Even individual functions can make working with a long folding machine considerably easier: Electronic back gauges handle positioning, gripper systems move the sheet metal, and modern controls execute programmed bending sequences.
Fewer manual steps, greater repeatability and shorter processing times – there are many possibilities. But not every production environment requires the same level of automation.
We explain which steps can be automated, how the different functions work and when they are useful.
The actual bending operation is only one part of the work involved in long folding. Sheets must be prepared, loaded, positioned and clamped. Depending on the profile, several bending steps and repeated repositioning may be required.
Automation can therefore be applied at different stages. It handles repetitive settings, supports material handling or combines several operations into an automated workflow.
01
Create profiles digitally, calculate bending sequences and transfer programs to the machine.
02
Support sheet loading and feed the material into the machine in a controlled manner.
03
Automatically adjust back gauges and align the sheet for the next bend.
04
Hold workpieces and move them automatically between bending steps.
05
Execute programmed bending sequences and automatically adjust machine parameters.
06
Compensate for mechanical deflection through automatic adjustments, such as crowning.
To produce an accurately dimensioned profile, the sheet must be positioned correctly for each bending step. More complex profiles require several changes in position.
Electronic back gauges and automatic guidance systems handle part of this work. Depending on the equipment, this ranges from automatically moving back gauge fingers to fully automated workpiece positioning.
The electronic back gauge automatically moves to the required positions. Dimensions are specified through the machine control and adjusted according to the programmed bending sequence.
Manual adjustment and repeated measuring are largely eliminated. This is particularly useful for profiles with multiple bends and ensures consistent flange lengths.
The tapered back gauge offers additional possibilities: It allows the production of profiles with varying depths (narrow to wide) and tapered sheet metal components.
While the back gauge defines the position, the gripper system handles the movement of the sheet. It holds the workpiece and automatically moves it into position for each bending step.
On the XBEND, this enables largely automated bending sequences without constant manual repositioning. This is particularly useful for complex profiles and larger production batches.
The automatic side feed guides the sheet into the machine in a controlled manner and aligns it for processing.
Combined with the gripper system, the XBEND can feed, position and move the workpiece through the bending sequence. This reduces manual intervention between individual operations.
In addition to material guidance, functions within the bending process itself can also be automated. Machine parameters are adapted to the job, mechanical deflection is compensated for, and stored bending programs are executed.
This reduces manual adjustments, particularly when working with different material thicknesses and demanding profiles.
When bending long sheets, considerable forces act on the bending beam. The resulting deflection can lead to variations in the bending angle along the machine length.
Automatic crowning compensates for this deflection during the bending process. This keeps bending angles consistent, even with long workpieces and different material thicknesses.
Different sheet thicknesses require different clamping beam settings. Automatic clamping beam adjustment adapts the clearance to the material thickness, taking the different bending radii into account.
This makes changing materials easier and eliminates the need for manual adjustments to the clamping beam.
Complex profiles require bending angles, flange lengths and individual operations to be coordinated precisely. The BMS Multi-Touch Control calculates bending sequences, displays profiles graphically and manages stored programs.
Once created, profiles can be recalled and modified for future jobs. Combined with automatic sheet guidance, bending sequences can run largely without manual intervention.
Saving Work Before the First Bend
Besides the bending operation itself, loading the sheets and preparing production data also affect the amount of work involved.
Loading aids make large sheets easier to handle. Digital work preparation allows jobs to be prepared independently of ongoing machine operation.
With Biegemaster’s own software, sheet metal profiles can be created on an office PC or tablet and transferred to the BMS Multi-Touch Control for further processing.
Loading long or large-format sheets can be physically demanding. On the XBEND, the optional loading tables extend when the machine opens, providing suitable support for the material.
This makes loading easier and reduces physical strain on the operator, especially when handling large or heavy sheet blanks.
It Depends on Your Daily Production Requirements
Not every production process requires a high level of automation. What matters is which tasks occur regularly, how frequently profiles change and which operations take the most time.
Batch sizes, profile geometries, material dimensions and the frequency of profile changes determine which functions are worthwhile.
In craft businesses and custom fabrication, profiles and dimensions often vary from job to job. Flexibility and easy profile changes are particularly important here.
Digital work preparation, stored bending programs and electronic back gauges make switching between jobs easier. Extensive automation of sheet guidance is not necessarily required.
Companies regularly producing similar or identical profiles benefit from stored settings and automatically positioned back gauges.
Programs can be recalled without entering all dimensions and bending steps again. This reduces preparation time and makes repeat orders easier to process.
For larger production runs and profiles with numerous bends, automating sheet guidance becomes increasingly useful.
Gripper systems, automatic feeding and programmed bending sequences can replace many manual operations. This allows even complex bending sequences to be completed with minimal manual handling.
Automating a single operation does not automatically make production more economical. The actual benefits depend on how the machine, equipment, material flow and work preparation work together.
It is therefore worth examining your existing processes:
Where do delays occur? Which manual tasks are repeated most frequently? Where is the most labor required?
The most useful automation is the one that addresses these specific bottlenecks.
The Right Machine. The Right Level of Automation.
Whether you produce individual components or large batches, the deciding factors are the profiles, material thicknesses and operations your machine needs to handle every day.
Biegemaster offers four different machine concepts: XBEND, S-BEND, BENDTRON and DURA. The choice of equipment depends on which functions your production actually requires.
Double folder with extensive automation options
Bends in both directions without turning the sheet. Optional gripper system, automatic side feed and loading tables enable largely automated workflows.
Hydraulic long folding machine for heavy-gauge materials
Bending capacity of up to 3 mm steel and 4 mm aluminum. Automatic crowning ensures consistent bending angles across the entire working length.
Electrokinetic bending technology
Electrokinetic drive without hydraulics. Quiet machine operation, precise control and digital preparation of bending programs.
Versatile hydraulic long folding machine
Robust bending technology with different control systems and equipment options – from basic applications to CNC-controlled profile production.
Which automation features would make a real difference to your production?
We review your profiles, production volumes and workflows to determine which machine functions and options are useful for your requirements.
Tell us about your production needs. We provide personal advice and help you select the right machine and equipment.
