The 4.0 evolution of bending in sheet metal working

How to optimise workshop time and link the technical department with the production department using Libellula.’s bending solutions

At the very heart of any sheet metal fabrication business, bending is one of the most delicate and strategic stages. Production managers, designers and benders face complex challenges every day: calculating the exact flat pattern of the sheet metal based on the actual tooling, identifying the correct bending sequence to avoid collisions, managing complex 3D assemblies provided by customers and, last but not least, monitoring what is happening on the production floor in real time.

The solution to these operational challenges lies in an approach driven by automation and data integration, in line with Industry 4.0 principles. Thanks to Libellula’s software suite, the workflow is tracked using specific solutions and modules designed to eliminate errors and maximise productivity.

Libellula.JOBSHOP for bending: the integrated solution for comprehensive production management

For companies aiming for maximum efficiency and adhering to the principles of Industry 4.0, the flow of information must travel seamlessly from the sales department through to production, with constant feedback being provided to aid in performance analysis. This integrated process is known as Libellula.JOBSHOP BEND, a modular and flexible ecosystem for managing the entire folding production workflow, designed around the actual operational practices of production departments and structured in sequential and synergistic steps:

STEP 1 – Intelligent planning and management of orders

The process begins in the technical department, where, thanks to mod.ORDER It is possible to organise cutting and folding orders and jobs in a structured manner. Together with the orders module, the mod.ROUTING It defines the operational and sequential routes that parts must follow through the various company departments, ensuring that all subsequent work cycles are automatically synchronised.

STEP 2 – Flexibility in CAM programming (Optional)

At this level, the ecosystem adapts to the operational strategy chosen by the company. If the aim is to maximise the efficiency of offline programming, Libellula can natively integrate its environment with the Libellula.BEND bending CAM or interface with a CAM system already in use on the production floor. However, it is also possible to continue programming directly on the machine’s CNC, without integrating any CAM software, whilst retaining the benefits of Libellula JOBSHOP’s production flow traceability.

STEP 3 – Monitoring and execution on the machine

The on-board system Libellula.VISIO Installed directly on the press’s numerical control unit, it will enable the progress of work to be monitored and managed on the machine in real time. With Libellula.VISIO, it is possible to manage the queue of jobs on press brakes, eliminating misunderstandings and data routing errors.

STEP 4 – Connectivity and data feedback 4.0

As part of Connectivity 4.0, Libellula.VISIO will work in synergy with the mod.LiveSync, the advanced connection protocol capable of retrieving information in real time directly from the numerical control unit of the cutting or bending machine.

The real added value of Libellula.JOBSHOP BEND lies precisely in this two-way communication: the operator views their production queue on Libellula.VISIO, whilst the press brake provides constant feedback to the technical department. If a part is flagged as faulty or rejected during the bending process, the system records the outcome and ensures that the relevant information is immediately fed back to enable production to resume. In this way, the company obtains a realistic estimate of costs and an accurate record of actual processing times.

Bridging the gap between the engineering department and production is a daily necessity that transforms workshops into environments digital intelligent.

Libellula.BEND: native programming for press brakes

CAM software Libellula.BEND It enables the configuration and programming of press brake machines entirely offline, ensuring a drastic reduction in machine downtime.

Thanks to an extremely intuitive interface, designed for quick and easy programming, the software allows 3D models to be imported directly in STEP and IGES formats, as well as most of the native 3D CAD formats available on the market, in addition to 2D DXF and DWG models. Through an integrated simulated 3D environment and advanced algorithms, Libellula.BEND ensures:

 

• • Calculating the exact sheet metal development by generating a DXF file based on the customer’s actual press brake set-up and tools.

• • Comprehensive support for the operator during the set-up stages and in the automatic or manual calculation of the optimal bending sequence to avoid collisions.

• • Managing advanced operations such as adding counter-folds, step folding or handling passive folds.

• • The radical elimination of production errors, leading to a marked improvement in overall productivity.

• • The generation of detailed workshop reports in PDF format and programmes ready for machine start-up.

Furthermore, Libellula.BEND integrates natively with the icon library from Libellula.CUT enabling the smooth handling of parts as they are fed into the system

Libellula.BEND and Batch&Remote technology: Total automation for complex assemblies

When a metalworking shop has to handle large volumes of orders or assemblies comprising a multitude of components, processing them individually risks slowing down the workflow. The add-on module Batch&Remote Libellula.BEND meets this need exactly. The software is capable of importing large numbers of individual 3D parts or automatically assembling complex assemblies, and can perform the following tasks fully automatically:

 

• • An exploded view of the assembly, showing its individual components.

• • The flat pattern of the parts produced using the precise press tooling.

• • Automatic identification of the ideal folding sequence.

• • The mass creation of CNC-ready bending programmes and workshop PDF reports for each of the machined parts.

The future of bending is flexible and integrated

Integrating the Libellula modular ecosystem means choosing a workshop management system that is tailored to the company’s actual production needs, because the ultimate goal remains the same: to eliminate bottlenecks, drastically reduce machine downtime and achieve flawless cost reporting in line with Industry 4.0 principles.

Would you like to find out how to optimise your company’s folding processes?