TD DOUBLE FOLDER

Thalmann Long Folding Machines
Integrated Automation

Integrated flipping device

Significant reduction of part handling by operators at the machine is achieved through an integrated flipping device that automatically turns parts. Parts are flipped automatically and subsequently placed accurately by the gripper units for the next bend.

The additional benefits are multiple: the operation is faster, it is safer for operators, it improves accuracy and it increases capacity at reduced costs.

In combination with the integrated sheet loading device CIDAN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

TD Long folder - integrated flipping device

Side loading device

The automated integrated side loading equipment mounted on a folder provides significant efficiency gains and operational cost reductions. The only operation required at a machine with automated side loading is to keep the feeder filled with sheet metal and turn or unload the folded sheet-metal parts. Reduction of labour time at the machine is significant. With the automated sideloading device multiple parts can be loaded and folded at the same time.

The loading table with a high load capacity is mobile, can be automatically adjusted in height and can be supplied in different lengths. Optionally, the sheets are automatically made available in single feed, from a stack or directly from an upstream de-coiler.

The additional benefits are multiple: the operation is faster, safer for operators and can be integrated on the operations with minimal need for extra floor space. The integrated sheet loading device improves accuracy and increase capacity at reduced costs.

In combination with the integrated flipping device CIDAN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

TD Thalmann Side loading device

SYNCHRONIZED TORSION SHAFTS

SYNCHRONIZED TORSION SHAFT TECHNOLOGY

The kinetic Torsion shaft technology provides maximal precision and reproducibility of folded parts. This technology is unmatched and unique to all THALMANN folders.

The synchronized distribution of force to the machine is at the heart of all THALMANN machines and can be compared to the synchronised mechanical control used in aircrafts. No other folder in the market is capable to deliver folded parts with an accuracy delivered through this technology.

ADVANTAGES OF THE TORSION SHAFT:

  • Extremely precise bending
  • Direct encoder measuring
  • Unrivaled angle and parallelism
  • Ensures equal wear of parts resulting in an even fold for the lifetime of the machine

Thalmann TZ Long Metal Folding Machine Torsion Shaft Lower Beam

SHEET SUPPORTS FOR AUTOMATIC LOADING

SHEET SUPPORTS FOR AUTOMATIC LOADING

The fully-automatic sheet loading and handling table helps operators load and unload the machine with sheet metal. This loading and unloading function can be programmed individually. In addition, the folding beam equipped with gliding units can also be used as a loading aid for easier material handling.

ADVANTAGES OF SHEET SUPPORTS

  • Simplified material handling
  • Increased output
  • Maximum efficiency
  • Allows one operator to form multiple parts at one time

Thalmann TD Long Metal Folding Machine Sheet Support Handling Table

Curved lower beam

A curved lower clamping beam allows more freedom and possibilities in the production of sheet metal profiles. The free space is extended through the folder cropped beam dimension. The additional space allows for bends with a 1:2 aspect ratio.

Architects, industrial designers and façade designers are continuously looking for new profile geometries. With the addition of a cropped bending beam on a THALMANN folder a wider range of dimensions of bended sheet metal parts can be produced. With this feature CIDAN customers are able to expand their product portfolio and business for folded sheet metal parts

Advantages of the curved lower beam:

  • Space around bent part is increased to a total of 275°
  • Significantly more flexibility during the folding process

Modular Tool Geometry

RECESSED LOWER BEAM

Additional free space and flexibility are provided by the newly designed clamping beams andoffset folding beam. With Thalmann’s modular tool geometry, the folding beam is offset, moved back to the folding line and set at a 15° angle. This increases the space around the bent part to a total of 275°, creating more flexibility during the folding process.

ADVANTAGES OF THE RECESSED LOWER BEAM:

  • Additional folding space
  • High-precision folding with folds as small as 15 mm x 15 mm

Thalmann Long Metal Folding Machine Folding Beam Thalmann Long Metal Folding Machine Recessed Lower Beam

Control system

A multi-functional touch screen controller that is ergonomically mounted on a swivel and can be tilted allowing for quick and easy data entry. The software application developed by Thalmann and customized for use in the sheet metal processing industry offers nearly everything you could wish for.

With the software installed on a remote PC or Tablet, parts can be designed and are being checked automatically if the dimensions are viable to be produced on the machine. If a viable part has been designed the optimal folding sequence is calculated and displayed. The parts that have been prepared in the software can be transferred to the controller on the machine via USB, Drive, LAN, or Wi-fi. Parts that have been designed or manufactured can be automatically stored in a data management system.

