EuroBLECH Bulletin

For the EuroBLECH Community

EuroBLECH 2016 Show Preview now available

As the global meeting place of the sheet metal working industry, EuroBLECH offers its audience a comprehensive overview of the prevailing technological trends. From 21 – 25 October 2016, more than 1,500 exhibitors from 40 countries will showcase a wide variety of products and services, from conventional systems to high-tech solutions.

The official EuroBLECH 2016 Online Show Preview, with detailed information on many exhibitors and their products, is now available. With this user-friendly online preview, visitors will be able to create and print their personalised Show Preview, with company and product descriptions sorted by hall or category. Additionally, new functions also allow sharing selected entries via social media.

We hope you enjoy browsing the Show Preview!

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Sign the EuroBLECH Guestbook

What are you expecting from EuroBLECH 2016? What are your thoughts regarding the recent trends of the industry?

Sign the EuroBLECH Guestbook and share your opinion with the rest of the community!

In the current environment of major changes in industry production (also known as smart manufacturing), connectedness and data exchange along the entire production value chain is gaining increasing importance. In this exciting time, we would like to bring the sheet metal working community closer together to create an interchange of thoughts, experiences and plans for the future. Join the EuroBLECH Community!

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Ticket Shop now open: Get your entry ticket in advance!

Entrance tickets for EuroBLECH 2016 are available now via our Ticket Shop. Tickets can also be purchased on-site during the exhibition.

Buy tickets in advance and save: A day ticket purchased in pre-sale via the Ticket Shop costs €30 instead of €38 on-site, and a 5-day season ticket costs €50 instead of €58 on-site.

Further important information and tips about visiting the show are available in the visitor area of the organisers' website.

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First EuroBLECH White Paper available to download

When Industry 4.0 took off in Germany, it rapidly made it to the international headlines. With the digital agenda of the federal government, it received highest political priority. The future of the entire manufacturing industry was affected. But where does Industry 4.0 stand in reality? In fact, a number of medium-sized companies offer interesting solutions. Research made big progress; it helps to re-think a number of processes completely.

Read the first EuroBLECH White Paper focussing on Industry 4.0!

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Last opportunity: Take part in the competition “The New Generation of Sheet Metal Working”!

The online competition “The New Generation of Sheet Metal Working” will reward six organisations or individuals in the sheet metal working industry for best practice, innovation, excellence and outstanding performance in six categories. The winners of the competition will be announced at a ceremony during EuroBLECH 2016.

Submission of entries is still possible until 31 August 2016 via the EuroBLECH website. The entire sheet metal working industry can participate in the online voting, which will start on 1 September. Detailed information about the competition and the entry requirements are available on the show website.

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EuroBLECH Job Board now online

The EuroBLECH website is once again offering a job board that allows specialists in the sheet metal working industry to search for a new professional challenge and to reach employers worldwide.

Job listings are published on the EuroBLECH website. Participation as a job seeker is free of charge. More information is available in the visitor section of the exhibition website.

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Always up-to-date – with Social Media

Would you like to receive the latest news on EuroBLECH 2016? Then visit the EuroBLECH Social Media channels and receive regular updates for visitors, but also for exhibitors and the press. You can find EuroBLECH on Facebook, Twitter, LinkedIn and YouTube. Take a look at our channels and follow EuroBLECH 2016! #euroblech

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Visa and Travel Information

EuroBLECH 2016 visitors who require a letter of invitation for their visa application should contact the relevant foreign representative. For the contact details of the representatives as well as more information on invitation letters please visit the travel pages of the exhibition website.

Hanover, with the world’s largest exhibition grounds, is famous for hosting leading international trade fairs. This friendly, cosmopolitan city has an excellent infrastructure and an efficient transport network in place, ensuring easy access for visitors from all over the world.

This year, there are several travel packages available from Deutsche Bahn, the German railway company, and Lufthansa Group Partner Airlines, as well as special offers for visitors from Prague. The Hannover Express also provides one-day return flights from Bergamo. Please visit the EuroBLECH website for further details.

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“Awards at EuroBLECH” presented by Blechnet and MM Maschinenmarkt

Once again, Vogel Business Media, publishers of the official EuroBLECH Show Daily, will be awarding a prize for the most innovative exhibits at EuroBLECH 2016.

All exhibitors are invited to send in their application for the following seven categories: Metal Forming, Punching, Automation & Handling, Joining, Separating, Surface Finishing and Measuring & Testing.

An expert jury will examine and rate all applications submitted. There will be an official award ceremony at EuroBLECH 2016, presenting the winners and introducing all the nominees’ innovations. The award ceremony will be held on 25 October 2016 at 5pm in the Convention Center.

