Tailor-made solutions: the Gasparini approach
Every machine designed by Gasparini is the result of an in-depth analysis of the customer’s needs, which in the case of Touratech included:
- The need to perform specific stampings on the parts in the first phase of the process.
- The possibility of performing complex bending in the second phase, taking advantage of a unique technical solution.
- The reduction of welds to ensure leaner production and excellent quality of the finished product.
The result is two custom-designed press brakes, each with unique features that complement each other to offer maximum flexibility and precision.
165/3000 press brake: Versatility for stamping
The 165/3000 press brake is designed to perform the first stage of Touratech’s production process: sheet metal stamping. This machine offers a combination of power and versatility, thanks to a structural modification to the workbench to accommodate several stamping stations.
Main features
The special feature of the 165/3000 press is its ability to adapt to moulding requirements thanks to a modified bench that can accommodate multiple stations. This makes it possible to create special shapes on parts, guaranteeing precision and repeatability in every operation. This solution eliminates the need for multiple fixtures, reducing set-up time and increasing efficiency.
This press brake with Easy Design, has a 500 mm reach and stroke, and is equipped with Gasparini’s Adaptive Crowning and E-Reflex Deformation Compensation systems. Together, these two systems provide excellent results in terms of quality, accuracy and repeatability of the parts to be bent.
CNC and software
The Delem DA-66T CNC manages all functions and axes of the machine, including the Panasonic 4-axis backgauge (X-R-Z1-Z2) with sensing references. Together with the CNC we supplied Delem Profile Lite TL 2D offline software and the TeleLink remote service platform. The press brake has been customised in livery and is equipped with the handy Syner-G remote control. To facilitate the operator’s work, the bending programme can be started either from the CNC or by pressing the down pedal.
Other systems and accessories
- ECO energy-saving package
- 2 sliding front supports
- GPS4 mechanical set-up
- DSP-AP laser safety system
- 1 standard footpedal
- LED work area lighting
115/4000 press brake: Innovation for complex bends
The 115/4000 press brake, with its Easy Design, 600 mm stroke and 700 mm open-height, is designed to perform complex bending in the second stage of the production process. This machine is distinguished by a unique upper beam designed to handle complex metal profiles.
Special upper beam
The distinguishing feature of the 115/4000 press is the customised upper beam with a central hole. This innovative solution allows complex bends to be made on the four specific profiles required by Touratech, reducing the need for welding and ensuring stronger and more uniform finished parts. This machine represents the perfect balance between precision and flexibility, giving Touratech a significant competitive advantage.
CNC and software
The CNC is the Delem DA-69S (on mobile console), with Delem Profile-S 3D offline software and third-party interface.
The DA-69S offers 2D and 3D programming including automatic bend sequence calculation and collision detection. Full 3D machine configuration with multiple tool stations providing real feedback on feasibility and product handling. Highly effective control algorithms optimise the machine cycle and minimise set-up times.
Backgauge
The backgauge is configured on 6 axes (X-R-Z1-Z2-X5-X6) fully CNC-controlled, with X-axis travel increased to 800 mm.
It is also equipped with:
- special flat reference as an alternative to the standard one
- third stop with special profile and height
- additional stop on a reference
Clamping system
This press brake was configured with the hydraulic upper clamping system for Wila tools (2 pieces from L=1785).
The lower clamping system is a hydraulic clamping system for Wila with wedge bending.
Other systems and accessories
- 2 standard front supports
- DSP-AP laser safety system with PLC
- 1 standard footpedal
- Provision for Tele-Link remote assistance
- Electrical interface for operator-robot configuration (with photocells and sensorised references)
- Electrical interface for tool change by robot
- Heat exchanger
- Gasparini holders for safety lasers
- LED lighting of working area
Results and customer benefits
Thanks to the two customised press brakes and the optimisation of the production process, Touratech has achieved
- A reduction in the number of welds, improving the quality and strength of the finished parts.
- A faster and more efficient production process, with fewer manual steps.
- The possibility of integrating the two machines in a robotized cell, automating the entire process and increasing productivity.
This case study demonstrates how Gasparini Industries is able to offer customised solutions, designed to meet the specific needs of each customer, always guaranteeing precision, innovation and flexibility.