The controller has interfaces for nuIT software and the DFX data format. Controllers on machines with the M-Guard option can be connected to our service department for remote service and software updates.

Finger drawing
Automatic folding sequence
Manual folding sequence
Professional mode
Folding sequence simulation
3D simulation
Profile management
Open interfaces
Hemming and roll forming unit

The TD Double Folder utilizes 50 mm synchronized torsion drive shafts on the folding and upper beam movement. With a total of five torsion shafts and the double folder’s pension for ensuring parallelism, the TD Double Folder is one of the best machines in regard to forming radius parts and the overall longevity of the machine. The incredible accuracy of this double folder is derived from the rotary encoders application directly on the torsion shaft. The synchronized distribution of force to the machine completely eradicate the “twisting” that generally occurs over time. That means the TD metal double folder will produce an accuracy of +/- 0.5 mm from its first fold to its last.

  • Tool geometry with 275° free space
  • Offset folding beam geometry
  • Fully-automatic gripper system
  • Multi-section gripper function
  • Highly dynamic DFT drive
  • Kinetic control shaft technology
  • High-performance hydraulics with oil cooler
  • Remote maintenance using TeamViewer software
  • Low-friction CDF supporting table
  • Multi-zone folding beam crowning
  • Graphic CNC touch-screen controller

Benefits

  • Increased bending accuracy and additional free bending space
  • Reduction of processing costs and increased capacity utilisation
  • Higher throughputs and increased capacity
  • Faster bending speeds and more flexibility
  • Better part quality and reduction of costs per bended part
  • Lean manufacturing processes and increased safety
  • Access to new markets and competitive advantages
  • Minimal maintenance requirements and longevity of machines
  • Integrated automated solutions and open interfaces

Typical applications for long folders

Play Video Button
  • Thalmann TD - Unloader unit parking under part buffer

  • Thalmann TD - two parts in one_unloading by forklift

  • Thalmann TD folding four parts in one sequence

  • Double folder with automated loader

  • TD Double folder with Integrated Flipping device

  • TD Double folder producing a wall panel

  • TD Double folder with Integrated Flipping device

SPECIFICATIONS
TD125
Model TD125 4.2 TD125 6.4 TD125 8.2 TD125 10 TD125 12
Gauge Capacity 1.25 mm 1.25 mm 1.25 mm 1.25 mm 1.25 mm
Bending Length 4 m 6.4 m 8 m 10 m 12 m
Backgauge Depth 1250 mm 1250 mm 1250 mm 1250 mm 1250 mm
Folding Accuracy ± 0.5° ± 0.5° ± 0.5° ± 0.5° ± 0.5°
Folding Range 143° 143° 143° 143° 143°
Folding Beam Width 10 mm 10 mm 10 mm 12 mm 12 mm
Number of Grippers 2 4 4 4 6
SPECIFICATIONS
TD150
Model TD 150 6.4 TD 150 8.2 TD 150 10 TD 150 12
Gauge Capacity 1.5 mm 1.5 mm 1.5 mm 1.5 mm
Bending Length 6.4 m 8 m 10 m 12.2 m
Backgauge Depth 1250 mm 1250 mm 1250 mm 1250 mm
Folding Accuracy ± 0.5° ± 0.5° ± 0.5° ± 0.5°
Folding Range 143° 143° 143° 143°
Folding Beam Width 10 mm 10 mm 10 mm 10 mm
Number of Grippers 4 6 7 8
SPECIFICATIONS
TD200
Model TD200 4.2 TD200 6.4 TD200 8.2 TD200 10 TD200 12
Gauge Capacity 2.0 mm 2.0 mm 2.0 mm 2.0 mm 2.0 mm
Bending Length 4 m 6.4 m 8 m 10 m 12 m
Backgauge Depth 1250 mm 1250 mm 1250 mm 1250 mm 1250 mm
Folding Accuracy ± 0.5° ± 0.5° ± 0.5° ± 0.5° ± 0.5°
Folding Range 143° 143° 143° 143° 143°
Folding Beam Width 10 mm 10 mm 10 mm 10 mm 10 mm
Number of Grippers 4 5 7 9 11

As standard, a straight lower-beam tool with a very flat angle of inclination of just 35° is supplied. This allows the manufacturing of profiles with an aspect ratio of 3:4 (ratio of height to depth).  A curved lower-beam tool, resembling a goat’s foot, can be optionally supplied. This tool can be used to shape parts with an aspect ratio of 1:2 (e.g. 1.5 inches height and 3 inches of depth).  This results in significantly more space available and an increased clearance of totally 275°, providing key flexibility when folding.

