to start a production run, the Mobile Bending Cell can be quickly and easily re-engaged, as it automatically aligns itself with the Xpert 40.

Although compact, the Xpert 40 still features an impressive 40-ton bending capacity and can carry out 1,028 bends an hour – three times more than larger press brakes. The ByMotion control system provides for high levels of dynamics with bending speeds of more than 25mm/sec.

This Bystronic combination also offers superb precision thanks to ByMotion software, which regulates the relationship between speed, power and balance. This gives unmatched component consistency during long production runs.

Energy conservation continues to be a major concern for South African fabricators. The Xpert 40’s process control offers substantial savings and reduced maintenance costs, by using a third less power than other press brakes.

Ease of use was a paramount parameter in the design of the Mobile Bending Cell/ Xpert 40 combination. With the Xpert 40’s control system, it is also possible to control the Mobile Bending Cell from a single touch screen. The ByVision Bending user interface has been designed to be process-oriented and intuitive; and has been equipped with an extensive database of sheet-metal types and bending tools. Operators can speedily decide on the appropriate tool set, the angle sequence and the bending force required.

ByVision software can be accessed by mobile devices. For example, an operator using a tablet can review the bending parameters and, if necessary, change these from anywhere inside the facility.

ByVision Bending software also seamlessly controls the Xpert 40’s Xpert Tool Changer. This system allows for the fast automated changing of tools, which, in turn, delivers reduced set-up times and improved bending quality. Remarkably, the Tool Changer scans any new tool and automatically includes it into the Xpert 40’s magazine, without having to re-programme or call on a service technician.

The Xpert 40 is equipped with the Fast Bend e-camera safety device, the least intrusive and most effective safety system in the bending industry. A monitoring service called the Observer is an option with the Mobile Bending Cell. This allows users to monitor all real-time processes in the press brake. The system supplies live stream and process data to mobile devices such as smartphones, tablets and laptops.

It is with good reason that this automated press brake combination has been referred to as the Swiss Army knife of bending. In developing the Mobile Bending Cell, Bystronic took customers’ feedback into account regarding their requirement for compact ergonomics, speed and productivity – not to mention energy and cost-savings.

With its plug and bend principle of operation, the compact Mobile Bending Cell can quickly be set up and activated in any manufacturing environment. The Mobile Bending Cell’s ease of deployment and extensive range of applications will be a significant value-add in any fabrication or manufacturing environment. The Xpert 40/Mobile Bending Cell combination offers a fast, versatile and cost-effective alternative to larger press brakes. As such, for a busy steel fabricator, this compact press brake system offers unmatched return-oninvestment and profitability.

For more information contact First Cut – Tel: 011 614 1112

VWSA Completes Investment Programme And Launches New Polo

Volkswagen launched its new Polo and showcased the R6.1 billion investment in its plant and new products, in the presence of Eastern Cape Phumulo Masualle, the honourable Deputy Minister Bulelani Magwanishe of the DTI, media representatives and key stakeholders.

In August 2015, VWSA Chairman and Managing Director, Thomas Schaefer announced an investment of around R4.5 billion rand in new product and facilities. The total investment exceeded R6.1 billion rand, which is partially due to exchange rate fluctuations and the approval of additional plant investments.

The majority of the investment spent was on Capital Expenditure for production facilities, local content tooling, quality assurance and manufacturing equipment as well as Information Technology upgrades. Localization remains a key priority for VWSA, with the new models at a 60% local content level, with ongoing plans to achieve higher levels.

Volkswagen introduces the innovative Oneline Concept for the first time as part of the investment. Traditionally vehicles are assembled on unique production lines. It has always been possible to build derivatives of the same platform on one line, but to build two completely different platforms on one line is a technical challenge, highly complex and requires new thinking and training for the employees. The introduction of the one line concept also includes a new integrated logistics concept.