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The visible machine: Full transparency with the Performance Cockpit by TRUMPF

With the new Performance Cockpit, sheet metal processors can identify the potential for optimization in their production at a glance. The machine tool and laser manufacturer TRUMPF offers a particularly innovative, web-based solution for this purpose. The data are prepared for the user online, analyzed and finally displayed on the individually configured dashboard, so that he always has the key data at hand. The data host is the TRUMPF subsidiary AXOOM. Thus, the data is stored in separate and secure environments for each customer in accordance with the latest security standards.

The unique feature: As it is a web-based solution, it is possible to use the Performance Cockpit regardless of your location. That means that the Performance Cockpit runs on all devices, including PCs, tablets and smartphones, even outside of the corporate network. This creates optimal transparency with regard to machine productivity, the materials and tools used as well as the manufacturing programs produced.

For example, regardless of where he is located, the sheet metal worker sees when the machine was run and when disturbance or even stoppages occurred. This performance data can be analyzed for the machine in general, for individual shifts or over a certain period of time, enabling companies to recognize whether optimization measures have actually increased productivity and where further opportunities for improvement may be hiding.
Information and statistics on material use can also be displayed via the Performance Cockpit: for example, it indicates the share of each material processed by the relevant machine. Just one click will bring up data about the type and thickness of the material used, thus improving planning for the next material order. Moreover, sheet metal workers can also see the percentage of scrap per type of material, which enables them to analyze their efficiency in material use.

The Performance Cockpit also makes tool use transparent: for example, the software displays the number of strokes of a punching tool during a selected period. This permits monitoring of tool usage and makes scheduling a required tool replacement easier.

In addition to machine productivity and material consumption, the Performance Cockpit also determines which production programs were started on which machines. This enables the production manager to check whether all of the scheduled programs were actually run. In addition, the display shows him whether there were any interruptions, enabling him to analyze the causes if necessary. This analysis helps the metalworking plant to achieve full transparency for all activities.

No on-site visits from service technicians are required to install the software - an element of implementation of TruConnect. The necessary connector kit is installed on the machine via a remote connection by TRUMPF. This means that all the user needs is an internet connection and a current browser. After installation, the user logs into his cockpit and can start analyzing his data. Thus, the Performance Cockpit offers an easy entry into the world of networked manufacturing.

Data security is a top priority at TRUMPF and the data host AXOOM. This means that the servers are not provided by third parties such as Google or Amazon, which are subject to foreign data protection and privacy regulations, but are located in Germany. The customers have full control over the data produced by their machines at all times, and release the data only for use by TRUMPF and AXOOM. It doesn’t get any more secure than that!

Picture: The Performance Cockpit displays current production figures on every end device.
Photo: Trumpf

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DESCH: The specialist for mechanical presses used in metal forming technology with planetary gears and system solutions

Servox® drives are among the most modern drive solutions for presses used in metal forming technology. They can help to increase productivity by more than 40 percent and boost output rates up to 70 percent. The various versions of the tried-and-tested planetary gears combined with integrated holding brakes – which can be used for a dynamic emergency stop function if required – deliver optimum results in terms of power density and torque and/or speed conversion in an incredibly small space. Variants can be configured based on the number of gear speeds, the number of motors or a combination of both. Ratios can range from i = 4 to more than i = 65 and output torques can extend from 10 kNm to over 1,000 kNm.

The Servox® family comprises one and two-stage planetary gears, stepped planetary gears and dual drives with a combination of planetary gear and spur gear stage and several motors on the drive side and a new addition to the family – the Servox® brake. This hydraulically actuated, spring-operated multiple-disc brake is used as a static holding brake with an emergency stop function and exhibits a special, protected disc design that features special wear protection depending on the design and therefore further boosts the availability of the press. The brake is intended for use on e.g. servo presses with conventional reduction gear ratios and needs only a free shaft end for the hub and a means of fastening the housing to the press frame.

Picture: Servox® gearboxes
Photo: Desch

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Kjellberg shows its competence with live cutting and welding

With models from the series HiFocus neo and Smart Focus Kjellberg Finsterwalde demonstrates its latest plasma cutting units. Visitors at EuroBLECH will have the opportunity to observe the cutting process and to convince themselves of the excellent quality and high cutting speeds. Alongside the Contour Cut technology, cutting with air as plasma gas will be demonstrated as well.

