Salvagnini showcases Social Industry concept at Blechexpo

At Blechexpo 2019 (held from November 5-8 at Stuttgart, Germany), visitors were be able to see Salvagnini’s most advanced tools that help in creating authentic flexible automation.
Salvagnini showcases Social Industry concept at Blechexpo
At Blechexpo 2019 (held from November 5-8 at Stuttgart, Germany), visitors were be able to see Salvagnini’s most advanced tools that help in creating authentic flexible automation.
 
Industry has changed: flexibility and efficiency are crucial requirements for managing increasingly smaller batches and rapid part code turnover. Salvagnini's vision evolved accordingly, and its offer is enhanced by the Social Industry model which is able to combine digital technologies – intangible by definition – with the most advanced concepts of production, process flow and smart manufacturing. Humans and their expertise become the point of contact between these two dimensions, that are apparently as distant as the social one of the immaterial and the physical one of the production processes. The result is a combination of adaptive, efficient and automatic processes which are perfectly balanced, interconnected inside and outside the company, respectful of humans and the environment, able to intercommunicate, eliminate production downtime, maximise productivity, offer customised production and minimise scrap and consumption.
Human centrality is key, the cornerstone of Social Industry. “We are making humans do something different than in the past. We enhance their skills, putting them in charge of the remote control and management of production systems and eliminating all the activities with low added value which are in some way alienating, allowing them to express all their potential. With our new software solutions, the operator can organise production in the best way possible, balancing the work flows and producing only what is needed, exactly when it is needed. The machines, which are fully sensor-equipped and adaptive, correct themselves during the cycle and consume only the energy required,” explained Tommaso Bonuzzi, Sales Director at Salvagnini.
 
We’re not talking of mere process efficiency, but of factory efficiency too: Salvagnini puts the most advanced tools at the disposal of humans to create authentic flexible automation. And this is the real added value of Social Industry, a totally integrated and perfectly balanced solution used to produce what is needed, when it is needed, whatever the batch size. This has always been in Salvagnini's DNA, and responds to the needs expressed increasingly frequently by customers. This is precisely the production experience that visitors saw first-hand at the Salvagnini stand in Blechexpo 2019 at Stuttgart.
 
“As well as a close-up look at numerous innovations, including the 6 kW high power density source introduced on the L5 high-dynamic fiber laser and the AU-TO automatic tool change on the B3 press brake, we are offering visitors a real production experience composed of our adaptive machines which work together in a set of concatenated flows,” explained Francesca Zanettin, Salvagnini's Head of MarkComm. 
“Visitors choose an object to produce – of course within a set range for a matter of practicality – and decide how to customise it before starting the production process. Each machine, whether it is a laser, press brake or panel bender, notifies the next one what it is machining in order to prepare it for the next process; each collaborates and interacts to produce what is required, when it is required. And each machine is connected through the use of self-guided vehicles (SGVs) which move freely between them, managing the flow of semi-finished parts. This is the real meaning of factory digitization and Industry 4.0, Salvagnini style,” concluded Zanettin.
 
A 6kW source to compete in all categories
“Over the years, the L5 has undergone continuous improvement and this year, at Blechexpo, it will be with 2 important new features: the 6kW high power density source and the compass system with an advanced, completely re-designed carbon fiber structure. These are particularly significant features, on show in Germany for the first time,” said Pierandrea Bello, Salvagnini Product Manager
 
The source completes Salvagnini’s range of 6kW solutions: it is a major new feature, because when combined with the characteristics typical of the L5, it enhances its performance, guaranteeing better results on medium-thin materials, even compared to sources with higher power.
 
“This source offers a series of benefits compared to the previous one. The first, and most obvious, is that we have a 6kW L5 available. The second, which derives exclusively from the source, is that we can increase our cutting speed over the widest range of applications of the L5, in other words medium-thin thicknesses, up to 6 mm. The third, linked to the specifications of the L5, is that thanks to its high cutting speed we can significantly improve cutting accelerations on thicknesses up to 4 mm. And that's not all: the data we have gathered indicates that this new source will achieve performance typical of solutions with higher power levels. And this without any negative effects on performance with medium-high thicknesses, thanks also to the contribution of the new Thunder nozzles developed internally to increase performance and quality when cutting thicker material under nitrogen,” added Bello.
 
The release of the new compass system with advanced carbon fiber structure, on the other hand, follows that of the new trajectory planner and helps to further enhance the advantages obtained by the new source: the greater dynamics on medium-thin thicknesses do not affect the excellent precision of the L5, and indeed even improves performance thanks to the higher speeds achieved in rapid movements, which translates into an increase in productivity of up to almost 10 per cent, depending on the type of nesting.
 
