Modular power package for demanding benders

Modular design has long since established itself in the automotive industry. Manufacturers offer a model in various editions and in addition to the standard specifications, customers can choose from a wide range of optional features. Bystronic was inspired by this principle when developing the Xpert Pro: Customers can choose between three editions and customize them with optional extras.
The three editions of the Xpert Pro will appeal to a wide variety of users: The Classic Edition is ideal for job shops with small batch sizes or for prototype builders. With the Performance Edition, medium-sized companies can produce larger series quickly and reliably. And the Dynamic Edition is ideal for companies that need even more speed to efficiently handle batch sizes of 1000 pieces and more. The dynamic top edition is like the super sports car of the Xpert series:

“Our goal was to launch one of the fastest press brakes on the market,” says Gerrit Gerritsen, Technical Sales Consultant Bending.

Click to share

With bending speeds of up to 20 millimeters per second, this is precisely what the developers at Bystronic have achieved.
 

In addition to the bending speed, the press capacity can also be adapted to individual requirements. Five performance levels are available for all three editions: The spectrum ranges from 100 to 320 tons. This enables sheets up to a thickness of 15 millimeters to be bent effortlessly. In terms of bending length, there is a choice of 3 or 4 meters. Companies that require even more flexibility can connect two machines together to process extra-long parts. Thanks to the wide range of configuration options, the spectrum of applications is very extensive: “The Xpert Pro enables both tiny parts that fit into a mobile telephone and very large parts such as those needed for a crane to be bent,” Gerritsen says.
Thanks to the modular concept, the press brake can be adapted very specifically to the requirements of the production environment. As these are currently changing faster than ever before, even a tailor-made press brake can rapidly no longer be the optimum solution – and in this respect Bystronic goes one step further than the car manufacturers: If the circumstances change, the Xpert Pro can be flexibly adapted to new requirements. The exchange of individual modules is straightforward and all optional equipment can be easily retrofitted. For example, if at some point a company wants to bend complex shapes in addition to rectangular parts, they can retrofit the backgauge from two to four axes, or even five or six axes.
 

Of course, companies that have already invested a lot of money in bending tools want to be able to reuse them when they purchase a new press brake. However, this is usually not possible when changing manufacturers, as there are almost a dozen different tool systems on the market that are not compatible with each other. With the Xpert Pro, this compatibility problem is a thing of the past. The developers deliberately designed the press brake to be so versatile that tool systems from other suppliers can also be used. “While the tool clamping system is usually milled into the upper beam of the press brake, the Xpert Pro’s modular design allows it to be docked on and thus easily exchanged,” Gerritsen explains.
The large selection of bending tools that can be used on the Xpert Pro offers users more freedom to bend a wide variety of parts. The Xpert series of press brakes has a proven track record of setting up tools very quickly, which also accelerates the bending process. The machine can be rapidly retooled when there is a change in the part that is to be bent. This can be achieved even more efficiently with the automatic tool changer, which is available as an option.
 

Manufacturing companies require maximum precision. They cannot afford angle deviations, as these result in rejects and thus in lower margins. Thanks to the tried-and-tested dynamic crowning, users achieve precise and consistent bending results from the very first part. Bystronic’s patented compensation system automatically adjusts the curvature of the lower beam during the bending process. The latest generation of pressure reference technology carries out corrections in real time based on state-of-the-art sensor technology.
For even higher process reliability, the LAMS angle measuring system is available as an option. This system compensates for deviations in the sheet thickness, which in practice can be as much as 10 percent. In addition to sheet thickness fluctuations, the reliable angle measuring system also automatically compensates for springback and rolling direction variations. In addition, corrections related to the metal sheet that is being processed can be stored and transferred to other machines – even to those that are not equipped with LAMS. This means that all other Bystronic press brakes in operation within the company also benefit from this function.
Thus, the Xpert Pro reduces the need for tedious manual corrections. The hectic day-to-day business hardly leaves enough time for these anyway. The Xpert Pro also reduces the operators' workload during the programming of bending processes: The ByVision Bending software solution determines the ideal bending process for every material thickness and bending angle. Convenient offline programming enables data to be imported without interrupting running production processes. Thus, the high-end press brake leaves nothing to be desired in terms of convenience. Bending has never been faster and more precise than with the new Xpert Pro from Bystronic.
 

Bystronic is a leading global provider of high-quality solutions for the sheet metal processing business. The focus lies on the automation of the complete material and data flow of the cutting and bending process chain. Bystronic’s portfolio includes laser cutting systems, press brakes, and associated automation and software solutions. Comprehensive services round off the portfolio.
The company headquarters are located in Niederönz (Switzerland). Additional development and production locations are located in Germany (Gotha), in Italy (Cazzago San Martino and San Giuliano Milanese), and in China (Tianjin and Shenzhen). Bystronic is actively represented by its sales and service subsidiaries in more than 30 countries and has agents in numerous other countries.
As a reliable partner, Bystronic stands for high-performance innovations, local expertise, and service excellence. Since 1994 Bystronic has been a part of the Swiss industrial holding company Conzzeta. In 2018, with more than 2800 employees, Bystronic achieved a revenue of 877 million euro.

Learn more about Bystronic !
Check out Bystronic’s press brakes machine catalog