“In the world of metal fabrication, it’s all about the PART,” says Kathy Etheridge, who heads marketing for Salvagnini America Inc. “We understand that in today’s economy, a manufacturer has to optimize the production process, reduce waste and operator intervention. That means parts need to be precise, machines automated and the technology easy to use yet progressive, with the ability to plug right into an Industrial Internet of Things network.”

Salvagnini’s core philosophy—precision, automation, reliability and technology (P.A.R.T.)—drives the equipment manufacturer’s approach to each machine it develops. “It’s all about the part the customer is making and how well they are making them,” Etheridge says.

In September 2021, Salvagnini introduced the S1, its new punch laser machine, to the North American market at Fabtech in Chicago. The machine has been designed to create a truly efficient production flow. The S1 can be configured to satisfy different production strategies with an extremely wide product range.

We broke it down into the four production pillars P.A.R.T.

Research and development efforts, along with customer feedback revealed that one of the best ways to ensure part precision is to reduce the amount of movement during the manufacturing process. “The more you can do in a single session, the faster and better quality part you will have,” says Etheridge.

The S1 is engineered with a multipress punching head able to host up to 59 punches, a fiber laser, stations dedicated to forming features, twin manipulators and an innovative sorting connection which eliminates the need for intermediate handling in-cycle. A single piece of sheet metal moves from punching and laser cutting to unloading, stacking, and sorting in one area.

Andrea Scarpari, head of engineering at Salvagnini America, points out, “The multipress head can house up to 59 tools at once, always ready to punch, supporting high quality punching and requiring no retooling or tool changes during the work cycle.”

Multitool holders ensure precision punch die alignment for improved quality machining. Stroke control of each punch promotes fast operations as well as extremely accurate machining. The fiber laser is attached on the side of the multipress head for maximum freedom in cutting geometries. The high head clearance [18 mm] along with a new tapping option [up to six different threads] affixed to the side of the punching head allow a wide range of forming possibilities during the punch laser operation.

The twin manipulator has two independent gripping devices that can also operate simultaneously to sort parts, with full reachability into the nest and on the stacking table. Parts are stacked on a carriage on the back of the machine, and the skeleton is then collected on another table through a dedicated comb embedded in the working surface.

“The combined punching laser head technology makes it possible for the S1 to produce precision cuts on delicate, filmed, or pre-painted materials,” says Scarpari.

S1 automation reduces the time needed to manipulate the sheet while it produces the required punches and cuts in a single pass, with zero setup time. The multipress head keeps each tool in a state of readiness. The machine integrates punching and cutting operations and automatically manages repositioning and separation of material. Most important to note, is the Cartesian manipulator automated loading and unloading device. The gripping devices pick up good parts directly from the work station and sort and stack them according to the pickup direction. This unique automation feature is within the barriers of the S1 walls and therefore takes up a very small footprint.

“For Salvagnini, punching is always a combined process that includes separating parts by a shear or laser,” says Scarpari. “With conventional punching, productivity and flexibility depend on the number of tool changes during the work cycle as well as the time it takes to move the sheet underneath the turret or single punch. Downstream separation operations also contribute to overall cycle time.”

The reliability of the S1 begins with its mechanical architecture.

“We use the same hybrid technology that is already working on our panel bender and press brake,” says Scarpari. “This approach minimizes electrical consumption and ensures the machine will work for a long time with reduced maintenance needs.” The machine doesn’t operate anymore with a hydraulic circuit and valves, simplifying and reducing the amount of operations needed. This punch laser machine is built to eliminate excess movement. With a footprint of 23 ft. by 26 ft., the S1’s mechanical structure includes a single frame to house the multipress head, forming options and fiber laser. This unit fits easily into a single freight container for streamlined transportation and faster installation on site.

The punch drive is robust, and maintenance is simplified because there are no mechanical gears. It is overload-proof and requires no water cooling. “The electric actuator gives just the right amount of pressure needed to punch that material in that moment, dramatically reducing power consumption and mechanical stress on the machine,” says Scarpari.

Technology, the final component, means superior mechanics and advanced automation, but intertwined with state-of-the-art software. There are four key technology components with Salvagnini machines. The first is the HMI [FACE] equipped on every machine: This was conceived to be intuitive and operator friendly, with a native touch screen design, and allows the operator to manage production and follow exactly what the machine is doing. The next components are the backend STREAM software and OPS systems. Essentially OPS enables the connection between the customer’s ERP system and the actual machine, so the entire process from order entry to completed part can be streamlined and connected, truly Industry 4.0. And finally, Salvagnini has its LINKS software, a connection that provides constant machine monitoring from any smart device, pushing information into the Cloud, where users can monitor productions and states of the Salvagnini systems. You can see what is happening with the machine, even when you are nowhere near the production facility.

“We are very excited about the opportunities the S1 brings to the market. We know there is a growing interest in material thickness and type, greater freedom in design and the ability to form louvers, tap and cluster punch,” Etheridge says. “The S1 truly is a technology packed solution for Industry 4.0 and Industrial Internet of Things practices.”