Whilst there are no short term financial benefits, there are synergies and efficiencies as well as people benefits that come about as the result of the one line concept. VWSA produced 110 000 cars last year, this will increase to 133 000 for 2018 of which 83 000 will be exported to markets around the world. This will include not only right hand drive markets but also some left hand drive markets, especially for the Polo GTI. Maximum annual plant capacity is expected to be reached with a 3 shift operation of some 160 000 vehicles in 2019.

The Volkswagen Group retained its number one position in the passenger market for the 7th consecutive year in 2017, achieving a 21.8% market share. One in every 5 cars bought by South Africans last year is either a Volkswagen or an Audi. The Volkswagen brand in the run-out year, of its volume models, the Polo and Polo Vivo achieved a share of 18.9% meaning that the Volkswagen Brand was the passenger market leader, even without its sister brand Audi.

COEGA – Full Steam Ahead

The Coega Development Corporation (CDC) opened its doors this year with revived tenacity and enthusiasm.

“We are encouraged by the improved business confidence this year and are optimistic it would translate to future business prospects,” said Dr Ayanda Vilakazi, CDC Unit head of Marketing, Brand and Corporate Communications.

In the year 2018, the CDC is poignant with enthusiasm as it awaits the completion of investment projects valued in excess of R12 billion. The projects, which include, Osho Cement – R600 million; Customs Control Area (in the logistics sector); Beijing Automobile International Corporation (BAIC SA) – R11 billion; Hella (Automotive investment in the CDC Logistics Park) – R53.3 million and MM Engineering – R350 million.

Heading into the latter part of the FY2017/18, the CDC forecasts at least twelve investors with projected additional 675 jobs. Some of the targeted investment sectors include automotive, agro-processing and chemicals just to mention a few.

“Casting our gaze to last year, the Coega SEZ saw the successful completion of five projects – Kenako Concrete, Corromaster, National Ship Chandlers, Sanitech and FinCorp valued at R180 million,” adds Vilakazi.

“Furthermore, on the jobs front, the CDC has secured no less than 9 441 additional construction jobs and realised 7 953 cumulative operational jobs. The organization has also ensured that it has its sights set on skills development, through training over 2716 people in the current FY,” highlights Vilakazi.

Mercedes-AMG With V8 Power Rolls Off The Line In East London

At its annual business results in 2017, Mercedes-Benz South Africa announced that three Mercedes-AMG models would be manufactured locally for export and local sales and the passionate employees who participated in the ramp-up to series production celebrated this achievement recently.

The first series unit of the locally produced Mercedes-AMG C 63 rolled off the line in January 2018.

The integration of the three new models (Mercedes-AMG C 43 4MATIC, Mercedes- AMG C 63 and Mercedes-AMG C 63 S), was smooth with absolute minimal interruption to the current production in the East London plant. More than 1 700 Mercedes-AMG C 43 units have been exported as part of the normal export plan from the plant, which once again reached record levels in 2017.

Mercedes-Benz South Africa invested an additional R200m into the passenger car manufacturing facility in 2016/2017 for the production of the AMG models.

The introduction of these AMG models into the Mercedes-Benz South Africa production line required the plant to bring in new infrastructure and technological innovations to accommodate the assembly of the performance models. This included modifications and additional devices at various stations – specifically in the engine and trim assembly lines. The new AMG model (with V8 power) is particularly distinguished by its notable engine sound and power and to achieve the successful production of this unit a new index device, conveyors and axle manipulators and equipment had to be added to the assembly process.

Cheetahs Take To The Skies Again In America

The contract includes return to service and flight acceptance tests in South Africa and aircraft delivery to the United States of America.

In addition, Denel is also pursuing post-delivery logistics support for the duration of aircraft operations.

Zwelakhe Ntshepe, the Group CEO of Denel, says this is a major achievement for the South African defence industry, as other South African companies will form part of the logistics support programme.

Human resources and skills that were utilized during the initial Cheetah programme will again be used for the maintenance and return to service parts of the transaction while specific workshop capabilities will be established at local South African entities.

