Pivotal Player: Standard, hybrid and servo electric bending options can give manufacturers the edge when matched with the right parts

Above: The Boschert Gizelis servo electric ElectroBend press brake promises higher productivity, accuracy and reliability as well as an energy savings of 50 percent.

March, 2024- The quarterback is considered the team’s most important player, making split-second decisions in the midst of fast-paced chaos that affects the game’s outcome. The team’s number two is the designated pass rusher 1, who is tasked to disrupt the opposition’s timing and passing game.

The press brake is a pivotal player for fabricators and manufacturers who have their own playbooks on how to outmaneuver the competition. Demand for sheet and plate bending machines is expected to rise rapidly through 2028. The uptick is due in part to increasing need for fabrication, automation and sustainable production.

“Interest in eco-friendly press brake technologies such as servo electric and hybrid models has created a niche for development of environmentally responsible solutions,” says Jeff Snyder, a press brake and shear specialist for Boschert USA. Boschert is the exclusive North American representative for fabricating equipment lines from Boschert GmbH, Boschert Gizelis, Stierli-Bieger, PBT and AMB Picot.

Use of high-performance materials like high-strength steel dictate a press brake that can meet stringent material quality requirements. Boschert’s line provides customers with a wide range of versatile options.

“Our standard hydraulic press brakes offer the widest range of sizes from 40 tons to 1,500 tons,” says Snyder. “Some of the applications that make a hydraulic press the correct choice are parts with high tonnage requirements, thicker materials or longer parts from 12 ft . to 20 ft . long.”

Boschert has fi ve diff erent hydraulic press brake lines engineered to support heavy-duty capacities, ultra-fast processing, speed and versatility and the capability to bend longer sheet lengths. In addition to supporting automated processes, the hydraulic press brake offers precise, fast parts forming.

Boschert helps customers choose the right press brake model—standard, hybrid or servo electric —based on part type.

Boschert’s hybrid hydraulic-electric press brake gives manufacturers the best of both worlds for bending a diverse group of parts.

GENERATING FORCE

“It’s important to consider the types of parts you need to make because there are some drawbacks with these machines,” Snyder notes. “Hydraulic press brakes use fluid to generate force. They have a large tank and long lines, which raises the potential for leaks and additional maintenance. But with certain types of forming, hydraulic press brakes are still the most cost-effective method.”

Bending parts that require 150 tons or less lend themselves to Boshert’s hybrid hydraulic- electric press brake which, according to Snyder, can “give a manufacturer the best of both worlds.” The configuration marries smaller-sized hydraulic cylinder technology with a servo-drive motor. The hybrid model can handle a diverse part grouping from roof flange components, ventilation system parts and electrical enclosures to brackets. The hybrid uses less oil, has smaller motors and only runs when the operator needs to generate tonnage.

Boschert introduced its Boschert Gizelis servo electric ElectroBend press brake to the U.S. market in 2020. It promises higher productivity, accuracy and reliability. The machinery builder claims that operational and maintenance costs are low. Increased ram speeds and reduced cycle times are complemented by an energy consumption savings of 50 percent. The servo electric press brake is available in 60, 80 and 100 tons.

BG Soft, Boschert’s proprietary bending and cutting software maximizes production resources. 

ElectroBend generates pressing force with two synchronized servo motors which transfer power with assistance from a special belt and pulleys. A rigid O-frame provides minimal deformation at full load. Since tools do not move laterally to the bend line, there is no horizontal deformation in the frame. Ram position is controlled by two linear encoders with an accuracy of +/-0.001 mm. In addition to providing faster bending cycle times, the ElectroBend consumes 50 percent less energy compared to hydraulic models.

“The servo electric press brake provides a much quieter work environment,” Snyder says.

AUTOMATION

Boschert is also helping job shops and manufactures find automation solutions that can ease the challenges of ongoing labor shortages.

“We look at robotics in a slightly different way,” Snyder says. “Our Athens, Greece, factory is partnering with U.S.-based integrators to provide service and support. We’ve built a network that has become a cooperative partnership.”

Boschert USA is working with a couple of customers who have multiple press brakes and wanted to add robotic forming. “We want to start by bringing RoboBend to the U.S. market,” Snyder continues. “The optional system can be produced and implemented quickly and we have U.S.- based service providers in place to provide aftermarket support.”

RoboBend allows any Boschert Gizelis press brake to function as an automatic robotic cell or as a manual machine run by an operator. “We can outfit any existing Boschert press brake with a robotic arm but we advise customers to start from the ground up. There are a lot of variables to consider, such as which press brake model and robotic arm are best suited to bend the parts in question, layout of the surrounding area and the type of material handling.”

Boschert has streamlined its evaluation process and plans to soon provide three different levels of robotic forming to U.S. manufacturers.

Boschert USA, 262/783-7816, boschertusa.com