Product category:
Pressbrakes and folding machines
News Release from: Safan | Subject: E-Brake at ACS
Edited by the Manufacturingtalk Editorial
Team on 20 December 2007
Press brake operates without crowning
A press brake concept is built around a servo-electric drive based on a patented pulley principle that results in a very even distribution of forces, so a crowning table is not needed for most jobs.
For the past 20 years, ACS has been supplying air filtration systems, helping manufacturers and their staff benefit from cleaner, safer and better working conditions Specialising in the control of coolant/oil mist/smoke from machining applications such as turning, milling and grinding, ACS customises all of its products and services to deliver practical solutions
This article was originally published on Manufacturingtalk on 21 Jul 2008 at 8.00am (UK)
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With business growing by 17% in the past 12 months alone, the demand is increasing for ACS products is from its OEM sales to machine tool companies, as well as its retrofit business direct to end users both in the UK and Europe.
Helping boost growth further is a subcontract 'sister' business located on the same site.
Launched two years ago, ACS Sheet Metal has won contracts from customers such as the construction division of Corus.
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"What with the success of our core air cleaning business, as well as ACS Sheet Metal, it was clear we had some thinking to do regarding the expansion of our manufacturing capacity, particularly forming, which was becoming a real bottleneck." said the company's managing director, Mark Lemkey.
Although perfectly happy with its existing press brake, ACS decided to fully assess the market for a new machine.
"It is easy to give repeat business but this can often mean you miss exciting developments," said Lemkey.
"I am glad we heard about the Safan E-Brake as it has given us many advantages we would now be without had we stayed with our previous press brake supplier." The Safan E-Brake press brake (brake press) concept is built around a servo-electric drive based on a patented pulley principle that results in a very even distribution of forces, such that in 98% of cases no crowning table is required.
Similarly, an entirely new generation of electronics and software makes E-Brake operation extremely fast, easy and precise.
In combination with low noise levels, 50% reduced energy consumption, extremely low maintenance costs and an integrated safety system, it is easy to see why the E-Brake is attracting the attention of OEMs and subcontract fabricators alike.
ACS is also close to installing a CNC laser cutter to complement is existing punch press capability.
This will allow the company to venture beyond its current 3mm maximum sheet thickness for subcontract work.
With this in mind, it was also imperative the new press brake could cope with thicker material.
Lemkey said: "Not only do we enjoy the benefits of all-electric technology such as faster bending speeds, lower maintenance and less energy consumption, we can also move seamlessly into thicker gauge processing as and when required".
Speed is critical at ACS, on both sides of the business, said Safan to manufacturingtalk.com.
Although the specification for each air cleaning system is bespoke according to the application, lead-time for new equipment is quoted at just two weeks.
Similarly, it is the speed of turnaround at ACS Sheet Metal that has helped the company enjoy considerable success in its first two years of trading.
"For batches of 50-off and over, I can't think of any competitors in the area that can beat us on turnaround," said Lemkey.
"And now that we have the Safan E-Brake, we will move even further in front as we can run two processes simultaneously.
The days of bottlenecks in the forming section and the resulting overtime required to dissipate the problem, are long gone".
The 4m bed on the E-Brake has already proved itself very useful since the machine was installed in October 2007.
"Originally we were looking for a 3m machine, but it so happened that Safan had a 4m model available," he explained.
"At first I didn't think we would need the extra bed length but as things turned out, the first job that arrived after installation was 4m long material".
Before buying the machine, ACS employed a new press brake operator and sent him and his supervisor to see the prospective Safan machine.
Suitably impressed, the machine was ordered as a package that included tooling and software, and now forms the centrepiece of the company's manufacturing facility.
"As the business grows we are getting more and more customers coming to see us," said Lemkey.
"The Safan E-Brake is an impressive sight and confirms to our clients that we are investing in both our future and theirs".
As well as being used in subcontract work, the E-Brake has also been set to work producing a number of parts for the company's air cleaning systems.
The ACS range of air cleaners are designed for direct attachment to most machine tools - removing respirable particulate from the machining enclosure thereby protecting people, computers, machinery, air conditioning and heating plant.
All mist is filtered, with the moisture draining back to the coolant system or into disposal trays while the clean air is vented to the workshop.
"Although uptake is strong, the potential market for this type of equipment remains vast," said Lemkey.
"Some manufacturers struggle justifying the investment because it doesn't add value to the end product.
However, what is the cost of a lawsuit from a retired worker who develops a cough only to discover he has lung complications from years spent working in a mist-laden machine shop?" asked Lemkey.
It's a salutary point and one that will surely prompt many manufacturers to ponder the benefits of working environment filtration.
* About Safan - for years, Safan has been leading the way in developing innovative solutions for the sheet metal working industry.
Underlying this prominent role is the experience accumulated since 1932.
Since that time Safan has established a series of technical breakthroughs and patents, from the first hydraulic shear in 1965 to the first servo-electric press brake in 2004; the Safan E-Brake.
Other innovative milestones include the first servo-hydraulic press brake (1980), the first press brake with robotics (1988), the first servo-mechanical press brake (1995) and the first shear with hybrid drive (1999).
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