TC Double Folder

The automatic sheet metal flipping unit ensures a high reduction in sheet metal parts handling and a leaner folding process. After the flipping process, the sheets are placed exactly at the gripper units for the next fold.

Customers also benefit from a simplified manufacturing processes, higher safety for operators, lower personnel deployment and reduced manufacturing costs.

In combination with the lateral sheet metal feeder, customers get an almost fully automatic solution for sheet metal profile production. The machine operators only loads the lateral sheet metal feed and then remove the finished profiles from the machine.

The kinetic control shaft technology offers sheet metal processors the highest folding precision and a high level of reproducibility of the manufactured sheet metal profiles. This unique technology is unmatched and at the heart of all Thalmann long folding machines.

The synchronized distribution of force to the machine can be compared to the synchronised mechanical control used in aircrafts.

The curved clamping beam tool provides customers more freedom and variety in sheet metal profile production. With the additional folding clearance, profiles with an aspect ratio of e.g. 1:2 (height to depth) can be easily produced.

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.

Thanks to the extendable handling table, both very long and multiple sheets can be loaded, bent and removed simultaneously by just one operator. Sheet metal parts handling is simplified and the entire manufacturing process is accelerated.

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.

An evenly distributed and very high clamping force development is provided by the vertical force drive (VFD) exclusive to Thalmann machines. The mechanical zero-point lock securely clamps the sheets and presses the folds evenly.

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.

The simultaneous movement of several machine axes enables faster folding processes without loss of precision. DFT creates the conditions for high productivity, increased capacities and a smooth folding process.

The technology of simultaneous movements ensures a minimum of stop times in a bending cycle.

Expand the product scope of your folded sheet metal parts with a wide range of interchangeable gripper designs.

Spring-loaded fingers are automatically activated to position the sheet metal in the right place when the smallest possible gripper measurement is exceeded.

For folding short sheet metal parts, TC models can be equipped with additional gripper units. Each single gripper can be extended by an additional gripper to a double gripper unit.

A fully automatically activated spring loaded finger can be placed left or right or both sides of the double gripper unit.

Even several tapered sheet metal profiles, that can be seamlessly sleeve into each other, can be produced quickly and easily at the same time.

With the option of an automated tapered gripper function, architects, roofers and engineers have the possibility to develop novel profile geometries and extend the scope of façade design.

Efficiencies, process flexibilities can be significantly enhanced by folding several sheets at the same time within one folding cycle.

The Thalmann machines can be custom equipped with fully automated multi section grippers that allows to handle and process several parts at the same time by one operator. For example 2 x 3 meter sheets can be folded simultaneously by one operator on a 6.4 meter Thalmann TD folder.

A wide range from 5 mm up to 1150 mm sheets can be folded with high accuracy with the installation of automated back gauge stop fingers on the Thalmann machines.

Back gauge stop-fingers will automatically be activated when the smallest possible grip zone is exceeded. The back gauge stop fingers will position the sheet metal in the right place.

The hydraulic material thickness adjustment allows for an automatic adjustment of the air gap between the bending tool and upper respectively lower clamping tool.

The result is an air gap that is always optimally set between the bending tool and clamping tool positioned precisely in accordance with the sheet thickness used, which guarantees a flawless bend radius.

Precisely bent profiles with even angles over the entire length is what you expect from a good folding machine. You can do this easily by means of the crowning function.

This innovation compensates for angular deviations as it can show in the center of the sheet (banana effect) and ensures the production of high-precision, parallel sheet metal profiles.

Laser guides around the machine guarantee a safe environment for operators to work in. The safety zone is placed as such that efficiencies and sufficient workspace during operation of the machine are maintained.

Thalmann’s safety concept is fully complient with the EU-guidelines for “Standard-Sicherheitsausrüstung” and “Sicherheit von Steuerungen”.

Mounted on the bending beam, a selection of different interchangeable beam extensions can greatly extend the scope of bends produced on a Thalmann machine.

To improve durability and for heavy duty bending operations, HARDOX 400 steel bending beams will greatly enhance tool life as well as maintain accuracy of folded parts. The type of steel used to produce the beams is similar to the steel used for excavator shovels.

The extremely wear resistant Hardox beams will under normal operation last the lifetime of the machine and can be welded when damaged. Hardox beams on a Thalmann machine improves the stiffness and stability of the machine.

The decoupling of the longitudinal slitter from the folding beam provides more geometrical freedom and relieves the entire mechanics. Additionally, the decoupling increases the flexibility for the use of the hemming and roll former units.

In addition to achieving operational efficiencies trough the integration of folding and slitting in one operation, the folded metal sheets are less prone to damaging due to the reduction of manual handling. Scratches or bumps will be avoided with an electric longitudinal slitter unit.

On one and the same guiding system slitters and hemming/roll former heads are interchangeable. Both reductions in costs and investments are clear benefits and can be retrofitted on an existing Thalmann machine.

Modular and interchangeable hemming and roll forming units extend possibilities of forming sheet metals on a Thalmann machine. The hemming and roll forming unit can be mounted directly on the Thalmann long folding machine. This unit is ideal for the production of calibrated highly accurate dimension panels and very tight hems.

In addition to achieving operational efficiencies trough the integration of folding and a hemming and roll former unit in one operation, the folded metal sheets are less prone to damaging due to the reduction of manual handling. Scratches or bumps will be avoided with an electrical slitter unit.

On one and the same guiding system slitters and hemming/roll former heads are interchangeable. Both reductions in costs and investments are clear benefits and can be retrofitted on an existing Thalmann machine.

Safety of machine operators is significantly improved through positioning of LED lights under the upper clamping beam.

Different colour settings can be selected to match the optimal light conditions.

For an efficient and extended scope of remote service, the optional M-Guard functionality is recommended. A secure and fast direct link between a Thalmann machine anywhere in the world and the service team in Switzerland is easily established with M-Guard.

M-Guard offers the possibility to perform software updates, software diagnostics and problem solving tasks. Up- to-date VPN technology ensures safe and fast data-transfer. Remote maintenance significantly reduces costs and time as no travel will be required to deliver this service.

The bottom folding beam can be used as a loading aid for the easier material feed and is equipped with gliding units which allow the sheet metal to be introduced more easily.

The ball sheet metal support table enables easy positioning and ergonomic handling of heavy sheet metal parts.

To achieve a consistent performance and service life in the long term, this sheet support is manufactured solely from stainless steel.

The low-maintenance high-performance hydraulic units provide a powerful drive, high folding speeds, short folding cycles and constant folding results.

Exceptionally high forces that release up to 25% more capacity can be achieved with the high-performance PRO hydraulic unit. The unit is driven by two powerful pump motors with double valve block injection and has two high-performance oil coolers.