Draken International is often described as the world’s largest private air force. It is based in Florida in the USA and has a wide range of tactical aircraft and jets in its fleet. The fighters are deployed by air forces across the globe and used for air support, pilot training and tactical exercises.

The Cheetahs will be the first South- African designed fighters added to Draken International’s inventory. The sale includes nine Cheetah C jets and three, dual-seat Cheetah D planes. The planes can fly at twice the speed of sound – Mach 2.2 – and operate at ranges of more than 1 300km.

Denel is the design authority of the Cheetah fighter that was locally developed as a variant of the Mirage III in the 1980s. The aircraft were retired from active duty following South Africa’s acquisition of its new fleet of Saab Gripen fighter jets.

Mike Kgobe, the CEO of Denel Aeronautics says Denel has received a number of expressions of interest for the remaining Cheetah fleet since it delivered 12 fighters to the Ecuadorian Air Force in 2011. Denel was also responsible for logistics and technical support of the aircraft in terms of a contract that ended in 2016.

The decision to sell the Cheetahs to Draken International followed on a visit to Denel Aeronautics by representatives of Draken International in July 2017. A letter of intent was received a month later.

Denel Aeronautics is further engaging with Draken International to secure a logistics support contract by end January 2018 for the supply of component and engine maintenance, repair and overhaul as well as design authority and systems engineering support.

Kgobe says the ongoing support will benefit the South African aerospace and defence sectors. Denel re-established the Cheetah support base both internally and within local industry after de-commissioning of the system by the South African Air Force. This re-established support base will form the backbone of supporting Draken International.

Denel recently acquired a controlling stake in Turbomeca Africa (TMA) and re-integrated the business into Denel Aeronautics. Engine MRO work on the Cheetah programme will be coordinated by this business unit (Aero Engines MRO) equipped with test benches and ground equipment acquired with the Cheetah package from Armscor Defence Materiel Disposal in 2010. Kgobe says the Cheetah contract is a viable project because of the re-established local capabilities. Denel also dealt with some of the avionics obsolescence issues on the aircraft since 2010 and is confident of supporting the aircraft into the future.

Another Record Year For Hurco

Sales growth of more than 22 percent in 2017 compared with the previous 12 months propelled Hurco Europe, High Wycombe, to another record year and a turnover of £23 million.

The company sold close to 300 Hurco machining centres and lathes into the UK and Ireland, 38 percent of which went to first-time users of Hurco machine tools.

In addition, under a long-standing agency agreement, the company delivered six German-built Roeders machining centres into the same markets, all but one in 5-axis configuration and two with advanced automation.

In parallel with the upturn in business, the number of employees at Hurco Europe has grown to 50, more than one-third of whom are service engineers. The number of application engineers has increased to six, reflecting the high level of support that is being provided to the firm’s expanding customer base.

Looking forward to MACH 2018 next April, David Waghorn, managing director of Hurco Europe commented, “we are excited that the show comes at a time when UK and Irish subcontractors seem to be busier than ever, especially in the automotive supply chain but also more widely from aerospace and medical to tool and mould making.

We will be launching a new range of bridgetype machining centres in Birmingham, with the BX50i in evidence on our stand, whilst the smaller BX40i machine was previewed at our open house in December. The design is ideal for producing tools, moulds and higher accuracy components.

“At our December open house, we welcomed in excess of 80 visitors from more than 50 companies into our showroom in High Wycombe. Sales of £1.5 million have already been secured in December. We look forward to continuing that success at MACH and making 2018 another record year for Hurco.”

Airbus And Williams To Explore Technology Collaboration

Airbus and Williams Advanced Engineering, the innovative engineering and technology business of Williams Grand Prix Engineering, are to explore potential areas of technological collaboration.

Under the terms of a newly signed MoU, the two companies will examine in particular applications that may combine Williams’ innovation culture, lightweight composites and battery expertise with Airbus’ Zephyr High Altitude Pseudo-Satellite (HAPS) programme.

