This latest investment is a continuation of Alpha’s long-term investment strategy which has seen installations of a STOPA storage system, TruPunch 5000 S12, TruLaser 3030 and Trubend 7000 machine take place over the past 18 months. It also comes shortly after work began to build a brand-new office and canteen facility on their 35-acre Hixon site.
The P4 Lean will replace the outgoing Amada TBZ panel folding machine which has been in operation for 15 years and will hugely increase Alpha’s sheet metal folding capabilities. A host of additional features and systems have been specified with the P4 to maximise productivity and efficiency, including Salvagnini’s latest interactive programming suite – Streambend, which allows programmers to run a virtual simulation of the part in a 3D environment before any material is processed. Alpha will be one of the first sheet metal fabricators in UK to use this software.
Streambend offline programming software, combined with the P4’s ability to integrate with Solidworks CAD software will dramatically increase Alpha’s panel folding capacity. By moving away from manual shop floor programming to offline office-based programming, Alpha will now be able to offer a much more efficient panel folding service.
The ABA blankholder automatically changes its configuration and its length according to the dimensions of the panel to bend without any input from an operator.
The CLA tool allows the P4 to make multiple positive and negative short bends to the same part, engaging and disengaging quickly and automatically between the blank and bending blades. This function is ideal for creating upward and downward tabs.
The P tool allows for the handling of very narrow profiles and creating tubular, hidden or radiused bends. It also allows for preformed parts to be folded easily and automatically.
MAC 2.0 (Material Attitude Correction) detects any material variations by the panel bender and, if values are outside the tolerance range, automatically compensates by adjusting the blade movements.
An automated loading/ unloading carriage positions the raw sheet in the machine whilst simultaneously pushing finished parts towards the unload conveyor.
Thanks to Salvanini’s clever automated tools, the p4 is able to fold much more intricate and complex parts, where limitations to the TBZ had previously seen these types of components folded manually on press brake machines. Complex parts with details such multiple positive and negative bends, tabs or embossing have until now been manually re-positioned by an operator for each bend. The P4 however, enables all of these to be achieved in one seamless process, dramatically reducing processing time and manual handling.
As with all of Alpha’s recent investments, the P4 forms part of a long-term factory development plan which will eventually see it integrated into the STOPA storage machine. This will further automate panel folding capabilities as raw material is fed into the P4 and removed once processed without any manual handling.
“The TBZ machine had served us well but the time came to replace it and as with all of our recent investments, we looked at the bigger picture when choosing a new machine. We don’t just want a like like-for-like replacement but an upgrade which opens up new capacity and opportunities for us whilst also fitting into our overall long-term plan for the business. The P4 ticked a lot of boxes for us in terms of its capabilities and what this allows us to offer our customers.”
Installation of the Salvagnini P4 is scheduled for early 2019 and will take around 6 weeks to complete. In the meantime, Alpha’s panel bend operatives and programmers will undertake intensive training on the new machine. Programs will be created well in advance of the machine installation so that production on the P4 can begin immediately.