Assembly in Action: Brake Systems Increase Productivity and Accuracy

From its modern 62,500-square-foot facility in Romeoville, IL,CGI Automated Manufacturingprovides cutting-edge sheet metal manufacturing services. For example, CGI is among the first three companies in the United States to use the Mitsubishi River Navigation system—an eight-tower, fully automatic material handling and processing system with 92 shelves and two lasers.

By using the Toyokoki HYB-250 machine, CGI Automated Manufacturing has increased its productivity of multiple bend brake parts by 20 percent to 30 percent. Photo courtesy CGI

Automated Manufacturing

Founded in 1976, CGI has received ISO 9001:2008 certification for its automated sheet metal manufacturing processes and quality control. Its primary services include shearing, sawing, laser cutting, CNC punching, forming, rolling, robotic welding, MIG and TIG welding of sheet metal including carbon steel, stainless steel and aluminum. The company also provides assembly, spot welding, fastener insertion, powder coating, plating and kitting services.

Recently, CGI installed two Mitsubishi Toyokoki press brake systems to increase production and improve product accuracy. The electric APB-5620W provides 56-ton capacity with ram position accuracy to 1 micron. The HYB-250 is a 250-ton hybrid electric machine with 3 meter capacity and ram repeatability to the 1 micron level.

“Both machines provide accurate and repeatable performance, which translates into better cost control,” says CGI co-owner Gary Gurzynski.

The APB-5620W has a bending length capacity of 78.74 inches, stroke length of 3.94 inches and back-gauge stroke of 19.69 inches. It features dual ballscrews that enable CGI to perform left-right, independent bending and angle correction without any shimming.

Automatic thickness sensing is standard on the APB-5620W, which automatically adjusts for varying thicknesses of metal stock to ensure consistent, accurate operation. Because the machine has six axes of control, CGI can perform multiple tool setups on the same machine for quick and efficient stage bending.

The HYB-250 combines the advantages of hydraulic and AC servo operations. It produces highly accurate, multiple-bend parts at a 20 percent to 30 percent faster rate than other machines CGI has used, with accuracy and repeatability to 0.001 inch, says Gurzynski.

For more information on press brake systems, call 630-860-4210 or visit www.mcmachinery.com.

The ASSEMBLY Show South

ASSEMBLY is thrilled to return to the Music City Center in Nashville, TN for The ASSEMBLY Show SOUTH on May 1-2, 2024. This is a booming time for manufacturing and the U.S. South is right in the heart of the action. According to ASSEMBLY’s most recent annual capital spending survey, the South is projected to account for 31 percent of total spending this year, marking the fifth straight year this region has accounted for at least 30 percent of capital spending in the U.S.

In this session, manufacturers will learn how Quality function deployment (QFD) can transform consumers’ qualitative demands into quantitative parameters that will shape the design of their product and, ultimately, their manufacturing process.

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