The L5 is also equipped with new features: the new SVS – Sheet Vision System – option which allows customers to reuse the classic sheet metal offcuts that often “populate” workshops, creating a dxf to be used as the starting format for nesting new parts to be cut directly on the machine; the new and innovative nesting algorithms which ensure shorter processing times, more orderly nesting diagrams and a better use of material, guaranteeing savings of between 5 per cent and 10 per cent; finally, the AVS artificial vision system, which allows the edges of the workpiece to be aligned quickly or the possibility of referencing any machining already present on the sheet, without restrictions on shape.
 
The press brake is AU-TO...matized
Of all the main sheet metal processing technologies, the press brake is probably the least evolved and integrated in the smart factory context and it still requires a strong operator presence and interaction. Precisely to meet the need to vertically integrate the press brake into the production process, as well as mitigate the difficulties in sourcing qualified machine operators and experts, Salvagnini has focused on the issue of automation: the result of this work is the B3.AU-TO press brake, equipped with the new automatic tool change, which is the concrete expression of a new concept of automated, scalable press brake.
 
“First and foremost, we simplified the use of the machine,” explained Giulio Farina, CEO of Salvagnini Robotica, “and we made sure it could communicate its own data to the other machines and company’s ERP. The aim is to make bending an operation that is less influenced by process variables and, as a result, provides greater certainties, for example, in terms of processing times, as well as costs and budgets. The MAC2.0 (Material Attitude Correction) guarantees greater process stability, simultaneously reducing cycle times. For example by a single laser detection, the press brake adapts to any variations in the material which, when necessary, are automatically compensated for.”
 
Panel benders look to the future
The panel bender is the machine that, more than any other, represents Salvagnini's spirit of innovation, a technology in which the Group is world leader. Fully automated and adaptive, with fifteen different models available, the Salvagnini panel bender confirms its place as one of the stars of the Social Industry. This is exactly why Salvagnini put up a third-generation P2lean-2120 compact panel bender on show: without a doubt this is one of the company’s most successful models, thanks to its high productivity and versatility, as well as its low energy consumption and compact size. 
 
In Stuttgart, the P2lean panel bender also came with an interesting feature: the development and implementation of a specific tool, as well as the integration with a third-party technology – an ACF Cornerformer – today allow the cold forming of panel corners without any additional welding, grinding, finishing or polishing activities.
 
“We think that this application will be highly useful in a number of industrial sectors – electrical, air treatment, catering/food equipment or metal furniture, and others besides. “The panel bender prepares the corners by exploiting the potential of the CLA/SIM tools, the modular-length auxiliary blades that are set up automatically and in masked time to make tabs, in this case upwards. The corners are then completed on the ACF Cornerformer. The end-user has dual benefits from this integration: on the one hand, it drastically improves the quality of the parts; and on the other, it drastically reduces operating costs and times. This is certainly an attractive opportunity in an increasingly competitive market,” informed Nicola Artuso, Salvagnini Product Manager.
 
STREAM: Natural evolution
System intelligence: this is what software means for Salvagnini. System intelligence, distributed everywhere, continuously enhanced and coordinated in real time to improve performance, bringing production technologies and operators together and allowing information to be processed, communicated and matched. Codes for thinking, planning and programming, guaranteeing maximum simplicity, effectiveness and efficiency, for managing the process as a whole, quickly learning from experience and the surrounding environment, for understanding complex situations and giving them a meaning, and for solving problems. 
 
“We realised that we had to make our programming activities more efficient, to maximise the performance of the systems installed in the workshop. To do this in the best way, we started again from our market and our customers: working alongside them and tackling their day-to-day problems. We realised that they focused more on their parts, their units and their finished products than on the technologies used to produce them. At that point, the natural evolution of our range could only be an integrated solution, which allowed for activities to be programmed throughout the whole production process, in which technology was almost a transparent element. And so we came up with STREAM,” said Stefano Cera, Salvagnini Product Manager.
 
STREAM is Salvagnini’s answer to the modern industrial context, a programming suite that improves reactivity and reduces costs, operating errors and process inefficiencies. STREAM is the integrated ecosystem for managing all activities in the office and on the factory floor, the only point of access for all technologies, from cutting to bending, meeting all planning, programming, production, management, control and optimisation needs throughout the production process.
 
The market demands compliance with normal production logics and a focus on the finished product, STREAM responds by upending the conventional logic of CAM/NEST software. Without forgetting that it can also be used to calculate costs, including upstream and downstream processes where necessary.
 
“This reality was unimaginable until a few years ago, but it makes programming and information flow management leaner. Only one other player on the market boasts the same broad range of hardware and software solutions that Salvagnini offers. But today, Salvagnini is the only one that supplies a single environment for managing all technologies: because integrated ecosystem means just that, being able to control punching machines, laser cutting systems, panel benders and press brakes in a single platform. A revolution for others, a natural evolution for us,” said Cera.
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