Tooling Geometry 1 Tooling Geometry 2

Architects, industrial designers, and facade designers are continuously looking for new profile geometries. With the addition of a cropped bending beam on a THALMANN folder, a wider range of dimensions of bended sheet metal parts can be produced. With this feature, THALMANN customers are able to expand their product portfolio and business for folded sheet metal parts.

Tooling Geometry 2

To increase the scope of product dimensions that can be folded on a THALMANN machine, a wide range of gripper designs can be selected.  Spring-loaded fingers are automatically activated to position the sheet metal in the right place when the smallest possible gripper measurement is exceeded.

TD Gripper

Efficiencies, process flexibilities can be significantly enhanced by folding several sheets at the same time within one folding cycle.  The THALMANN machines can be custom equipped with fully automated multi section grippers that allows to handle and process several parts at the same time by one operator. For example 2 x 3 meter sheets can be folded simultaneously by one operator on a 6.4 meter Thalmann TD folder.

TD MultiGripper

Significant cost reductions and efficiencies can be obtained through high speed of folding cycles which is guaranteed by the simultaneous movement of several machine axes. This innovation has been designed to speed up cycles without any loss of folding dynamics and accuracy.  Dynamic Folding Technology (DFT) is the basis of increasing productivity and capacity utilization of the folding operation. The technology of simultaneous movements ensures a minimum of stop times in a bending cycle.

DTF

The kinetic Torsion shaft technology provides maximal precision and reproducibility of folded parts. This technology is unmatched and unique to all THALMANN folders.  The synchronized distribution of force to the machine is at the heart of all THALMANN machines and can be compared to the synchronized mechanical control used in aircraft. No other folder in the market is capable to deliver folded parts with accuracy delivered through this technology.

Torsion Shaft

High-performance hydraulics with oil cooler.  The unit with depressurized circulation principle guarantees low energy consumption and low noise level.

Hydraulic

For efficient remote service, THALMANN comes with the ability to access the control through TeamViewer.  Remote maintenance offers the possibility to quickly help with application and also troubleshoot.

Precisely formed profiles with even angles over the entire length is what you expect from a good folding machine.  The crowing system and dial indicators allow this operation to be adjusted quickly and accurately.  Thalmann’s are known for not having to adjust crowning for most profiles, but when in need this innovation compensates for angular deviations.

Crowning

High performance 10-axis PC from Beckhoff with 21,5” multi-touch 16:9 widescreen panel. The TD’s DS3000 software includes the ability for, Manual, semi-automatic and automatic operation, Sketch programming and profile auto sequencing, Bending simulation with collision display, Graphical visualization of profiles in 3D, Interface to DXF data format,as well as nuIT, Stand-alone software for PC and laptop programming.

Controller

Significant reduction of part handling by operators at the machine is achieved through an integrated flipping device that automatically turns parts. Parts are flipped automatically and subsequently placed accurately by the gripper units for the next bend. Click here to see the flipping device in action.

The additional benefits are multiple: the operation is faster, it is safer for operators, it improves accuracy and it increases capacity at reduced costs.

In combination with the integrated sheet loading device CIDAN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

The automated integrated side loading equipment mounted on a folder provides significant efficiency gains and operational cost reductions. The only operation required at a machine with automated side loading is to keep the feeder filled with sheet metal and turn or unload the folded sheet-metal parts. Reduction of labour time at the machine is significant. With the automated sideloading device multiple parts can be loaded and folded at the same time.

The loading table with a high load capacity is mobile, can be automatically adjusted in height and can be supplied in different lengths. Optionally, the sheets are automatically made available in single feed, from a stack or directly from an upstream de-coiler.

The additional benefits are multiple: the operation is faster, safer for operators and can be integrated on the operations with minimal need for extra floor space. The integrated sheet loading device improves accuracy and increase capacity at reduced costs.

In combination with the integrated flipping device CIDAN offers a fully automated solution for the folding operation. Operator activity is limited to loading a stack of sheets in a feeder and discharge bended parts from the machine.

A curved lower clamping beam allows more freedom and possibilities in the production of sheet metal profiles. The free space is extended through the folder cropped beam dimension. The additional space allows for bends with a 1:2 aspect ratio.

Architects, industrial designers and façade designers are continuously looking for new profile geometries. With the addition of a cropped bending beam on a THALMANN folder a wider range of dimensions of bended sheet metal parts can be produced. With this feature CIDAN customers are able to expand their product portfolio and business for folded sheet metal parts.

