Precision profiles

01 Aug 2013 Editorial Team

For machine manufacturer Thalmann, maximum precision and speed in production of profiles with customer satisfaction are key ingredients to its success.

Based in Frauenfeld (Switzerland), Thalmann Maschinenbau AG specialises in sheet metal bending. Introduced to the market in 1960, the first hand-operated machines were followed by hydraulically driven and combined machines for cutting and bending sheet metal. Today, the company offers a comprehensive range of standard and special machines for forming sheet metal of up to 18.2 m long with a bending capacity for sheet steel up to 3 mm in thickness (400 N per sq mm).

Double bending

The swing-folding process is used to produce edge bends on flat sheet metal and to produce profiles. It is a gentle processing technique in which the bending beam rolls upwards about its pivot point and on the material, without damaging the surface of the sheet. But Thalmann's modern type TC and TD double benders are equipped with two bending beams; the sheets can be bent upwards and downwards without being turned or swivelled during the bending process. This speeds up the bending process and increases the machine's throughput considerably. A total of nine axes must be controlled in the double bender.

Integrated safety

The automation of the Thalmann machines is managed by Regatron AG from Rorschach, Switzerland, with whom the former has worked successfully for 25 years. Operator safety is of prime concern. Thalmann uses the Beckhoff EL6900 Safety PLC terminal, which is seamlessly integrated into the EtherCAT Terminal system. This TwinSAFE solution is certified for applications up to SIL 3 according to IEC 61508 and DIN EN ISO 13849 PLe. Safety functions such as emergency stop, safety door monitoring, two-hand control, etc, are user-friendly. They are conveniently configured in the standard TwinCAT System Manager and run on the same PC platform as the machine programme. The safety functions can be linked to the machine programme, but are independent of it.

Dynamics under control

The servomotor-driven axes of the bending machines are controlled by AX5000 EtherCAT drives from Beckhoff. For the servomotors, Thalmann uses the AM3000 series of pole-wound motors from Beckhoff. The hydraulic valves are controlled via EL4001 EtherCAT analog output terminals. Numerous monitoring functions are also incorporated in the machine programming to ensure trouble-free operation. In the case of hydraulic oil, its temperature is monitored, the flow rate is measured and the oil filters are checked.For Thalmann, the focus is always on the customer. Hence, there is no traditional standard machine, but only custom machines that take the customer's requirements into account and vary with regard to size, length, functionality, etc.

(Communication by the management of the company)

For machine manufacturer Thalmann, maximum precision and speed in production of profiles with customer satisfaction are key ingredients to its success. Based in Frauenfeld (Switzerland), Thalmann Maschinenbau AG specialises in sheet metal bending. Introduced to the market in 1960, the first hand-operated machines were followed by hydraulically driven and combined machines for cutting and bending sheet metal. Today, the company offers a comprehensive range of standard and special machines for forming sheet metal of up to 18.2 m long with a bending capacity for sheet steel up to 3 mm in thickness (400 N per sq mm). Double bending The swing-folding process is used to produce edge bends on flat sheet metal and to produce profiles. It is a gentle processing technique in which the bending beam rolls upwards about its pivot point and on the material, without damaging the surface of the sheet. But Thalmann's modern type TC and TD double benders are equipped with two bending beams; the sheets can be bent upwards and downwards without being turned or swivelled during the bending process. This speeds up the bending process and increases the machine's throughput considerably. A total of nine axes must be controlled in the double bender. Integrated safety The automation of the Thalmann machines is managed by Regatron AG from Rorschach, Switzerland, with whom the former has worked successfully for 25 years. Operator safety is of prime concern. Thalmann uses the Beckhoff EL6900 Safety PLC terminal, which is seamlessly integrated into the EtherCAT Terminal system. This TwinSAFE solution is certified for applications up to SIL 3 according to IEC 61508 and DIN EN ISO 13849 PLe. Safety functions such as emergency stop, safety door monitoring, two-hand control, etc, are user-friendly. They are conveniently configured in the standard TwinCAT System Manager and run on the same PC platform as the machine programme. The safety functions can be linked to the machine programme, but are independent of it. Dynamics under control The servomotor-driven axes of the bending machines are controlled by AX5000 EtherCAT drives from Beckhoff. For the servomotors, Thalmann uses the AM3000 series of pole-wound motors from Beckhoff. The hydraulic valves are controlled via EL4001 EtherCAT analog output terminals. Numerous monitoring functions are also incorporated in the machine programming to ensure trouble-free operation. In the case of hydraulic oil, its temperature is monitored, the flow rate is measured and the oil filters are checked.For Thalmann, the focus is always on the customer. Hence, there is no traditional standard machine, but only custom machines that take the customer's requirements into account and vary with regard to size, length, functionality, etc. (Communication by the management of the company)