Coil Punching and Automation

PX20/1 – 20 tons 1 punching head : 800-1550 mm

On a coil punching machine, first of all, the products to be processed have to be examined. Pieces that have two sides equal to the width of the strip maximise the advantages of coil punching on a conventional punching machine.

With the present coil punching machine it is possible to process very complex products. The working program decides the length of the piece : coil punching machines can process very long products.

The user-friendliness of the coil punching machine is strictly connected with low management costs: once the metal strip has been introduced, the machine produces automatically without the need of a continual supervision.

Advantages of a coil punching machine

  • Optimization of the raw material up to 20%
  • Automatic production
  • Investment with short payback time
  • Compact layout
  • Optimized raw material storage
  • Standard thick turret tools
  • Standard rotating tools
  • Simple line management
  • High productivity

The first economical advantage consists in labour saving. In a coil punching line the decoiler is the automatic loading system of the metal strip. The coil punching line operates automatically and the continuous presence of an operator is not necessary.

The product does not need to be manually separated from the sheet and this permits a further labour saving.

Furthermore, the costs of a complete coil system including decoiler, straightener and punching unit are much lower than in a sheet metal punching machine with automatic loading and unloading system.

The coil punching machine allows an easy management of the sheet metal stocks.

Another economical advantage is the compact layout of the machine in comparison to a sheet metal punching machine with automatic loading and unloading system.

Nowadays compact coil punching machines are available which are the ideal solution for both medium and small companies, and are suitably dimensioned for all workshops.

Feeder of the machine

The feeder is with grippers. Depending on the requested speed the feeder can have either simple or bi-alternating grippers. Typical for the feeder with grippers is the high precision of the feed, which would be impossible with roller feeders. The feeder with simple grippers (standard) has two mobile grippers and one fixed gripper. During the feed-cycle the fixed gripper holds the material while the moving grippers draw back.

The feeder with bi-alternating grippers (optional) use two sets of moving grippers, saving the recovery time needed on the feeder with simple grippers. The feeder with bi-alternating grippers guarantee a superior feed-cycle time.

The feeders with grippers can be used on raw and prefinished materials, with or without protective film (pre-painted metal strip, stainless steel, mirrored aluminium) from 0,6 to 2 mm.

The setting up of the coil width on the feeder is manual. It is obtained by the simple turning of a flywheel that centres the material.

The punching head

The main axis of the machine are the X and Y – axis. The material moves along the X-Axis whilst the tool moves along the Y-Axis.

The punching head is hydraulic, which enables a punching speed of over 800 punches/minute.

To obtain the maximum flexibility it is possible to rotate the tool (made up of punch and die) around its axis.

These axis, with the rotating function, are called the C (punch) and C1 (die).

The punching of the material is operated by an intelligent hydraulic ‘hammer’. To obtain a maximum quality of punching at high speed, it is necessary to have full control of the stroke and the speed of the hammer. The machine is equipped with a hydraulic punching head with a very particular axis – the Z-Axis.

The hydraulic hammer has a high precision positioning and punches in few milliseconds. Combined with this high speed it is nevertheless possible to punch at low speed for certain types of materials or processing.

Definition of the used tools

The machine is made to use commercial Amada ‘THICK TURRET’ tools measure D. These ‘thick turret’ tools are still the most used tools on the market.
The ‘D’ measure corresponds with any geometric figure within a diameter of 88,9 mm.
A multitool can be mounted in the D-station :

Available are:

  • 4 times B station (diam. 31,7 mm)
  • 6 times diameter 24 mm
  • 8 times diameter 18 mm

The tool is selected by turning the C/C1 axis. With the simple turning of the axis the tool of the multitool is selected.

Procon has applied an extra function that allows the tool of the multitool to be indexed.

It is clear that this additional possibility promises a flexibility without comparison, which results in an mayor feasibility of the work piece for the client.

Different models – technical features

Coil machine – dimensions

The coil punching machine differentiates in 6 models depending on the type of punching head and the width of the coil :

PX20/1 – 0800 : – punching capacity 20 tons

  • 1 punching head
  • Coil width from 50 to 800 mm
  • Coil thickness from 0,6 to 3 mm

PX20/2 – 0800 : – punching capacity 20 tons

  • 2 punching heads **
  • Coil width from 50 to 800 mm
  • Coil thickness from 0,6 to 3 mm

PX20/1 – 1550 *: – punching capacity 20 tons

  • 1 punching head
  • Coil width from 200 to 1550 mm
  • Material thickness from 0,6 mm up to :
    • Coil width up to 1000 mm : 2 mm material thickness
    • Coil width up to 1550 mm : 1,5 mm material thickness

PX20/2 – 1550 : – punching capacity 20 tons

  • 2 punching heads **
  • Coil width from 200 to 1550 mm
  • Material thickness from 0,6 mm up to :
    • Coil width up to 1000 mm : 2 mm material thickness
    • Coil width up to 1550 mm : 1,5 mm material thickness

PX30/1 – 1550 : – punching capacity 30 tons

  • 1 punching head
  • Coil width from 200 to 1550 mm
  • Material thickness from 0,6 mm up to :
    • Coil width up to 600 mm : 3 mm material thickness
    • Coil width up to 1000 mm : 2 mm material thickness
    • Coil width up to 1550 mm : 1,5 mm material thickness