Folding several sheets at the same time, folding of very long parts can be done by one instead of two machine operators if the double folder is equipped with a variable extending automated loading and handling table.

The direct fixed cost reductions compared to traditional folders are often well over 50%, especially in combination with the integrated sheet loading and flipping device. In combination with stoppers and grippers the positioning of sheets is fully automated, this greatly enhances reproducibility and accuracy of folded parts sheet after sheet. In addition, the bending process becomes safer for the operator.

The ability to fold parts down to 200 mm can be achieved by selecting double gripper units on a THALMANN machine. Each existing single gripper can be made into a double gripper unit by “adding” an additional gripper.

A fully automatically activated spring loaded finger can be placed left or right or both sides of the double gripper unit.

The production of tapered parts is possible up to dimensional offset of +/- 250 mm. The positioning of the sheet metal is fully automated and multiple sheets can be manufactured in a tapered shape at the same time on one machine.

With the option of an automated tapered back-gauge, architects, roofers and engineers have the possibility to develop novel profile geometries and extend the scope of façade design.

Efficiencies, process flexibilities can be significantly enhanced by folding several sheets at the same time within one folding cycle.

The THALMANN machines can be custom equipped with fully automated multi section grippers that allows to handle and process several parts at the same time by one operator. For example 2 x 3 meter sheets can be folded simultaneously by one operator on a 6.4 meter TD folder.

Laser guides around the machine guarantee a safe environment for operators to work in. The safety zone is placed as such that efficiencies and sufficient workspace during operation of the machine are maintained.

THALMANN’s safety concept is fully complient with the EU-guidelines for the main legislations governing the harmonisation of essential health and safety requirements for machinery at EU level.

Mounted on the bending beam, a selection of different interchangeable beam extensions can greatly extend the scope of bends produced on a THALMANN machine.

To improve durability and for heavy duty bending operations, HARDOX 400 steel bending beams will greatly enhance tool life as well as maintain accuracy of folded parts. The type of steel used to produce the beams is similar to the steel used for excavator shovels.

The extremely wear resistant Hardox beams will under normal operation last the lifetime of the machine and can be welded when damaged. Hardox beams on a THALMANN machine improves the stiffness and stability of the machine.

Companies that apply additional cutting of folded sheets can integrate this operation on the THALMANN machine by adding a fully automated slitter unit. Investment in additional dedicated cutting or de-coiler units can often be avoided selecting this machine option.

In addition to achieving operational efficiencies trough the integration of folding and slitting in one operation, the folded metal sheets are less prone to damaging due to the reduction of manual handling. Scratches or bumps will be avoided with an electrical slitter unit.

On one and the same guiding system slitters and hemming/roll former heads are interchangeable. Both reductions in costs and investments are clear benefits and can be retrofitted on an existing THALMANN machine.

Modular and interchangeable hemming and roll forming units extend possibilities of forming sheet metals on a THALMANN machine. The hemming and roll forming unit can be mounted directly on the THALMANN long folding machine. This unit is ideal for the production of calibrated highly accurate dimension panels and very tight hems.

In addition to achieving operational efficiencies trough the integration of folding and a hemming and roll former unit in one operation, the folded metal sheets are less prone to damaging due to the reduction of manual handling. Scratches or bumps will be avoided with an electrical slitter unit.

On one and the same guiding system slitters and hemming/roll former heads are interchangeable. Both reductions in costs and investments are clear benefits and can be retrofitted on an existing THALMANN machine.

Safety of machine operators is significantly improved through positioning of LED lights under the upper clamping beam.

Different colour settings can be selected to match the optimal light conditions.

For an efficient and extended scope of remote service, the optional M-Guard functionality is recommended. A secure and fast direct link between a THALMANN machine anywhere in the world and the service team in Switzerland is easily established with M-Guard.

M-Guard offers the possibility to perform software updates, software diagnostics and problem solving tasks. Up- to-date VPN technology ensures safe and fast data-transfer. Remote maintenance significantly reduces costs and time as no travel will be required to deliver this service.

Exceptionally high bending speeds and short bending cycles are achieved through a powerful hydraulic drive unit.

The unit with a depressurized circulation principle guarantees low energy consumption and low noise levels. A 250 Litre oil tank ensures ample capacity reserves for extended operational time.

Depending on the TD model or the requirement for additional cycle time reductions the machines can be equipped with “Super-High-Speed-hydraulic drive unit”.