Long term Bystronic press brake customer Haigh Engineering specialises in the disposal of waterborne waste and provides process improvement to the hospital and waste water industries.
The company designs and manufactures all of its waste control technology solutions which include sewage screening and screenings handling for the water PLC’s, and bedpan and incontinence pad disposal for hospitals and care homes. A number of specialised disposal products are also manufactured for the shipping, kennel, hotel and waste industries. The majority of Haigh products have stainless steel fabrication which require folding.
The company is an existing user of four Bystronic press brakes including 100 tonne and 400 tonne PR8 4 metre machines. However, the need for additional capacity encouraged Haigh Engineering to invest in an additional machine, this time a 200 tonne, 3 metre Bystronic Beyeler Xpert.
David Brown, Haigh Engineering’s manufacturing manager, comments: “Our confidence in Bystronic the company, its products, its professionalism, our relationship and the service it provides, is such that we never even looked at other machines when the decision was taken to invest in a new press brake. The only decision we had to make was which machine to choose!”
“This new machine had to be multi-axis, it had to have the accuracy and repeatability and high on our list of priorities was it had to be quiet.”
The Bystronic Beyeler Xpert press brake is equipped with the world’s most comprehensive database which is based on DIN and Hämmerle data and is simple to expand with data for new parts and materials. The machine’s operator has complete freedom when processing his orders. He can utilise his own experience to select between a fully automatic bending process and the manual input of the individual process steps.
It is the only press brake that produces zero angle error itself and is said to deliver the highest level of repetition accuracy on the market. This results in increased productivity and is reflected in the fact that part optimisation is reduced to a minimum.
The Beyeler Xpert automatically calculates how differences between the target value and the actual value are to be corrected resulting in positioning accuracy of four thousandths of a millimetre. This precision guarantees the same angle and leg length each time. All parts are bent with the greatest precision and every angle produced is correct.
These accurate bending results are achieved at the touch of a single button. The bending sequence and the positioning of the backstops are determined, the tool plan is created and the process data is generated – all automatically. The open control allows the operator to change all the calculations individually.
The programming on the Beyeler Xpert is simple. It takes just six mouse clicks to get from the 3D data file to the 3D part. Furthermore, numerical inputs can be made directly on the machine negating the need for an additional PC.
Ease of operator use is guaranteed by the simple and intuitive menu guidance on the operating panel which also incorporates every single operating element, and the hydraulic dynamic sheet support developed by Bystronic. This can be moved via a pivot point and an H axis, which effectively prevents counter-bends and increases the bend quality to a maximum.
Haigh Engineering’s tooling costs will be reduced as they will benefit from being able to use their existing tooling on this new machine. The fully automatic parameterisation and the optimally controlled workflow ensure wear of the machine is reduced resulting in reduced maintenance work and costs. Furthermore installation time is reduced significantly due to the automatic adjustment of the control. Remote diagnostics ensure machine downtime is kept to a minimum, service visits can be rapidly and selectively planned.
Haigh’s latest machine features eight axes: Y1 and Y2 control the depth positioning of the two main hydraulic cylinders; X1 and X2 for the independent in/out movement of the back gauge heads; R1 and R2 for the independent up/down movement of the back gauge heads and Z1 and Z2 for the independent sideways movement of the back gauge heads.
Mr Brown concludes: “I have no doubt this new machine will live up to Bystronic’s reputation for manufacturing and supplying high specification press brakes and will provide Haigh Engineering with the quality of bend we require.”