BTS100SD – SHEET FEED PRESS 100 TONS SINGLE DIE

This sheet-feed press is characterized by SAFE and ACCURATE feeding of sheets, better MATERIAL UTILIZATION AND HIGHER PRODUCTIVITY.

KEY OBJECTIVE AN BENEFITS

Below is a list of the benefits using the BONFIGLIOLI TECHNOSYSTEM sheet feed press:

Material savings. The production from entire sheet with a zig-zag movement always allows material savings respect a production from strip. BONFIGLIOLI TECHNOSYSTEM technical department is always available to conduct studies in order to verify the percentages of material savings depending on the format. Based on the amount of annual production can occur with precision the economic benefit derived from it.

Reducing the footprint on the ground. Working from the entire sheet means eliminating from the production cycle any shears, conveyors and feeders, depending on the level of automation that is achieved. This implies further important advantages:

Reduction of movements and then of the working times. It reduces the time for the movement of materials in the feed phase by reducing the risk of nicks and scratches in the sheet.

Reduce the cost of maintenance and spare parts stored in the warehouse. The maintenance staff is focused on a single machine and can be kept in stock items only few parts of consumables by reducing the freezing of company resources.

Reduction of energy costs. The reduction of the machinery used and movements, combined with the use of new technology, developed in consideration of a reduction of consumption, make sure improvement in energy costs.

Reduced costs for lubricants and consumables. Less moving machinery allow a reduction in the consumption of oils, greases, bearings, trucks, guides, bushings, and everything can be consumed in normal work cycle. The savings increases also in consideration of the fact that the press sheet from Bonfiglioli Technosystem is equipped with recovery system, filtering and automatic recirculation of the lubricating oil.

Reduction of production time. This avoids downtime for storages, loading and unloading intermediates.

Reduction of staff to the same production line. Eliminate equipment means being able to move the staff previously engaged to manage them, to other tasks with substantial savings and optimization of human resources.

Reduced risk of injury on the job. Not being necessary to handle strips of sheet for manual loading of the warehouse of the press (where the system is not complete of automatic load) reduces the risk of cuts or crushing due to handling of the sheets, while also reducing the risk of occupational diseases that arise due continues to manipulation of weights. The processing of the material on a lower number of machines improves the quality of the work areas; more compact and for the most of the part completely inaccessible from the operators.

FEATURES

Extremely rugged structure in welded and stabilized steel
Power from 100 t
Flywheel in direct drive or with gearbox
Ram balanced pneumatically
Max speed 180 strokes/min
High-precision ram guides with pre-loaded linear roll bealings
Anti-friction bushing and bearings for the crank-shaft
Centralized lubrication
Adjustable speed by the a.c. control of the press
Sheet lubrication by sprayed liquid oil spray in a close boxin

REGULATORY AND INDUSTRIAL ISSUE

According to the machinery directive
At the end of the installation of the plant will be issued the Declaration of conformity type “B” (Declaration of manufacturer) according to regulations, directives and dispositions:

REGULATIONS:
• UNI EN 12100:2010
• IEC 34-1 or DIN VDE 0530 (electrical motors)

DIRECTIVES:
• “Machinery directive” 2006/42/CE
• “Low voltage directive” 2006/95/CE
• “Electromagnetic compatibility directive” 2004/108/CE

TECHNICAL FEATURES

Press type BTS100SD
Press force KN 1000
Nominal power path mm 5
Nominal stroke rate 1/min. 50
Maximum stroke rate 1/min. 150
Stroke length mm 120
Slide adjustment mm 50
Motor power Kw 15

ASSOCIATED COMPONENTS

Motorized roller

motorized-roller

Motorized roller

Double motorized roller for two pallets, one at work and one waiting.


Sheet-feeder

sheet-feeder

Sheet-feeder

Designed to introduce the sheets directly in the squaring area of the feeding system.

Can be easily connected to the system for moving the sheet.


