Meticulous finishing of prototype automatic tool holder

The holy grail in folds today? Minimizing tool changeover times. Therein lies the key to greater productivity. With the patented Ziptool system, Bart Embrechts has found the answer to that challenge. This tool holder automatically puts the tool in the right place for each fold. Embrechts is currently working on creating a first full-size prototype. The Mazak Variaxis C600 provides an accurate translation of his idea into reality.

Every bending bench manufacturer today has an automatic tool changer in their lineup. "These have already greatly reduced the changeover times required to prepare the tool for a new piece. However, time is still lost. To prepare the pieces, but also the operator often has to move to another station during the bending of a piece. This can sometimes amount to half of the actual production time. Lost time, which we no longer have today," says Bart Embrechts, manager of Ziptool. With his own experience with and on bending benches in mind, he had a fit while driving. What if the tools came to the operator instead of the other way around? 

Five to ten times as fast

Necessary experiments later, the concept of Ziptool was on point. "Each tool in this tool holder is driven by a compact linear motor, individually controlled and positioned. For each fold, the right combination of tools is thus brought to the operator. No more set-ups required, therefore, for every product change: changeover times are a thing of the past. The only thing left to do is organize your production according to sheet thickness. But the time gain thickens by a factor of 5 to 10." 

Embrechts knew immediately that his concept would charm the sheet metal working industry. He has since patented his invention worldwide. "The advantages are not only in the time savings. By only needing one more station, the bending bench itself can also be built a lot more compact."

Building first prototype

To bring his idea to market now, Embrechts is building his first prototype himself. "Ultimately, a software interface between the tool holder and the bending bench will be needed to achieve seamless operation. That's why the idea is to find partners, either among tool manufacturers or sheet metal machine manufacturers. And the best way to warm them up is to build a working prototype yourself." 

Embrechts was able to convince his wife to convert part of the garage into a workshop. All that was now missing was the right machining machine to build the tool holders. "It had to be an A-brand anyway to achieve the high-end finish I envision," he said. Mazak and Dirk Vermeulen were the most convincing. I see Mazak as the most user-friendly machines on the machining market. The state-of-the-art technology, the brand new control that will be supported for years to come, the proximity to the European distribution center for spare parts..."

Five-axle vehicle with an eye on the future

Reasons enough for Embrechts to choose the Variaxis C600. To get started quickly, he chose one from stock: "An 18,000 rpm spindle with integrated cooling, 90 tools...: options that charmed me. A five-axle machine may seem ambitious for a starter, but it makes it so much easier to handle the complexity of the pieces needed. Instead of clamping everything six times, I can now finish each piece in two fixtures, which gives me much better accuracy," Embrechts explains. 

Therefore, another Renishaw probe was integrated into the five-axle unit. "That way you already know that your program is right before it's too late," Embrechts adds. He also already dared to look further ahead. The machine was fully prepared to later fit a robot to it. 

Excellent support

By the end of the summer, the first full-scale prototype should be completely finished. Embrechts is even skipping the annual family vacation for it. "For me, the Variaxis is also a bit like a toy. It's incredible how many possibilities it offers for making pieces. I am now experimenting with the machine to get the hang of it. If I do run into a problem, I can always count on Mazak's excellent support. I always have an answer to my question within an hour. You notice that there is a lot of experience behind the help desk."