Main Features of Tandem Press Brakes
We are going to deliver questions, the answers of which will surely get you to know the benefits of installation of these brakes.
Large parts can be bent not just by big-sized press brakes. It is possible to combine more than one press brake in tandem to make the process more productive and efficient.
When are tandems needed? First, evaluate your needs, look into the working principles of these machines as well as any application suitable for them. Answering the questions below will reveal which one offers more efficiency; a big-sized press brake or the one combining 2 of them?
1. What is the operation of a tandem brake like?
Tandem press brakes bear a CNC system. The precision of plunger depths and stability is gained through weights and lineal coders. Each component evaluates the plunger positioning of the plunger more than once p. m. second and send this data back to the CNC, which controls the hydraulic systems that feed the machine. A tandem brake reads 4 scale positions rather than 2 and adjusts respectively.
Control of tandem brakes is possible through one station to operate as a whole long machine, but these brakes can operate as 2 separate machines. Certain CNC systems offer options allowing joint programming of parts on both press brakes.
While operating in a tandem kit the proper setting and calibration of press brakes are crucial. Start from such machine components as the rack, plunger, and tools. In case of poor alignment of the mentioned features, you will fail to gain proper bending. Not just one method exists to provide precise alignment. You will be offered support with this by rigging firms.
After synchronizing the machinal items, make sure that each press brake functions suitably, as any trouble with one of them surely affects the other machine. For example, when a scale represents the positioning of Y1 of cylinders incorrectly in one end, the tandem will fail to ensure consistency for the eventual bending angles along the whole longitude of a part. Moreover, if accessory features like the back gauge, the crown device are applied on the two brakes, they must work inaccurate connections with each other to gain high-quality parts.
Most operation principles for individual brakes have to be practiced to tandem machines. The 1st point to consider is the press brake carrying capacity. There is a prevailing misunderstanding that bearing 2 brakes in tandem increases tonnages, no matter where bending occurs. Complete, joint tonnages of brakes are applied to parts working along the whole lengths. Any attempt to employ complete tonnages to parts not working along the entire lengths of the tandem will cause the constituent elements to outwear. Besides, increasing the tons p.f. value of the tool brings on out-wear or, even worse, punch and die crashing. The off-centered load of brakes puts an extra strain upon the elements, like the gib and cylinder seal. One thing that should be kept in mind: any problem during the work of a separate press brake will surely affect the tandem.
2. What is the application list suitable for tandems?
Tandems are perfect tools, from small production workshops as well as the ones with a high degree of variability to manufacturers with more specialized processes, but the main thing is the list of applications. While considering tandems, the following advantages should be taken.
Flexibility: Tandems enable you to deliver flexible operation for brakes as well as offer universal shops for part production. Take a workshop, which employs 2 press brakes of 500 tons and 20 feet combined in tandem. It will be able to create 40- long-foot parts and meanwhile apply each machine separately, increasing power for each 20-feet parts or parts with shorter lengths.
In terms of changing states, workshops have to be flexible and capable of accomplishing various tasks. Tandems are perfectly suitable to meet these needs. Besides, explore the ability to synchronize any recent machine with an existing device to gain the necessary flexibility.
Prevention of risks: Purchasing tandems will allow for avoiding risks. Possessing 2 press brakes, the workshop will still have the option to create small pieces through one of the brakes if the other one has to be forced to inaction.
Speeds: 2 small machines provide more speed compared to 1 larger machine. Although the bend duration may not be an extremely decisive point while producing parts, the fast operation allows workshops to provide higher productivity.
Machine expenses: A single standard brake is less expensive compared to the large custom one. However, 2 standard machines can be cheaper having evaluated the entire costs.
Additional expenses: Costs of extra brakes or tandems make just a part of the entire costs of the operation. Prior to buying production outfits, evaluate thoroughly the support expenses. What is the difference between transporting one larger brake and two small brakes? Are there any restrictions? What are the tooling costs for different types? Are extra preparatory steps required to configure certain types? What about the income powers and hydraulic oils? The accurate calculation of all these factors will ensure the refund of your investments.
3. What are the applications not proper for tandem press brakes?
Tandems provide quite extensive bend lengths, up to 60 feet or above this. Yet, in tandems, each press brake still bears side casing. The majority of OEMs provide custom neck sizes. While bending large parts, lateral casings can interfere. Although bending large parts minimizes the demand for welding small parts, remember that a tandem kit with complimentary lateral cases may be unsuitable for its use.
In addition, the purchase of a tandem kit means the purchase of 2 press brake machines, accordingly, the number of parts that can be exposed to potential failure is doubled. Maintaining tandems is crucial, as mentioned previously.
4. Which materials are suitable to be handled by tandems?
How are they different from single press brake machines?
Speeds of the formation may not appear the most important point in manufacturing operations with tandems. Thus, if you consider setting up tandems keep in mind that materials handled by tandems are no different from the ones handled by a single press brake machine.
Transportation of materials to machines and from them consumes too much time. Most commonly, a high-performance workshop succeeds if it bends 20-25 % of the time. Wide part bending through tandems takes relatively more.
Similar to many metal formation machines, the most widely applied accessory components are cranes. In tandems, there may be need of applying one more crane, primarily if the 2 press brakes operate separately. The purchase of tandems and the production of more parts after they remain in anticipation of the crane operating time increases bending time and increases the costs of work.
Alternative supporting components might be applied, particularly in workshops using tandem machines in special processes. A powerful position system assists in moving and adjusting hard steel plates. It may as well serve as a front and back gauge system.
Many OEMs deliver an ejecting system of parts, which allows extracting parts from press brakes. An added conveyor, a collecting table at entrances and exits of brakes saves time and costs.
Though certain supporting components are pretty expensive, they provide increased productiveness, safe working conditions as well as save labor while estimating the ROI in tandems.
Prior to buying tools, it is advisable to consider the existing states of your work. What kind of parts do you produce? How much do they cost you? What is the level of sustainability of continuing to produce parts through the current manufacturing process?
Make attempts to discover more about your work. How to gain higher productivity, save costs? What are the advanced markets offering the latest products? What are the changes in the production field in the last few years? Purchasing tandems seems quite a serious financial resolution. Start with estimating clearly the state of your work and get the answers to the questions on how to increase the productiveness of your further operation and achieve the utmost profits possible.