Rules of the Game

Automated rule processing bends the traditional rules associated with diemaking.

By Chris Bauer

For Many facets of the printing industry, automation is the name of the game. And when it comes to rule processing equipment, automation seems to be par for the course for many suppliers' offerings. But with all the automation and bells and whistles available on today's rule processing units, it is the simple rules of diemaking that remain the most important.

"If nothing else, it should be accurate," contends Ellen Adams, co-owner of Adams Technologies. "The lengths are the most critical of all. If you have a piece of rule and it is the wrong length and the bends are in the wrong place, you've got a piece of junk. That is the bottom line." Whether a machine cuts, miters, or has other options are all just bonus features, she says. Currently there are two types of rule processing units marketed worldwide. According to Dale Kengott, president of Ken Technologies, most of Europe and small parts of the United States prefer to process the rule first in one machine, which performs the functions of cutting, notching, and mitering, and then send it and its cad file to another machine for angle or contour bending. These "bending machines" are not automatic, since double-handling is required to finish a section of knife.

On the other hand, he continues, the majority of the American market believes automatic means the machine must perform both processing and bending functions. "Because of these two differences, competitors producing these two types of machines have only marketed their products successfully in the region whose beliefs match their product," Kengott explains. "This has limited competitors in each region, and according to some schools of thought, it has slowed some of the potential research and development that could have propelled this technology further along than it currently is today."

New and improved

Suppliers report customers want more power and more features in rule bending equipment. This need is being driven by the many different types of cad files being sent to diemakers from their customers, suppliers say. The ability to correct and edit files on the bender instead of in the cad room is proving to be very important. Adams notes that fixing files on the bending machine has become a vital part of the customer demonstrations they provide.

Performance, accuracy, amount of waste generated, and price are major considerations for customers. The speed and ease to maneuver around in the software also concerns rule bending equipment users. Adams notes new Windows-based software is in the works, which is expected to extend current speed abilities. Adams Technologies machines now do the work of three to four people over the course of the work day, she says.

The cost of rule processing equipment has more or less leveled off, Kengott says. This has been a result of more suppliers in the market. "A couple of years ago, the price was higher for most equipment, but only because there were few competitors," he points out. "With more competition, the price has dropped from the level of two years ago, but has leveled off since then to a predictable range."

For the future, suppliers see even more competition entering the rule processing market. Customers can also look forward to the advent of different styles of machines, able to bend rule in many ways not now available. Speed and accuracy are expected to soar, and learning to operate systems will become even easier. "More functions will be included in the work process, and die designs of any type will no longer pose any problems to the machine operator," Kengott predicts.

What's out there?

The Adams Technologies EasyBender Turbo series of automated steel rule diemaking equipment offers the same speed and accuracy of the EasyBender but with enhanced features The EasyBender Turbo features a compact nozzle assembly which can be replaced in a fraction of the time of the previous model. Finger changes take little time. EasyBender Turbo configurations include: 1.5 point, 2 point, and 3 point steel rule on a single bender.

Designed for use wherever steel rule dies are made, the Bar-Plate Manufacturing Standard Rule Bender's interchangeable male and female dies are used in forming rule to a desired shape without disturbing previously made bends. The Standard Rule Bender is equipped with an adjustable stop, which may be instantly set, limiting the amount of die movement and enabling the user to readily make duplicate symmetrical bends. The Standard Rule Bender is also equipped with an adjustable gauge which can be used on either side of the machine to locate the position of the rule relative to the dies.

From Helmold, the Diemaster is a fully automated rule processing system. Once it is set up to produce a job, it does not need any other operator assistance. It can process rule strips or coils, and processes all standard rule including serrated. The Diemaster's one-piece bending tool helps prevent jamming. It features in-line automatic notching, bending, and mitering capabilities.

The Utility Bender series ram-style bender manufactured by the J.A. Richards Co., is made up of three different model machines: the MUB10 is a 10 ton unit, MUB15, a 15 ton unit, and the MUB25, a 25 ton unit. These machines can bend solid flats, round flats, squares, schedule 40 pipe, and crushbend rectangular steel tube. With a rotary attachment, thin wall tube and rebar can be bent. The rotary attachment is capable of bending 180 degrees. The Multiform Utility Bender is designed for job shops, and is suited for small production runs.

The MBS 900-B is the deluxe model most often ordered by Ken Technology customers to process a wide variety of rules. The stand-alone control unit enables this machine to accept up to five different miter stations mounted on the front, which provides the diemaker total flexibility in processing the many different requirements of today's die shops.