Kjellberg’s cutting technology will be completed by the fibrelaser XFocus. From its integrated technology database the optimum cutting and marking parametres are available at the push of a button for cutting range from 0.3 up to 20 mm in total. As ready-made complete solutions, the fibrelaser systems can be used on all common guiding systems for plasma cutting – separately or in combination with other tools.

With its practically relevant welding demonstration, Kjellberg Finsterwalde shows the application range of the InFocus technology at EuroBLECH. It achieves process-stable and reproducible results in fully or partly automated production processes. Various steels and non-ferrous metals with a broad range of material thicknesses can be welded or soldered. InFocus produces high-quality joints thus fulfilling the most demanding industry standards.

With InFocus, thick sheets can be root welded. By using the TIG keyhole process the web can be made bigger and the opening angle can be reduced. The smaller seam cross section reduces the number of layers that have to be applied during the subsequent submerged arc welding. When using InFocus as root layer it is also not necessary to gouge the root. Savings in labour costs and electric energy have further positive effects on the efficiency of the production process.

At EuroBLECH, Kjellberg Finsterwalde will also show the well-tried technique for equipping manual, partly and fully automated welding workstations for submerged arc welding.

Picture: CNC plasma cutting with InFocus
Photo: Kjellberg Finsterwalde

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Schuler Smart Press Shop: Increasing process reliability and cost-effectiveness through networked systems

Many operators have already wished that their system could tell them exactly what the problem is. In the age of the Industrial Internet, machines that communicate are no longer something to aspire to in the future. At the EuroBLECH trade fair, Schuler’s “Smart Press Shop” concept will be demonstrating how networking solutions in forming technology can increase not only process reliability, but also cost-effectiveness in production.

In a modern servo press line from Schuler, around 30 industrial PCs are networked with one another. This is the only way to ensure a high level of productivity and safe part transport from one press station to the next. Single presses, laser blanking lines, and various automation components also already have the necessary interfaces for comprehensive networking.

What is the maximum speed at which a specific sheet metal can be formed? Forming simulation provides valuable information for the virtual optimization of the entire system. To stay with the example of a servo press line: long before the tool sets are clamped into place, the virtual model of the system produces one part after another.

By simulating the entire system, including all press stages and automation components, the time needed for part transport is minimized. Schuler offers tools for optimizing output, helping to reduce the time required for commissioning considerably. The customer can also get information on the energy required for production.

The systems provide data measured by sensors installed at numerous points, for example to monitor the press force. By drawing the right conclusions from this information, this area also has huge potential. If the press force progression deviates from a particular pattern, this indicates irregularities in the process. These solutions gather important information that can be used to maintain the line, thereby preventing damage to the machine and tool.

If it becomes apparent that not everything is running smoothly, the service engineer can connect to the customer's system online. In nine out of ten cases, problems can already be solved remotely through the Schuler Remote Service. Condition-based maintenance can therefore help save a lot of money.

Many of these examples are already common practice at Schuler. According to Chief Technical Officer Dr. Stephan Arnold, Schuler had the key advantage of having equipped press plants throughout the world for decades, from the decoiler through to the automatic racking system. This experience helped enormously when it came to developing intelligent functions for the ‘Smart Press Shop’ and the press plant of the future.

Picture: The correct conclusions have to be drawn from the data which is provided by the systems.
Photo: Schuler

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Transfluid creates expanded prototyping options for new pipe forming geometries

Pipe forming technology is a complex matter – with ever smaller tolerances for advanced new projects from the different industries. These companies with their fresh ideas are, of course united by the wish of transferring the new product to serial production safely and reliably at once after development. This also applies to high-tech machine constructor Transfluid, which uses its pipe processing technologies for research in its internal prototyping department. This is not only about sampling of its own new developments, e.g. in the area of tool technology. Companies without machinery of their own can have their pilot series analysed and precisely improved at Transfluid.

According to Stefanie Flaeper, managing director at transfluid, the support in this area was in higher demand than expected. Therefore, transfluid had expanded their research and prototyping department once again just recently. They could perform diverse tests on components and tools with pipe diameters up to 65 mm there, said Stefanie Flaeper. A CNC-controlled type SRM rolling forming machine and two axial forming machines are used for this with a forming power of up to 25 tons. The entire process chain can be implemented with an additional CNC-controlled pipe bending machine and an orbital pipe separation system - to ensure that requirements, e.g. regarding burr formation, can be met.

For specific customer projects, the experts in the department are testing new forming geometries and tool concepts for serial maturity and quality. The Transfluid team relies, among others, on a tactile and visual measuring system for components and tools. The interim results up to the certain result are documented reliably.

