Automatic punching machine S4 series

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Overview
Introducing the Salvagnini S4: a hybrid punching-shearing machine offering unmatched productivity, efficiency and flexibility. The S4 integrates punching, forming and part separation in one seamless operation, automating loading, punching, forming, separation and unloading to eliminate semi-finished parts and minimize manual intervention.

Performance and concept
The S4 is designed for companies seeking high productivity, flexibility and efficiency. It combines punching, forming and subtraction-based part separation (shear) in a single work center to reduce lead times, avoid regripping and provide consistent high-quality output for sectors such as HVAC, metal furniture and similar industries.

Adaptive system

• The advanced hybrid actuator solution progressively delivers energy, modulating consumption according to the machining operation, material and required force.
• Centering control system measures the incoming sheet and adapts the program to the actual measured dimensions if necessary.
• The manipulator adjusts its dynamics according to the size and weight of the sheet and controls programmable opening of the pincers based on the percentage of sheet already machined.
• An automatic system checks thermal expansion of manipulator axes and compensates any variations to guarantee extreme positioning precision.
• The shear automatically records clearance and modulates required force in-cycle depending on thickness and material.

Multi-press head / Tools
The multi-press head features a die structure housing up to 117 thick turret tools in stations B, C and D, with station D providing a maximum force of 30 tons. Tools maintain a 9 mm sharpening margin and are available over the largest sheet area. The head can mount lower cylinders and, on station D, Multitool forming tools. Each tool is individually actuated and always available (no re-tooling in cycle).

High-performance tooling
Recommended thick turret tools are supplied by Matrix Tools (standard, parametric and tailored solutions) to meet high quality and reliability standards. Salvagnini also provides the TOOLS software module for graphic management of the punching tool database: it defines tools interactively, simplifies insertion of punches of various shapes, creates set-ups for punching heads and manages punch/die behaviour across materials and thicknesses.

Tapping option
An optional electrical tapping unit can be installed to the side of the operating head housing up to 6 different tools; it is positioned outside the head so it does not occupy the head tool area.

Manipulator
The manipulator centers the sheet at start, with a maximum stroke of 3030 mm (allowing sheets up to 3048 mm without regripping). It has 9 pneumatic pincers with independent opening/closing to enable scrap-free nests and reduced scrap. A patented hand-over system modulates dynamics according to sheet weight.

Integrated shear
The integrated shear uses two 500 mm blades, independent and orthogonal, equipped with blankholders for cutting any length. Installed next to the multi-press head, it ensures optimal alignment and superior machining quality and supports simultaneous or independent X/Y cutting sequences.

Modular automation
Storage and automatic loading/unloading devices increase system autonomy and efficiency. Automation options cover stand-alone operation, integration into flexible cells or lights-out factories. Typical automation modules referenced include automatic pack destacker (PD), single sheet handling store (MD), pack handling store (MV), automatic table stacker (IA) and Cartesian manipulator for sorting/loading (MCU).

Software and connectivity

• TOOLS: graphic management of the punching tool database and interactive tool definition and setup.
• STREAM: programming suite to improve reactivity and reduce costs and process inefficiencies.
• OPS: modular production management software to optimize the entire production process and exchange real-time data with factory ERP/MRP.
• LINKS: IoT solution for real-time monitoring and performance analysis to increase machine global efficiency.

Process benefits

• Single work center producing finished parts without re-machining or retooling.
• Elimination of regripping and progressive part flow downstream to feed subsequent operations (e.g. panel benders).
• High repeatability, reduced scrap and resource optimization through adaptive closed-loop controls and sensors.

Technical data (table)
Model: S4-30 | S4-40
Maximum sheet dimensions (mm): 3048 x 1650 | 4064 x 1650
Maximum sheet diagonal (mm): 3650 | 4655
Minimum sheet dimensions (mm): 600 x 400 | 600 x 400
Maximum speed (m/min) - X axis: 132 | 132
Maximum speed (m/min) - Y axis: 117 | 117
Speed with both axes moving simultaneously (m/min): 176 | 176
Maximum acceleration (m/s²) - X axis: 30 | 30
Maximum acceleration (m/s²) - Y axis: 17 | 17

Punching/shearing material limits (summary)
Aluminum (UTS 265 N/mm²) max thickness: Punching 5.0 mm¹ | Shearing 5.0 mm
Steel (UTS 410 N/mm²) max thickness: Punching 4.0 mm¹ | Shearing 3.5 mm
Stainless steel (UTS 610 N/mm²) max thickness: Punching 4.0 mm¹ | Shearing 2.0 mm
Minimum material thickness (mm): 0.5 (punching and shearing)

Caractéristiques / spécifications techniques

• Model: S4 (series)
• Maximum sheet size options: up to 4064 x 1650 mm (depending on model)
• Manipulator stroke: up to 3030 mm (machines support sheets up to 3048 mm without regripping)
• Multi-press head: up to 117 turret tools across stations B/C/D; station D up to 30 tons force; 9 mm sharpening margin
• Integrated shear: two 500 mm orthogonal blades with blankholders; supports Punch&Cut sequencing
• Axes max speed: X 132 m/min, Y 117 m/min; simultaneous axes speed 176 m/min
• Axes max acceleration: X 30 m/s², Y 17 m/s²
• Material thickness capabilities (examples): aluminum up to 5.0 mm, steel up to ~4.0 mm (punching), stainless up to ~4.0 mm (punching) — shear limits differ per material
• Minimum material thickness: 0.5 mm
• Automation modules available: PD (pack destacker), MD (single sheet store), MV (pack handling store), IA (table stacker), MCU (Cartesian manipulator)
• Software ecosystem: TOOLS, STREAM, OPS, LINKS for programming, production management and IoT monitoring
• Energy / efficiency: advanced hybrid actuators reduce average consumption compared with equivalent electrical solutions and minimize maintenance needs