A 204

CNC Punching
and
Shearing System
for
Angles

TECHNICAL DESCRIPTION

Size of the material to be processed

Angle capacity based upon
A-36 material minimum 1-5/8” x 1-5/8” x 3/16”
maximum 8” x 8” x 1”
Grade 50 material minimum 1-5/8” x 1-5/8” x 3/16”
maximum 8” x 8” x 1”
Flats (with optional device) minimum 2” x 1/4”
maximum 8” x 1”
Diameters available for each leg of the angle 2
Maximum diameter with standard tooling 1-1/4”
Diameter through thickness in A-36 material 1-1/4” x 1”
Grade 50 material 1-1/4” x 1”
Maximum speed of the angle 131 FPM
Maximum gauge line positioning speed 23 FPM
Length of bar to be processed (as standard) minimum 59”
CNC axes 5
Minimum programmable increment X axis ± 0,01 mm [1/25”]
Y axis ± 0,01 mm [1/25”]
Z axis ± 0,01 mm [1/25”]

2301 Industry Court ● Forest Hill Industrial Park ● Forest Hill, Maryland 21050
410-588-5800 ● Fax 410-588-5900
www.ficepcorp.com
 TECHNICAL DESCRIPTION (continued)

Positioning tolerance within (*)

Within holes or hole pattern positioned at

L distance (L measured in meters) ± 0,3 + (L x 0,14)

L in meters and accuracy in millimeters E

Accuracy between two holes at L distance = ± 0,3 + (L x 0,14) X
A
Considering a 49 ft. bar: 49 ft. = 14,9 meters — we will consider 15 meters
Accuracy = ± 0,3 + (15 x 0,14) = 2,4 mm = 0.0944" = ± 1/10" M
P
Considering a 61 ft. bar: 61 ft. = 18,59 meters — we will consider 19 meters
Accuracy = ± 0,3 + (19 x 0,14) = 2,96 mm = 0,12" = ± 1/8" L
E

(*) The above accuracies apply only to properly adjusted machines with sharp and
correctly fitted tools and do not consider possible distortions of the section
occurred during the working operations.

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 SYSTEM CONFIGURATION

WU WORKING UNITS

WU-1 Main Base for Working Units

This base can hold the two punching units, the
shearing unit and as an alternate, the marking unit
or versa press.

WU-2 Punching Units

Two hydraulic presses — one unit is
provided to punch one leg of the angle
and the second unit is to punch the
second leg of the angle. Each press is
equipped with two quick-change punch
holders to permit a punch and die change
in seconds.

The positioning of each quick-change punching tool is accomplished with

a ball screw and a servomotor to achieve an infinite number of gauge
lines by selection from the program. Each press is fixed mounted to the
table for maximum rigidity. Only the inner c-frame that contains the
punch and die is positioned to the programmed gauge line. Each press
is equipped with multiple hydraulic hold-downs and strippers to clamp
the angle securely during punching.

Main specifications of each punch station:

►Capacity 112 tons

►Throat depth 6-1/8”
►Stroke 1-3/4”
►Maximum diameter with standard tooling 1-1/4”
►Maximum thickness 1”
►Gauge line stroke with respect minimum 0.4”
to the inside of the angle leg maximum 6.69”

Each punching unit is provided with two punches and two dies for round
holes.

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WU-3 Shearing Unit
The shearing unit is made of one hydraulic single cut
shear complete with hydraulic hold-down. The shear is
furnished with one set of angle blades.

Shearing capacity
►Maximum available shearing capacity 505 tons

WU-4 Angle Positioning and Measuring System

The longitudinal angle positioning
system is CNC controlled and
composed of two devices (one at
the infeed side of the punch units;
one at the infeed side of the
shear). Each device adjusts
automatically to the material
according to its mill tolerance and
consists of rolls to support and
transfer the angle and vertical hold-downs to ensure the angle is
clamped securely and is always a true 90 degrees when measured to
ensure accuracy as angle material can vary significantly. The roller feed
drive and measuring systems float both vertically and horizontally to
accommodate rolling mill deviations that differs from one bundle of angle
to the next. A servomotor controls the movement of the positioning roll
with encoder feedback from the measuring rolls.

OC INFEED MATERIAL HANDLING

OOC- Idler Roller Infeed Conveyor for 40 ft. Angles

01/2
Idler roller infeed conveyor for the manual conveying
of angles having a maximum length of 40 ft.

OOC- Powered Device for Infeed Conveyor

04 Device to be positioned on the edge of the idler roller infeed conveyor,
suitable to transfer the angle from the conveyor to the first group of
rollers for the longitudinal positioning, placed on board of the machine.

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HY HYDRAULIC AND PNEUMATIC SYSTEM

HY-1 Hydraulic Power Pack

The system includes:
● Hydraulic power pack to generate the high and low pressure for the
press cylinders and for the auxiliary circuitries.

