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MANZONI MACHINERY
MANZONI MACHINERY Innovative Solutions for Cold Forming
The revolutionary machine that
has changed the world of
cold forming headers
Completely built in steel, thanks to the revolutionary sliding system
without bronze liners, Manzoni Absolute Zero Clearance , it is able to
manufacture at high speed, complex shape parts with great precision.
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MANZONI MACHINERY
INNOVATIVE SOLUTIONS FOR COLD FORMING
Manzoni Machinery machines are the result of a new study that has changed the headers construction
technique. Indeed, thanks to a great work of research, for the first
time on this kind of machines have been applied innovative
technologies that allowed the use of new and more resistant
materials. Furthermore the machine has been conceived with a
new timing diagram that along with a design caring about the
masses in movement, it permits to reach high speed of work,
smoothly, without loss of balance and in total absence of
vibrations. The result is a machine of innovative design, completely
built in steel, of small size, able to manufacture at high speed
complex shape parts with great precision, with exceptional
characteristics of stability and sturdiness.
Sliding movement without bronze liners Manzoni Absolute Zero Clearance
Differently from traditional headers, Manzoni Machinery machines do not use bronze liners. Indeed ram and
transfer are mounted on special bearings specifically developed for this application. This assure the total
absence of any play and, therefore, an high heading
precision even at high speed. Manzoni Absolute
Zero Clearance®
permits to produce with great
precision parts with very tight tolerances.
Furthermore, thanks to the absence of plays,
punches are always aligned and no adjustments
are needed, drastically reducing the time of
change over.
Manzoni M odular S teel Frame
Manzoni Machinery machines, differently from traditional headers, are built only with special steel using the
Manzoni Modular Steel Frame®
concept. The machine�s frame is made of steel with a special assembling
technique that assures sturdiness, rigidity and high resistance to overloads. Compared to machines with cast
iron frame, it�s possible to reach higher heading tonnage while containing
machine�s dimension. This allow a big space saving on the shop floor. Headers
built with the Manzoni Modular Steel Frame®
are 3 times more tough than
traditional machines.
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MANZONI MACHINERY
Easy and fast tool change thanks to the system Read, Set & Go®
In order to make the tool change easy for the operator and above all, to reduce downtime, Manzoni
Machinery machines are conceived with the comfortable system Read, Set & Go®
that allows any operator
on the shop floor, even without experience, to quickly and easily set up the header. Indeed
the position of all machine�s mechanical devices is clearly indicated by indicators,
readers and displays that allow the operator to set up the machine as it was last
time the same reference has been produced. This assures a drastic reduction of
change over time. Furthermore the ergonomic design, the lower frame and
the great accessibility of all adjustments make the operator�s job easy and
comfortable.
Innovative Timing Diagram
The machine is based on an innovative timing diagram that, analyzing time and masses in movement, it
permits to reach high speed of work, smoothly, without loss of balance and in total absence of
vibrations. This great steadiness is the key factor
that allows Manzoni Machinery machines
to reach high speed without
mechanical stress and with very
low noise emissions.
Easy Move Control Panel®
with user friendly Touch Screen
A comfortable touch screen colours control panel, easily moveable where needed, allows
the operator to control all functions of the machine, without the need to move around.
Based on a advanced technology computer, it is user friendly and simple
to understand. Thanks to its big memory it can save the
complete set up of the machine under an article number so
that next time the same part will be produced, the machine
adjustment will be a lot more quick and easy.
MANZONI MACHINERY
High speed bushing cut off
A special system of cams and levers produces a very high cutting speed and
gives to cut off precision and accuracy. The knife is guided trough all its
length to avoid even minor flections that may reduce blank�s precision and it
does not require any adjustment during job change. For this reason Manzoni
Machinery machines are particularly suitable for the manufacturing of high precision parts
where accuracy of cut off it�s necessary.
