Written by: Andrea Comparin - Senior Technical Specialist & Head of Sales for Americas
Introduction:
The metal forming industry is on the cusp of a revolutionary breakthrough with the introduction of FACCIN Group’s PGS-Absolute™, a CNC solution that synthesizes 40 years of CNC experience from FACCIN and 40 years from Roundo. This system unites the best features of both brands’ previous CNC technologies into a single, perfect solution for plate and profile bending. Designed to enhance productivity, precision, and ease of operation, the PGS-Absolute™ is set to redefine bending operations for metal fabricators worldwide. As companies strive to automate processes and improve output, the PGS-Absolute™ offers unparalleled performance and flexibility.
User-Friendly Hardware for Control Console
This year, FACCIN is introducing another breakthrough in the plate roll world. At Fabtech 2024, FACCIN presented the PGS-Absolute™ software along with an innovative control console designed to maximize operator convenience. The new control console features a rotating 19-inch Siemens color screen, and includes a wireless remote as a standard feature, empowering operators to handle the rolling process effortlessly and efficiently from anywhere—without moving the main console, enhancing flexibility.
No more dealing with the hassle of moving a bulky console on wheels—the new portable control enables users to move freely around the workspace. This compact unit can work in sync with the CNC system for automated tasks or be used manually for complex, one-off jobs. Operators can now measure, operate cranes, and perform other tasks with complete freedom, significantly reducing wasted time and improving overall workflow efficiency.
One Control for Angle Rolls and Plate Rolls
Many metal fabricators work with both plates and profiles, often using the same operators for both angle rolls and plate rolls. To simplify operations, FACCIN has developed a universal CNC system for both applications. Drawing on decades of multi-brand experience from FACCIN and ROUNDO, the company has created a system where the logic, calculations, and interface are identical for both types of machines. This unified control system reduces the learning curve for operators, enabling them to switch between different machine types with ease, thus boosting overall workshop productivity and effectiveness.
Unmatched Hardware and Software Integration for Maximum Efficiency
At the heart of the PGS-Absolute™ is its seamless integration of powerful hardware and software. The system maximizes performance while providing flexibility for a wide range of metal bending tasks. It utilizes Siemens™ industrial displays and PLC controls, ensuring reliable performance and easy sourcing of components, which minimizes downtime.
FACCIN’s Advantage Package gives operators precise control over all machine movements, allowing for micro-positioning, variable speed control, and simultaneous movement of rolls. This level of control is crucial for achieving complex shapes with accuracy and consistency, even for large-scale projects like wind towers or tanker trucks. The advanced hydraulic system within the PGS-Absolute™ ensures optimal energy efficiency, directing only the required amount of oil for roll movement and rotation. Combined with a state-of-the-art cooling system that maintains optimal oil temperatures, the machine achieves maximum repeatability and high precision in any production setting.
User-Friendly Interface with Easy Programming Options
One of the most significant innovations of the PGS-Absolute™ is its intuitive interface, designed to accommodate operators with varying levels of experience. The system offers three versatile operating modes: Manual, Auto-Teaching, and Self-Programming—allowing operators to choose the mode that best suits their needs.
The self-programming process has been simplified into just two easy steps. First, users select a material from an extensive library that includes a wide range of preloaded materials or customized entries based on vendor specifications or previous tests. This library supports both plate and profile bending, making the PGS-Absolute™ adaptable to various industries. Second, operators create the desired shape by selecting from common options—such as circular, elliptical, multi-radius, or open shapes—or by importing a DXF file for custom designs.
With just a click, the PGS-Absolute™ can automatically calculate the bending program for all machine movements, including roll movement, rotation, supports, and handling equipment. Features like the program bending simulator and program self-correction simplify fine-tuning adjustments, significantly reducing the learning curve and empowering operators to produce complex shapes with minimal effort.
Dynamic Program Modification for Material Variability
One challenge faced by metal fabricators is the inconsistency in material properties between different batches or suppliers. The PGS-Absolute™ addresses this issue through its Dynamic Program Modification feature, allowing operators to adjust programs in real-time to accommodate material variations. Whether working with thinner plates or denser profiles, the system maintains the highest level of precision.
For tasks like pre-bending and rolling, FACCIN has integrated correction factors based on decades of data, ensuring accurate bending and rolling even in challenging conditions. The system also offers automated correction based on real-time feedback, further streamlining the process and improving product quality.
Precision and Performance Through Advanced Measurement Technology
FACCIN’s PGS-Absolute™ goes beyond basic CNC capabilities, offering advanced measurement technology to ensure accuracy at every stage. The system includes Eye-Bend™ technology, a laser-based system that measures the developing plate radius during the rolling process. This contactless measuring system enhances operator safety, as it allows the operator to take measurements without having to approach the ferrule, reducing the risk of accidents. This real-time feedback enables the CNC to make automatic adjustments, ensuring that the finished product meets exact specifications without manual intervention.
This precision technology is particularly beneficial for complex one-off productions, where errors can be costly. By providing hands-free precision, operators can confidently produce custom parts with first-part-good-part results.
Automation and Industry 4.0 Integration
Automation is at the forefront of modern manufacturing, and the PGS-Absolute™ is fully equipped to integrate into an Industry 4.0 environment. Additionally, the system integrates with ERP systems, allowing manufacturers to manage and analyze production runs more efficiently. By offering real-time access to data, the PGS-Absolute™ helps businesses optimize processes, reduce downtime, and increase overall productivity.
Remote Service and Cloud-Based Monitoring for Reduced Downtime
In an era where machine uptime is critical to production, FACCIN has integrated advanced remote service management tools into the PGS-Absolute™. This cloud-based Remote Service Management (RSM) system allows for real-time diagnostics, troubleshooting, and maintenance scheduling from anywhere in the world. Whether via Wi-Fi, Ethernet, or SIM card, the system ensures that operators and maintenance teams can access critical machine data whenever needed.
Features such as remote tele-assistance, cloud backup, and online documentation make it easy for companies to keep their machines running at peak performance while minimizing downtime. Predictive maintenance tools notify operators when service is due, ensuring that problems are addressed before they lead to costly breakdowns.
Conclusion:
The PGS-Absolute™ from FACCIN Group is a revolutionary solution that blends cutting-edge CNC technology with decades of industry expertise. With its advanced hardware, user-friendly software, precision measurement systems, and full automation, the PGS-Absolute™ software is essential for any metal fabricator seeking to improve efficiency and accuracy. Whether producing complex custom parts or managing large production runs, this innovative system delivers exceptional results with minimal effort, ensuring a higher return on investment and a streamlined production process.
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