The Transfluid experts have special experience as a technology leader and initial developer of incremental pipe forming, which permits partial rotation-symmetrical forming of pipes made of high- and very-high-strength materials. In particular review and assessment with light-weight components and high-strength materials is possible as well. Depending on geometry, this can even be done tool-independently. Thus, the company can offer the pilot series or prototype production particularly cost-optimised.

Picture: Unlimited opportunities of pipe forming, axial and rolling.
Photo: Transfluid Maschinenbau GmbH

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Hypertherm: New products and technologies, impressive demonstrations and more

Hypertherm, manufacturer of plasma, laser and waterjet cutting systems will introduce a new generation cutting system in its Powermax® line of light industrial plasma cutters, new cutting technologies for high end automated plasma cutting and its new company vision “Shaping Possibility” at EuroBLECH 2016.

For the first time, Hypertherm will host a special guest to cut live with a completely new light industrial cutting system. EuroBLECH will be the first exhibition where visitors will be able to see this system and witness its impressive features and capabilities.

In addition, Hypertherm will introduce new technologies in its HyPerformance® line of automated plasma cutting systems. These will further improve cut quality on mild steel and non-ferrous materials and reduce operating costs. Also featured will be industry-leading SureCut™ applications like True Hole® and True Bevel™ which maximize cutting performance by automatically applying optimized process parameters that simplify cutting, reduce the need for operator intervention and ensure high quality, consistent results.

Besides all the new products and technologies, the company will feature its HyPrecision™ Waterjet cutting products, CAM nesting software line, automation products as well as torch and consumable technologies from Hypertherm and its Centricut® and AccuStream® brands.

Picture: Live demonstration of new products and technologies.
Photo: Hypertherm

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Pure flexibility: Extension arms of the eT-Hover-univac by euroTECH facilitate format changes

The compact lifting device eT-Hover-univac is modularly extendable. With the corresponding extension arms and four additional suction plates, not only can the device be adapted to different plate formats, but the maximum carrying capacity can also be increased to 700kg. In its compact standard version with four suction plates, the device can lift 360kg vertically and 500kg horizontally. The vacuum lifting device by Eurotech is designed as an attachment for crane and lifting equipment in accordance with the DIN EN 13155 standard. It is suitable for lifting and moving large-surface loads made of glass, wood and coated particle boards, as well as other materials such as stone, metal or plastic.

Whether intended for interior design purposes such as handling of wood panels or for outdoor use during window installation, the battery-powered eT-Hover-univac is available both as construction lifting equipment as well as in the indoor version. A quick change of the plate formats, which are to be attached by suction, is no problem. The extension arms and four additional suction plates and the corresponding vacuum hoses, which are easily docked to the existing suction plates, can be attached to the device individually. Without extension arms, two positions for each suction plate are possible, and with the extension, there can be three more positions per suction plate. For rough and structured surfaces, such as brushed wood or structured glass, other suitable suction plates can be attached.

The lifting device can be continuously rotated manually by 360° and pivoted automatically or manually by 90°. In order to be able to work on narrow surfaces, such as between the scaffold and building facade, the swing arm can be removed. All operating elements are integrated into the device. Its scope of application is expanded further by an optional remote-control function: the suction and rapid ventilation functions can be controlled wirelessly. This increases safety during work on ladders and scaffolds, facilitates handling, and in many cases saves the need for additional labour. The range of the radio remote control comprises about 50 to 100 meters in disturbance-free environments.

By means of the quick venting function, the load can be quickly detached from the eT-Hover-univac. This saves time during the tedious work process. An energy-saving function ensures that the vacuum pump will only remain switched on until the necessary vacuum suction has been reached.

In the dual-circuit version, all vacuum components starting from the vacuum pump, such as the non return valve, the vacuum reservoir and the vacuum gauge, are present in duplicate. The lifting device, which is mounted on the crane, is ready for operation once there is sufficient under pressure. The controller continuously monitors the vacuum. Disruptions or a loss in vacuum suction is indicated by optical or acoustic signals.

Picture: eT-Hover-univac in the standard version with four suction plates
Photo: euroTECH

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Rösler: Preservation lines – for improved quality, productivity and cost efficiency

In such diverse industries like steel fabrication, steel trading and ship building the temporary corrosion protection of steel plates and beams is critical for producing high quality end products. Preservation lines are key in providing such corrosion protection coatings. With numerous innovative technical features, preservation lines from Rösler offer significant operational and cost benefits.