Soft Kick Out Cam®
on die side
Kick out on die side is realized through cams with the special
profile Soft Kick Out Cam®
with a smooth and progressive
action that makes possible to easily produce very short parts
without the need of special tooling or too complicated and
expensive mechanical devices.
Kick out on punch side
K.O. stroke and K.O. position can be individually adjusted simply setting
P.K.O. cam. The long K.O. stroke permits the production of special parts
and in case of very short length the K.O. pins may be used to sustain the
parts while is ejected from the dies, giving more
time to fingers to grab them.
MANZONI MACHINERY
Punches always aligned: quick and easy change over
Thanks to the total absence of plays, punches are always aligned.
Avoiding the need of alignment at each tools change, change over time are drastically reduced.
Transfer fingers with M anzoni Extra Deep Forming ® system
Transfer fingers are designed with a special movement that allows the production of very special
parts. The Manzoni Extra Deep Forming®
system indeed, thanks to the quick and wide movement
of fingers, permits the production of parts with big heads and allows the
punches to penetrate into the dies to make extra deep holes. The
production of the same part on a standard header would require a
machine of bigger size, and therefore more expensive.
Manzoni Short Parts Holder®
In case of very short parts, the short blank can be steadily held between die and punch K.O. pins while is
ejected from the die, giving more time to fingers to grab it.
Extra transfer finger
All machines are equipped with an extra transfer finger to place the produced part as needed. The extra
finger is very useful for the production of rivets and rivet nuts because it make sure that parts are always
stripped out of the pin, avoiding in this way dangerous overloading to the machine.
Machine stop with transfer fingers open
To avoid tool damages, the machine always stops with transfer fingers open.
MANZONI MACHINERY
Wedged ram
Ram movement is realized through a new system that allows to discharge all heading forces on the wedge
instead of loading connecting rod and crank shaft. This eliminates all plays and wears
allowing a high and steady heading precision, even after several years of work.
Wire feeding: linear with grippers or standard with wire feed rolls
Customer can chose between a linear wire feed with grippers and a standard system with wire feed rolls.
The linear wire feed assures higher cut off precision, reduces wire change
time and can handle a wide range of wire diameters
without the need of any
change.
Tool set up made easy thanks to the innovative system Manzoni S low M otion Ram®
The advanced technology inverter along with the vector motor, allow the
operator to approach punch and dies
at extremely low speed, to check and
avoid any possible tool damage. A
simple touch of an icon on the
touch screen activates the
Manzoni Slow Motion Ram®
mode.
MANZONI MACHINERY
Controlling the power to save energy
The main motor of the machine is another innovation in this field. For the first time, indeed, has been
installed on a header a vector motor with double encoder and torque control.
Manufactured in Italy by a company leader in this field, the motor is controlled by an
advanced vector driver and it�s in constant dialog with 2 encoders installed
on the crank shaft and the motor. This powerful system guarantees a perfect
torque control allowing the header working always with high
performance, even at low speed. The new vector control
releases power to the motor
only when is needed, allowing
low consumption and
important energy saving, that
reach even 50% of traditional
machines.
Main electrical cabinet on board
Electrical cabinet is designed and manufactured in Italy using Telemecanique products and
fulfils all CE requirements. The use of advanced technology products has allowed to
increase the calculation power while containing dimensions of the cabinet.
Therefore the cabinet has been integrated into the machine, inside the sound
enclosure, eliminating those cumbersome cables always left on the floor and
allowing at the same time, big space saving and easy movement around the
machine. The electrical circuits are easily accessible by an external door directly
into the sound enclosure.
MANZONI MACHINERY
Manzoni Teleservice Assistance®
Beside a fast and timely on site technical service, MANZONI MACHINERY provide his customers with the comfortable and efficient
Manzoni Teleservice®
Assistance. In case of an anomaly, an engineer
located at the headquarter, thanks to a fast modem line, can
connect his computer with the machine in the plant and
detect any potential defect without the need of travelling
with the inevitably long waiting time for the customer. With
Manzoni Teleservice®
Assistance is possible to perform an
alarms diagnosis, check data log, verify functions state and, in case of a new
software release, upgrade the PLC.