● Hoses and connections.

● Cooling system with air/oil heat exchanger.

● Hydraulic system complete with solenoid valves and required hoses.

►Working Pressure (high) 3915 PSI
►Working Pressure (low) 725 PSI

EL ELECTRIC SYSTEM

EL-1 Interconnecting Machine Wiring

EL-2 Electrical Cabinet

The electrical cabinet contains the power and control equipment for the
unit’s positioning axes and for the auxiliary services.

The standard equipment is manufactured according to established

standards. Specific requests requiring both special rules and regulations
will be considered upon the customer’s request.

The power supply is 460 V – 60 HZ – 3 Phases.

Note: Our equipment as quoted complies with the CE electrical code which is
required for European manufactured machine tools. In the event that
you require compliance with a special local electrical code, please
provide the specifications so we can respond accordingly.

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CN FICEP PEGASO CONTROL SYSTEM

The new generation control unit, with seven controlled axes, is based on
a fieldbus CAN (Computer Area Network) open technology.

The CNC is positioned on a pedestal in a mobile control panel so that

the operator can have a complete view of the machine.

All the input and output cards are connected to the bus and located on
the machine.

The CNC is equipped with:

● digital inputs (24V - optoisolated)
● digital outputs (24V – protected transistors)
● analog inputs, analog outputs

The control system is an industrial PC that hosts the CNC, the PLC and
the HMI. The power supply and the three CUPs (HMI, realtime and
CANbus) are all mounted on a single board. Mass storage relies on solid
state technology (flash memory) and the operating system image is write-
protected against voltage dips or power losses.

Specifications:

HMI section (Human Machine Interface)

● 1.6 Ghz CPU dual core
● 2 GB DDR3 RAM with 512 kB x 2 L2 cache
● 8 GB compact flash
● 6 USB ports
● Touch screen color video LCD TFT 15”
● 10/100/1000 Mbit/s RJ45 Ethernet port
● Serial port RS232
● WINDOWS 7 embedded operative system

Realtime section
● Processor 800 Mhz ARM RISC 32 bit
● 1 MB PC dual port memory
● 128 kB CANbus dual port memory
● 128 MB RAM DDR2 memory

CANbus section
● Fujitsu processor with 3 CANbus controllers
● 1 MB flash memory

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 Programming
● Simplified data input (with tables and workpiece on-screen graphics)
● Base line and hole to hole dimensioning
● Diameter input
● Simplified data input for symmetrical hole patterns

Processing
● Tool position tracking
● Automatic system offset
● Quantity tracking

Execution
● Automatic cycle stop for setup, modification and on-screen indication of
the tools to be changed

3D Graphics
● Display of the piece in 2D
● Display of the piece in 3D. With this modality, operations such as pan
and zoom are possible.

All the indications are clearly displayed on the screen, for example:
● Current program indication with a clear description of the program
running at the moment
● CNC inside and outside alarms
● Registration of the date and time of the last 100 alarm messages
● Diagnostic messages to the operator

Diagnostics
● The Pegaso control system incorporates extremely comprehensive
diagnostic software that is uniquely tailored to the FICEP product line
and their applications.

The user can utilize this capability directly or via internet connection to
FICEP Corporation’s technical support team located in Forest Hill,
Maryland. From this remote location, our support staff can perform all
the testing routines as if they were standing in front of the control such
as:

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 Review ladder logic
Analyze past alarm messages that were generated
Verify the part program
Check hardware functionality at the board and component level
Place remotely an oscilloscope on the respective servo drives to
analyze their performance
Remotely activate specific components such as valves to isolate and
identify a faulty component

This diagnostic capability of the Pegaso system translates into quick

resolution of problems to reduce your downtime and to eliminate the
time and cost after the warranty period to have a service technician
visit your facility to diagnose a problem. This service is without charge
for as long as you own the FICEP product.

PA STANDARD PAINTING
The system is painted in the following standard colors:
●Light Grey RAL 7035

●Black Grey RAL 7021

●Yellow RAL 1028

TD TECHNICAL DOCUMENTATION
The system is supplied with the following technical documentation:
●Programming, maintenance, operator and instruction manuals
●Electric schematics
●Pneumatic schematics

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SP SAFETY PROTECTIONS

SP-1 Protections on the Machine (Included)

SP-2 Outside Protections

Proper protection barriers, suitable to prevent the access of people to
the working and material handling areas must surround the system.
Such barriers need to be determined according to the system location
inside your plant. Once you have determined what perimeter guarding
would be desired, we are prepared to render an appropriate quotation.

