BRE series – servo-driven rotary die inserts
The BRE series rotary die-cutting inserts can be directly integrated into a profiling machine. Unlike the BRS series, the profiling machine handles all material handling. The forming process begins immediately after die-cutting with the corresponding profiling passes. The rotary die-cutting insert has its own servo drive, which is synchronized with the profiling machine.
Line structure BRE
Baust manufactures the machine inserts with the corresponding interchangeable plates according to the requirements of the profiling machine manufacturer. This integration eliminates the space otherwise required in front of the profiling machine. The die-cutting inserts can be integrated into the line as needed or removed again, thus providing greater line flexibility. Safe handling, high processing speeds, and simple, space-saving integration are just some of the advantages of rotary die-cutting.
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Servo-driven rotary punching insert for profiling systems
Our servo-driven rotary punching inserts of the BRE series integrate seamlessly into your existing profiling line. The profiling line handles all material handling, while the punching insert is solely responsible for precise hole processing. Its own servo drive synchronizes electronically with your main line, ensuring exact positioning at any line speed.
We manufacture each servo-driven rotary die insert individually according to your requirements, with matching interchangeable plates for quick pattern changes. We reliably process material thicknesses from 0,5 to 3,0 mm with tensile strengths up to 600 N/mm². Since 1981, we have been developing die-cutting systems for the metalworking industry and have built up extensive expertise in the process.
Increased efficiency through space-saving stamping technology
By integrating our rotary die-cutting inserts directly between two profiling stands, you significantly reduce your space requirements. Production lines can be shortened by 15 to 25%, as separate pre-cutting and intermediate buffers are completely eliminated. The saved floor space can be used for other purposes or used to save on investment costs for new buildings.
Our servo-driven rotary die-cutting units operate with cycle times of less than 0,3 seconds per die-cutting operation and enable line speeds of up to 120 m/min. A measuring wheel in the profiling system detects the strip speed and transmits it to the servo drive in real time. We automatically compensate for accelerations and decelerations, ensuring that hole positions are maintained precisely even with variable profile lengths. This allows you to achieve throughput increases of up to 30% compared to systems with an upstream die-cutting station.
Servo-driven rotary die insert with synchronized drive
The electronic coupling between your profiling system and our punching insert is based on a master-slave control system. We use modern servo controllers with resolutions of 0,01 mm and achieve positional accuracies of ±0,1 mm across the entire profile width.
We monitor every punching operation using force sensors. Deviations caused by material thickness variations or tool wear are automatically detected by the servo-driven rotary die insert. Strip breaks or double layers of material are detected and stopped within 50 milliseconds. With proper maintenance, the service life of the die-cutting tools reaches 500.000 to 2.000.000 punching cycles. We offer service contracts with scheduled maintenance appointments to minimize your production downtime.
Easy handling thanks to modular design
We can integrate our modular, servo-driven rotary die insert into your existing profiling line without extensive modifications. Standardized connection dimensions ensure compatibility with common profiling stands from various manufacturers. Installation between two forming roll stands, including commissioning, can be completed in two days.
Tool changes are performed without tools using quick-release clamping systems. Your operators can exchange die-cutting patterns in under 15 minutes without having to dismantle the profiling system. Interchangeable inserts are aligned with millimeter precision using positioning pins and pneumatically secured. Repeatability after tool changes is 0,05 mm. For product changes that don't require a die-cutting tool, the insert can be removed from the line within 30 minutes.
Continuous material processing without intermediate buffers
Our servo-driven rotary die-cutting inserts completely eliminate intermediate buffers and material loops. The material runs continuously from the reel through the die-cutting unit directly into the profiling rollers. This continuous material flow reduces mechanical stress and lowers the risk of strip breakage or surface damage.
The absence of buffer systems significantly simplifies your plant control. Voltage monitoring and loop control are completely eliminated, reducing potential sources of interference and increasing plant availability to over 95%. Profiles with length deviations of less than 1 mm are standard. We have installed over 400 systems worldwide – from the automotive and electrical engineering industries to the building materials industry. This experience is continuously incorporated into our ongoing development.