Quick Change out of machine (options)
When frequent job changes are needed, the quick change out of machine allows important time saving as it
permits to the operator to prepare the next tooling on the bench, while the machine is producing. To change
job is therefore only needed to replace the various tools already set up and to run the machine without any
need of other adjustments. Downtime is drastically reduced.
Quick change kit consists of:
- punch block holder
- die block holder
- set up bench
- transfer jig
- electronic adjustment of cut off length
- electronic adjustment of kick out dies
- memory store of electronic adjustment under the article number
MANZONI MACHINERY
TECHNICAL SPECIFICATIONS
MA MB MC ME
Number of dies 5 5-6 6 6
Max wire diameter (600N/mm2) 8 mm 11 mm 20 mm 33mm
Cut off length 90 mm 100 mm 150 mm 220 mm
Max K.O. die side 90 mm 90 mm 140 mm 210 mm
Max K.O. punch side 22 mm 30 mm 42 mm 80 mm
Max head diameter 20 mm 24 mm 32 mm 50 mm
Heading tonnage 70 Ton 100 Ton 200 Ton 650 Ton
Max speed 370 pcs/min 280 pcs/min 180 pcs/min 110 pcs/min
Power 29 kW 38 kW 70 kW 150 kW
Weight 11 Ton 13 Ton 34- Ton 120Ton
Dimensions (included electrical
cabinet)
2.200 x 3.600
X 2.000h mm
2.200 x 3.600
X 2.000h mm
3.000 x 5.700
x 2.800h mm
4.200 x 8.000 x 3.500h mm
Max diameter Dies Ô50 x 165 mm Ô60 x 165 mm Ô94 x 238 mm Ô150 x 300 mm
Max diameter Punches Ô40 x 100 mm Ô45 x 105 mm Ô70 x 140 mm Ô120 x 220 mm
Knife Ô 26 mm Ô 32 mm Ô 56 mm Ô 92 mm
Bushing knife Ô 25 mm Ô 30 mm Ô 55 mm Ô 90 mm
MANZONI MACHINERY
EQUIMPMENT
STANDARD EQUIPMENT
Manzoni Absolute Zero Clearance®
Soft Kick Out Cam®
Manzoni Short Parts Stopper®
Manzoni Slow Motion Ram®
Manzoni Modular Steel Frame ®
Manzoni Extra Deep Forming®
Easy Move Control Panel ®
Read, Set & Go®
Manzoni Teleservice Assistance®
Double encoder vector motor with torque control
High speed bushing knife
Safety brake-clutch on flywheel
Positive K.O. on each station, independently adjustable
Display of position of K.O. pins inside dies
Pneumatic lock of backing screws
Extra transfer finger
Motorized lifting and lowering of transfer unit
Wire feed: choice between linear system with grippers or wire feed rolls
Double antibacklash system on wire feed rolls
Trimming station on last die, with cam always installed
2-hand jog system
Transfer unit set up jig
Double set of wire straightening rolls
Double lube system with filtration
Separate tanks for tool lube and machine lube
End of coil switch
Tool area lamp
Safety switches on all doors
Short feed detector with pneumatic release of first finger
Housing for load monitor sensors
Housing for induction coil heating system
Housing for air cleaner
Sound enclosure
Electrical cabinet and safeties made in compliance with CE standards
MANZONI MACHINERY
OPTIONS
Good parts conveyor
Scrap conveyor
Induction coil heating system
Quick Change Kit out of machine
MANZONI MACHI NERY: The only headers in the world guaranteed 3 years
Designed in Italy, built in China by Italian engineers.
ITALIAN QUALITY - CHINESE PRICE