Lifting assembly controlled by a double gear system “Motovario” coupled with a self-braking motor.

motovario

Lifting assembly controlled by a double gear


Sheet-feeder equipped with a lateral separator (with magnets and airblow jets) and a rear separator (with magnets and pneumatic cylinder to wave the sheet before introduction).

lateral-separator

Sheet-feeder equipped with a lateral separator


Zig-zag controlled motion

zig-zag-controlled-motion

Zig-zag controlled motion


Zig-zag controlled motion2

Zig-zag controlled motion

It’s essentially made of:

  • A squaring area (for scrolled or non-scrolled sheets).
  • An overhead structure holding the linear motors for “x” and “y” motions.

It takes directly in charge each sheet by its grippers, releasing the sheet only after the last stamping operation.

Zig-zag controlled motion3

charge each sheet by its grippers, releasing the sheet only after the last stamping operation

The grippers are equipped with a control system of the taken of the sheet


Press “O” type model BTS100SD

type model T100-P

Press “O” type model BTS100SD

The press is made of a monolithic structure in welded steel,

submitted to appropriate thermal treatment of stabilization. Its project is made with finite element calculation.

Main motor 15kW controlled by inverter.

Balancing cylinders maintenance-free

The ram is sliding on 16 high-precision roll-pads, oil-lubricated, suitable for high-speed presses.

Eccentric shaft made in forged and heat-treated steel

OMPI clutch-brake system.

OMPI clutch-brake system

Lubrication system with oil recovery tank and recirculation.

Lubrication system

Output conveyors for components 

Output conveyors

The structure of this system is made of Al profiles that supports the exit magnetic conveyor for the components.

A system controlling the stamping operation is also mounted on this structure, being in phase with the press Upper Dead Point

Upper Dead Point

PECULIARITIES

Lubrication system of the sheet

Lubrication system of the sheet

At the exit of the feeder can be applied a roller lubrication system of the sheet, equipped with side tank filling and automatic adjustment of the times of release of oil in the dosers.

The system ensures a constant and uniform application of the lubricant.


Hydraulic safety overload system

Hydraulic safety overload system

It allows the adjustment of the wanted max work tonnage (from 10 to 100t). If the pre-set level of force is exceeded the press is stopped and hydraulically exhausted.


Collection sheets area

Collection sheets area

In the same structure a bay is created to collect and regularly stack the sheet skeletons. The dimensions of this bay can be fixed according to the range of width and lengths of the sheets being worked in the press


Soundproof cabin

Soundproof cabin

It includes fume aspiration and lighting system.

The cabin guarantees a sufficient noise reduction to allow operators in its surrounding to work without ear protections

1) High production flexibility.
The machine is designed mainly for top & bottom ENDS with single or double die.
The possibility to ADJUST the position of BDC (Bottom Dead Centre) of the ram allows to:
• Maintain a fixstroke
• Use again most of present dies by which you produce in your traditional presses
To increase the RAPIDITY of FORMAT CHANGE there are several possibilities:
• Memorize the steps of each format recalling them up with a touch screen
• Pre‐arranged “T” slots in the ram and in the press bench to fix in a simple and quick way the same
dies used in your traditional presses.
Possibility to fix BLANKING DIES to the press, using the machine as a blanking press to make DISKS:
• Optimizing the material saving
• Feeding with disks your traditional presses.
Using disks you’ll get the same material saving of a sheet‐feed press for finished ends.
The disks can be stored to be riutilized in a second time or can be feed directly to existing traditional presses by automatic feeding systems.

2) Material saving.
Our system offers the best compromise between:
• flexibility
• reasonable investment
• format changeover speed
• material saving

The saving is obtained optimizing sheet size and zig‐zag desplacement for the smallest possible waste.

3) Tailored investment costs amortizable in short terms.
Our stamping lines have been studied to follow the principle of MODULARITY.
The lines are adapted to follow the concrete needs of clients, choosing among different types of rollers
(motorized or not), sheet feeders, presses, controls, I/O management systems, components expulsion,
orientation, stacking and buffering, skeleton collecting etc.
Modularity means to tailor one’s investments:
• To fit exactly the productivity demand with a flexibity for the future
• To amortize the machines in reasonable time
• To re‐utilize as much as possible existing machines and dies

Video