PX30/2 – 1550: – punching capacity 30 tons

  • 2 punching heads **
  • Coil width from 200 to 1550 mm
  • Material thickness from 0,6 mm up to :
    • Coil width up to 600 mm : 3 mm material thickness
    • Coil width up to 1000 mm : 2 mm material thickness
    • Coil width up to 1550 mm : 1,5 mm material thickness

* The present folder always refers to model PX20/1

** The second punching head can add a second multitool or a tool for shearing, a cluster tool, louver tool, roller ball tool, etc…

Materials :
All types of ferrous materials, thickness 0,6 to 2 or 3 mm depending on the model. Special kinds of material, ex. with high hardness or breakage, have to be confirmed by Procon from time to time.

Axis :
X 750 mm (single stroke without repositioning)
Y 800 – 1550 mm
Z 20 mm
C/C1 360° continuous

Cutting shear
The cutting shear (optional) is positioned at the end of the machine. Due to the existing punching speed the cutting shear is normally used for the production of maximum sized panels.

Unloading system

Various types of unload systems can be applied on the coil punching machine.

We offer a stacking bench, which is adapted to the speed of the coil punching machine and offers a very good stacking precision.

Procon can offer all sorts of unload systems choosing from robotised stacking systems, with vacuum suction and aspiration based on the cycle-time and end product indicated by the client.

Precision of the positioning :
X 0.1 mm every 1000, (error of repositioning 0,2 mm)
Y 0.1 mm
Z 0.1 mm
C/C1 0.01 °

Axis – speed :
X up to 1 m/s
Y up to 1 m/s
Z up to 200 mm/s
C/C1 up to 720 ° /s

Punching speed :
The punching speed depends on the type and thickness of the material, displacement and requested force. The maximum cadence is 800 punches / minute.

Punching force :
The punching head can work on two different types of pressure, programmable on the CNC. The force in low pressure is 10 Ton, whilst the force in high pressure is 20 Ton. The choice between two types of pressure has been made to reduce the punching force and economize on the electrical cost.

CNC control

General characteristics :

CNC M9500 controller

system Windows
Touch-Screen
Networking (optional)
Possibility nesting (optional)
Parametric programming

The CNC uses RoBoPunch. RoBoPunch is a sophisticated firmware program used for controlling punching machines. It is Windows-based and therefore easy to use. Firmware is the machine-software, which means the instructions are stored in the Flash/Eprom (hardware) and without it the machine won’t be able to fulfill its target function.

The included simulation module allows the user to monitor the entire punching process.

To facilitate the communication between the operator and the machine, all the messages appear on a colour screen. Thanks to the simple dialogue, everyone, even those who have no experience using the control can work with it in a short period of time.

The keyboard, protected by poly-carbonate, is able to resist dust, grease and oil.

Production :

All actions relating to the actual punching of the material, execution of programs and tooling management have to be performed in the Production mode. This is the main user interface you will primarily need during production.

The real-time simulation allows continuous monitoring of the entire production process.

Macro – programming :

Macros are default shapes that can be achieved by entering only a few parameters. These shapes are then automatically converted to PGP-code and integrated in the program. The PGP of the macro can be consulted (and edited) in the editor.

Coil punching – loading systems

A coil punching line is made up of :

  • The decoiler
  • A straightener
  • The coil punching machine
  • Unload system

The coil punching machine can be placed in front of a wide range of decoiler and straightener systems.

The decoiler

The decoiler is the device that holds and unwinds the coil to be worked. The decoiler can be configured for the capacity, the rotation and the expansion.

The decoiler used for the coil punching machine is motorized because it has to be able to rotate thinner and more delicate strips up to 1,5 mm thickness. Thicknesses from 1,5 to 2,5 mm can be motorized or idle.

The expansion of the three jaws is manual or hydraulic. Usually the expansion for coils up to 2000 Kg can be manual as well as hydraulic, whereas for superior weights hydraulic expansion is recommended.
The capacity of the decoiler : important is to consider if the coil will be transported with forklifts or bridge cranes.
The snubber roll is a necessary option to process strips from 2 mm up. For coils over 4 tons it is advisable to use a loading chair to load the coil on the decoiler.

The straightener

There is a whole range of straighteners that can be implemented, depending on the result that has to be obtained. This choice starts from simple machines with 2 introduction rollers and 3+2 straightening rollers up to straighteners with 2 introduction rollers and 9+8 straightening rollers.

Procon offers a standard straightener that can work the following sheet thicknesses (independent of punching machine capacity) :

  • from 300 to 600 mm : sheet thickness up to 3,5 mm
  • from 300 to 1000 mm : sheet thickness up to 2 mm
  • from 300 to 1550 mm : sheet thickness up to 1,5 mm

The machine has 2 introduction rollers and 4+3 straightening rollers with diameter 100 mm.

On top of this standard machine Procon can offer a wide range of measure made solutions.

On the market a wide range of straighteners, stretching and flattening machines are available that can be implemented to obtain the requested result.

Demo Movie

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