Innovations

We at THALMANN are at the forefront of developing and innovating novel solutions in folding technology. The focus of the engineering department is entirely directed towards what customers need.

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Our customers tell us they want technologies that deliver a range of benefits that increase efficiencies, improve product quality and result in an economical sheet metal profile production. THALMANN offer a range of unique benefits:

Benefits

Increased bending accuracy and additional free bending space

Reduction of processing costs and increased capacity utilisation

Higher throughputs and increased capacity

Faster bending speeds and more flexibility

Better part quality and reduction of costs per bended part

Lean manufacturing processes and increased safety

Access to new markets and competitive advantages

Minimal maintenance requirements and longevity of machines

Integrated automated solutions and open interfaces

Functions

SHEET-UNLOADING UNIT

THALMANN’s most recent innovation is now available: a fully automated sheet-unloading unit. This innovation builds on our recent focus to offer integrated automated solutions that can be added to the double folder product line. With the integrated side-loading and integrated flipping units we make the sheet metal folding process fully automated.

The side-loading unit allows metal sheets to be fed automatically into the double folder, the flipping unit automatically turns the sheets and the sheet-unloading unit brings the folded parts to a position where they can be easily discharged for packing.

The modular unit offers a high degree of flexibility. The sheet-unloading unit can be folded away and be ‘parked’ or ‘stored’ underneath the buffer framework for the folded parts. In this configuration the space in front of the double folder is free for machine operators and jobs can be processed without full automation.

The complete double folder setup with fully automated units can be operated by one single employee. The fully integrated automated solutions from THALMANN offers significant value that increases safety, frees up operator time, reduces manufacturing costs and minimizes risks of damaging sheets and folded parts.

INTEGRATED FLIPPING DEVICE

Significant reduction of part handling by operators at the machine is achieved through an integrated flipping device that automatically turns parts. Parts are flipped automatically and subsequently placed accurately by the gripper units for the next bend.

The additional benefits are multiple: the operation is faster, it is safer for operators, it improves accuracy and it increases capacity at reduced costs.

In combination with the integrated sheet loading device THALMANN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

SIDE LOADING DEVICE

The automated integrated side loading equipment mounted on a folder provides significant efficiency gains and operational cost reductions. The only operation required at a machine with automated side loading is to keep the feeder filled with sheet metal and turn or unload the folded sheet-metal parts. Reduction of labour time at the machine is significant. With the automated sideloading device multiple parts can be loaded and folded at the same time.

The loading table with a high load capacity is mobile, can be automatically adjusted in height and can be supplied in different lengths. Optionally, the sheets are automatically made available in single feed, from a stack or directly from an upstream de-coiler.

The additional benefits are multiple: the operation is faster, safer for operators and can be integrated on the operations with minimal need for extra floor space. The integrated sheet loading device improves accuracy and increase capacity at reduced costs.

In combination with the integrated flipping device THALMANN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

EXTENDING HANDLING TABLE

Folding several sheets at the same time, folding of very long parts can be done by one instead of two machine operators if the THALMANN double folder is equipped with a variable extending automated loading and handling table.

The direct fixed cost reductions compared to traditional folders are often well over 50%, especially in combination with the integrated sheet loading and flipping device. In combination with stoppers and grippers the positioning of sheets is fully automated, this greatly enhances reproducibility and accuracy of folded parts sheet after sheet. In addition, the bending process becomes safer for the operator.

MODULAR TOOL GEOMETRY

A cropped bending beam allows more freedom and possibilities in the production of sheet metal profiles. The free space is extended through the folder cropped beam dimension. The additional space allows for bends with a 1:2 aspect ratio.

Architects, industrial designers and façade designers are continuously looking for new profile geometries. With the addition of a cropped bending beam on a THALMANN folder a wider range of dimensions of bended sheet metal parts can be produced. With this feature THALMANN customers are able to expand their product portfolio and business for folded sheet metal parts.

TORSION SHAFT TECHNOLOGY

The kinetic Torsion shaft technology provides maximal precision and reproducibility of folded parts. This technology is unmatched and unique to all THALMANN folders.

The synchronized distribution of force to the machine is at the heart of all THALMANN machines and can be compared to the synchronised mechanical control used in aircrafts. No other folder in the market is capable to deliver folded parts with an accuracy delivered through this technology.

DYNAMIC CROWNING

Uniform angles over the full length of the folded parts is guaranteed trough a dynamic automatic upper beam crowning system. This innovation ensures that the unwanted effect of overbending at the profile ends (the “banana effect”) is eliminated fully.

DYNAMIC FOLDING TECHNOLOGY

Significant cost reductions and efficiencies can be obtained through high speed of folding cycles which is guaranteed by the simultaneous movement of several machine axes. This innovation has been designed to speed up cycles without any loss of folding dynamics and accuracy.

Dynamic Folding Technology (DFT) is the basis of increasing productivity and capacity utilisation of the folding operation. The technology of simultaneous movements ensures a minimum of stop times in a bending cycle.

VERTICAL FORCE DRIVE

Evenly distributed ultra-high pressing force is critical to clamp the sheet metal parts for challenging folding cycles such as open or closed hems. The unique design of the rigid C-frames combined with the vertically positioned clamping beam is the basis for this unique Technology not found in any other design of folders around the world. All the force is evenly distributed over the full length of the sheet being bent.

THALMANN’s Vertical Force Drive (VFD) ensures that all forces are vertically applied to the sheet metal that is being bent. This design principle of THALMANN machines guarantees that the forces applied for the bending process are efficiently used without significant losses.

Unlike other technologies in the market the vertical force is applied directly at the zone where the actual bend is being formed.