Turnkey preservation lines usually consist of special transport systems for loading/unloading steel plates, beams and pipes. In addition, they incorporate a preheater, a roller conveyor shot blast machine, an automatic paint booth with overspray separation and paint drier with slat conveyor. All of these components are interlinked for fully automatic operation with little or no operator involvement. If the work pieces are stored outside, a blow-off station in front of the pre-heater removes loose contaminants and moisture from the plates and beams. The use of solvent based paints requires the exhaust air from the drier to be guided to a thermal regenerative oxidation station. Critical for the overall quality, productivity and cost efficiency of any preservation line is an equipment concept that is best suited for the respective work pieces and technically sound design of the individual system components. Rösler preservation lines can be custom-engineered to process work pieces with different heights and widths. Numerous innovative technical features guarantee high throughput at relatively low costs. This is reflected in transport speeds of up to 8 meters/min (27 feet/min) with unmatched coating qualities.

The newly developed high convection pre-heater, with its 250 mm (10”) thick insulation, quickly heats the work pieces to a temperature of 20 to 40°C (68 to 104° F), ensuring optimum paint adhesion and short drying times. In contrast to conventional pre-heaters the Rösler convection system incorporates multiple fans, equipped with frequency inverters for quick adjustment of the fan speed. This allows adaptation of the heat output to the work piece mass (for example, thickness) and the transport speed. At the same time, the air circulation ensures that all work piece areas are equally exposed to the hot air. This not only contributes to quickly bringing the work pieces to the required operating temperature but also helps to reduce energy consumption.

From the pre-heater, the work pieces are transported to the roller conveyor shot blast machine. The blast chamber is always made from manganese steel. In addition, the direct blast area is lined with overlapping, easily replaceable plates, also made from manganese steel. The shot blast machine itself is equipped with Gamma 400 G turbines available with different power options, which allows the turbine’s performance to be tailored to the respective machine size. Compared to conventional blast wheels the Gamma 400 G turbines produce a 15 – 20% higher blast performance with at least 100% higher uptimes.

The turbines are placed in the upper and lower section of the blast chamber at an incline so that the blast media hits the work pieces at a defined angle. Compared to turbines hitting the work pieces at an angle of 90 degrees, this inclined turbine arrangement results in a 15 – 20% higher de-scaling/de-rusting effect, which significantly reduces the required cycle times. The integrated cleaning system for removing residual blast media from the work pieces consists of a rotating brush and a targeted high velocity air stream. It is equipped with a work piece recognition system and automatic height adjustment. This ensures that the work pieces are leaving the blast chamber free of blast media and dust.

At the same time, it eliminates the need for lengthy manual adjustment and minimizes the wear of the rotating brush. The capacity of the blast media cleaning and recycling system and dust collector are tailored to the machine size. Both can be placed on top of the machine, resulting in an extremely small overall machine footprint. Large doors allow easy access to the blast chamber for maintenance work.

A critical cost factor in any preservation line is the paint and primer usage. For this reason, the automatic paint booth is equipped with sensors precisely measuring the work piece dimensions. The system controls then guide the paint gun movement, which precisely follows the work piece contours. This guarantees that the paint is only applied at the required thickness. The result is significant paint savings and a minimum of overspray.

Practically all solvent or water based paints with 1, 2 or 3 components can be utilized. For applications requiring different types of paint, the automatic paint booth can be equipped with multiple independent paint delivery systems. The cabin exhaust air system features an innovative trapezoidal, flow-optimized arrangement, which prevents air turbulence and safely transfers the exhaust air mixed with paint mist to the standard dry separation unit, consisting of a patented brush pre-separator with slowly rotating brush rollers. Once they are dry, the paint particles stick to the brush and fall to the bottom. This pre-cleaning stage is followed by a sinter-plate filter, which reduces the residual dust load significantly below the legal requirements. The brush pre-separator reduces the filter load dramatically so that uptimes of around 15,000 hours for the sinter-plate filter can be achieved. Another benefit of this optimized air cleaning system is that minimal paint particles are deposited on the Teflon coated inner walls of the cabin resulting in reduced cleaning times and lower operating costs.

Special steel slat conveyors are used to transfer the work pieces, which are still wet with paint, to the paint drier. They have only six contact points per square meter (about ten square feet) keeping the risk of disturbing the paint at an absolute minimum. For heating of the paint drier to be between 40 and 80° C (104 to 176° F) the exhaust air from the preheater is utilized. This eliminates the need for any additional energy input for the paint drying stage. Recirculating fans and special air guides ensure an even, all-around drying of the painted work pieces.

Picture: At the center of any preservation line is the roller conveyor shot blast machine with automatic paint booth designed for the specific customer requirements.
Photo: Rösler Oberflächentechnik GmbH

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