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 INSTALLATION & TRAINING

CO INSTALLATION
(TRAVEL, MEALS AND LODGING EXPENSES ARE INCLUDED)
The supply includes services of our personnel to supervise the
installation, initial start-up and training at the customer’s site. This
includes the supervision of the electric, electronic, hydraulic and
pneumatic connections.

Excessive installation hours due to reasons beyond our control will

be paid for by the customer in accordance with standard FICEP
Corporation rates applicable at the time.

The following costs are not included:

● The customer must provide skilled personnel to assist our service
engineer during the installation and operation of the system as well
as the necessary rigging.

● All required foundation work is to be completed by the customer’s

personnel in accordance with the drawings supplied by FICEP
Corporation.

The supply of the following is excluded:

● Material and parts for the electric, hydraulic and air connections

● Air compressor for the air-operated equipment

● Oil and lubricants

● Customer specific materials for parts that are to be processed on

the line are not included in the quote price.

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 SUPPLIED WITH FOLLOWING OPTIONAL FEATURES

OWU-01 Marking Unit with 38 Positions Mod. MKT 38N

(One set of alphanumeric characters included)
The marking unit is suitable to mark (one character at a
time) on flange of angles, flats and the web of channels.

The marking unit is fitted with a 38 position turret whose

rotation is CNC controlled by means of a servomotor.
The marking cycle is automatically selected by the CNC
program and synchronized with the movement of the
angle through the line to accommodate the required part
marking.

►Marking stations 38
►Size of letter / number 5/8” x 3/8”
►Marking strength (on every character) 9 tons

OWU-011 Device for Processing Flats

Device to process flats having the following technical specifications:
►Width minimum 2”
maximum 8”
►Thickness minimum 1/4”
maximum 3/4”

Note: The effective measuring accuracy when processing

flat material becomes ± 1/8” in lengths up to 20 ft.

OOC-02/X Idler Outfeed Table for 10 ft. Long Angles

(one-side unloading)
Idler outfeed table for the manual
conveying of angles having a maximum
length of 10 ft. The table can be tilted to
one side to unload finished parts.
Note: The bin to be positioned near the outfeed
table to receive the unloaded pieces is
customer supplied.

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OCN-04 Air Conditioning for Electrical Equipment
This accessory is necessary to use the system in extremely hot and
humid climates.

OSW-01 Office Technology Central — 1st License

(Hardware excluded; commissioning and training included)
Office Technology Central (first licence) includes:
a)  2D & 3D visualization
• Multi-companies, multi-sites and multi-projects management
• Documents traceability management
• The software is storing all the data in a Microsoft SQL Server
database.

b)  Import of parts and bars from other modules

• Post-processor
• Parts 2D and 3D view
• Production feedback (automatic or manual) on the CNC
machines

c)  Nesting automatic assistant

• Management of commercial length, scrap and offcut
• 3D vision of bars
• Material and production optimization
• Section lot management
• Multi Projects nesting
• The software is storing all the data in a Microsoft SQL Server
database.

d)  Import of files under DSTV format into the database

• Managing of all the geometric and processing data of the
workpieces already drawn with a CAD system
Minimum configuration: Microsoft SQL Server express 2008 R2 or
2012 (the Microsoft SQL Server license has to be provided by the
customer).

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 Installation & Training
It consists of loading the software on the personal computers.
Please note that the Customer should install the computers and
connect them to a network in advance, according to the technical
specifications that will be supplied by Ficep. The training and
installation period will depend on the final software configuration
chosen by the customer.

PRICE of A 204 equipped as described above ---------------------------- $395,900

SOFTWARE MAINTENANCE

Steel Projects software includes updates and support for one year from the date
of installation. Additional support can be secured for an annual fee.

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 CONDITIONS OF SUPPLY

W WARRANTY Labor — 6 months

Parts — 12 months or 2000 hours
whichever comes first
Our warranty requires the exclusive use
of original FICEP spare parts.
Note: Our ability to provide tech support is greatly enhanced by having an internet
connection to the CNC control on your FICEP equipment. It is for this reason
that we can only extend our service warranty as stated if we have the ability to
make a remote connection to the CNC control on your FICEP equipment
through an internet connection.

Throughout the life of the system there maybe situations which extend beyond
the warranty period where it could be advantageous to enter your CNC control
as part of our remote “TeleService” diagnostic process. This tech support is
without cost to you even after the warranty period, thus we strongly
recommend that this link be established at the time of the installation of the
FICEP line to minimize any downtime that could occur during the useful life of
the CNC system.

D DELIVERY TIME Stock – subject to prior sale

DT DELIVERY TERMS CIF Forest Hill, Maryland

Ownership of the machine will be transferred to
customer at the date of the bill of lading.

PT PAYMENT TERMS 40% with order

55% prior to shipment
5% net 30 days

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Photos are for reference only and may not be provided or reflect what is furnished based upon final machine configuration.