Zephyr is a record-breaking, solar-powered, unmanned aerial system (UAS), or drone, with unique communications and surveillance capabilities. It will fly at more than 65,000ft, above commercial air traffic, for months at a time. The first production examples are being manufactured at Farnborough for the UK Ministry of Defence.

As sole battery supplier to the FIA Formula E championship since its inception, Williams Advanced Engineering’s battery technology has been tried and tested, and its world-leading expertise in electrification has become core to the business. And with four decades of experience at the pinnacle of motor racing, where lightweight materials and structures are crucial, Williams is now developing these technologies and finding innovative solutions to weight saving.

Emirates To Acquire 36 Additional A380 Aircraft

Dubai-based Emirates Airline has signed a Memorandum of Understanding (MoU) to acquire up to 36 additional A380 aircraft.

The agreement was signed recently at the airline’s headquarters in Dubai by HH Sheikh Ahmed bin Saeed Al Maktoum, Chairman and Chief Executive, Emirates Airline and Group and John Leahy, Chief Operating Officer – Customers, Airbus Commercial Aircraft. The commitment is for 20 A380s and an option for 16 more with deliveries to start in 2020, valued at US$16 billion at latest list prices.

Following delivery of its first A380 in July 2008, Emirates took its 100th A380 on the 3rd November 2017 in Hamburg, Germany.

The A380 is an essential part of the solution to sustainable growth, alleviating traffic congestion at busy airports by transporting more passengers with fewer flights. The A380 is the best way to capture growing world air traffic, which doubles every 15 years. It flies 8,200 nautical miles (15,200 kilometres) nonstop and can accommodate 575 passengers in four classes.

The spacious, quiet cabin, smooth and most comfortable ride have made the A380 today’s passenger favourite, resulting in higher load factors wherever it flies. The A380 is the world’s largest passenger aircraft, with two full widebody decks, offering the widest seats, wide aisles and more floor space. It has the unique capability to generate revenue, stimulate traffic and attract passengers, who can now specifically select the A380 when booking a flight via the innovative iflyA380.com website.

To date, over 200 million passengers have already enjoyed the unique experience of flying on board an A380. Every two minutes an A380 either takes off or lands at one of the 240 airports around the world, ready to accommodate this magnificent aircraft. To date, 222 A380s have been delivered to 13 airlines.

Boeing Sets Airplane Delivery Record

Boeing delivered more commercial airplanes than any manufacturer for the sixth consecutive year and set an industry record with 763 deliveries in 2017, driven by high output of the market-leading 737 and 787 jets. At the same time, the company grew its backlog with 912 net orders, reflecting healthy demand for its single-aisle and twin-aisle airplanes.

Boeing reached a new high on the 737 program as it raised production to 47 airplanes a month during the year and began delivering the new 737 MAX, contributing to a record 529 deliveries, including 74 of the MAX variety. On the 787 Dreamliner program, Boeing continued building at the highest production rate for a twin-aisle jet, leading to 136 deliveries for the year.

“The record-setting performance is a testament to our employees and supplier partners who continue to innovate new ways to design, build and deliver the most fuel-efficient airplanes to customers around the world,” said Boeing Commercial Airplanes President & CEO Kevin McAllister.

On the orders front, 71 customers placed the 912 net orders, valued at $134.8 billion at list prices. The total extends Boeing’s backlog to a record 5,864 airplanes – at year end – which is equal to about seven years of production.

“The strong sales activity reflects continuing strong demand for the 737 MAX family, including the ultra-efficient MAX 10 variant that we launched last year, and the market’s increasing preference for Boeing’s family of twin-aisle jets,” said McAllister. “Our planned production increases over the coming years are designed to satisfy this robust demand.”

While in 2017, the 787 Dreamliner family racked up nearly 100 net orders and the 777 family 60 net orders, other major commercial airplane milestones include the first flights of the 737 MAX 9 and the 787-10 Dreamliner, as well as the start of production of the 737 MAX 7 and the new 777X

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