A tandem press brake is a sophisticated sheet metal bending system that combines two or more press brake machines operating in synchronisation. These systems are specifically designed to handle exceptionally long workpieces that exceed the capacity of a standard press brake. In tandem configurations, multiple hydraulic press brakes work together as a single unit, sharing control systems to ensure uniform bending across the entire length of large metal sheets. This technology enables manufacturers to produce longer, more consistent bends while maintaining precision throughout the workpiece—making tandem press brakes essential for industries requiring large-scale metal forming operations.
Understanding tandem press brakes
Tandem press brakes are specialised metal forming machines designed to bend extra-long metal sheets with consistent precision. Unlike standard press brake machines that operate as standalone units, tandem systems link multiple press brakes together to function as a cohesive unit.
At their core, tandem press brakes solve a fundamental challenge in the metal fabrication industry: how to bend exceptionally long workpieces without sacrificing accuracy. When metal sheets exceed the capacity of a single machine, tandem configurations distribute the bending force evenly across multiple synchronized units.
These systems are particularly valuable in industries producing large-scale components such as construction panels, agricultural equipment, architectural elements, and industrial enclosures. The ability to handle workpieces that can stretch several metres in length makes tandem press brakes indispensable for manufacturers working with oversized metal components.
How does a tandem press brake system work?
Tandem press brake systems work by synchronising two or more individual press brakes to function as a single, unified machine. The hydraulic press brakes in the configuration are aligned precisely and electronically connected to ensure perfectly coordinated movement during the bending process.
When a bending operation begins, the control system sends identical commands to each press brake simultaneously. This synchronisation ensures that the ram (the moving part that applies pressure) on each machine moves at exactly the same speed and to precisely the same position. The result is a perfectly uniform bend across the entire length of the workpiece, even when that length spans multiple machines.
The control system constantly monitors the position and pressure of each machine, making micro-adjustments as needed to maintain perfect alignment. This real-time coordination is what allows tandem systems to produce consistent, high-quality bends on exceptionally long workpieces without deflection or variation.
Modern tandem systems feature advanced CNC controls that manage this complex synchronisation automatically, allowing operators to program bends as if working with a single, larger machine rather than multiple coordinated units.
What are the main components of a tandem press brake?
A tandem press brake system consists of several critical components that work together to ensure precise, synchronised operation across multiple machines. The primary components include:
- Synchronised control system: The central “brain” that coordinates all machines in the tandem setup, ensuring they operate as a single unit with matching speeds, positions, and pressures
- Multiple press brake units: Two or more individual press brakes positioned side by side, each with its own frame, ram, and bed
- Hydraulic systems: Powerful hydraulic cylinders and pumps that generate the necessary force for bending operations, carefully calibrated across all machines
- Alignment mechanisms: Precision systems that ensure all machines maintain perfect alignment during operation
- CNC controllers: Advanced computer controls that manage the programming and execution of complex bending sequences
- Tooling: Specialised upper and lower dies designed for tandem operation, often featuring segmented construction for flexibility
- Backgauges: Positioning systems that ensure accurate placement of the workpiece before bending
These components must work in perfect harmony to maintain bending consistency across the entire length of the workpiece, regardless of its size or the complexity of the bend.
What are the advantages of using tandem press brakes?
Tandem press brake configurations offer significant advantages over standard press brakes when handling specific manufacturing challenges. The primary benefits include:
- Extended bending capacity: The ability to bend exceptionally long workpieces that would be impossible on a single machine
- Increased tonnage capability: Combined force from multiple machines allows for bending thicker materials
- Uniform bending quality: Synchronised operation ensures consistent bend angles across the entire length of large workpieces
- Reduced material handling: Processing long pieces in a single operation eliminates the need for multiple setups and joining operations
- Production flexibility: The ability to use the machines independently for smaller jobs or combined for larger workpieces
- Cost-effectiveness: Often more economical than investing in a single, custom-built extra-large press brake
- Reduced floor space requirements: Multiple standard machines often require less specialised floor space than a single extremely large machine
These advantages make tandem press brakes particularly valuable for manufacturers working with oversized components or those seeking maximum production flexibility.
How do you set up a tandem press brake operation?
Setting up a tandem press brake operation requires careful attention to detail to ensure perfect synchronisation between machines. Follow these key steps for proper setup:
- Align the machines: Position all press brakes in perfect alignment, ensuring they’re level and precisely spaced
- Connect control systems: Establish the master-slave relationship between machines through the control network
- Calibrate hydraulic systems: Balance the hydraulic pressure across all units to ensure uniform force application
- Install and align tooling: Mount compatible tooling across all machines, ensuring perfect alignment at the junction points
- Synchronise ram movement: Test and adjust the synchronisation to ensure all rams move at identical speeds and positions
- Program the CNC controller: Set up the bending program with appropriate parameters for the tandem operation
- Perform test bends: Execute test bends on sample material to verify alignment and synchronisation
- Make fine adjustments: Refine settings based on test results until perfect uniformity is achieved
The large press brake configuration requires more extensive setup than standard machines, but this investment in proper preparation ensures successful bending operations for oversized workpieces.
Key takeaways about tandem press brake technology
Tandem press brake technology represents an innovative solution to the challenges of bending exceptionally long or thick metal workpieces. By synchronising multiple press brake units to function as a single machine, manufacturers can achieve unprecedented bending capabilities without sacrificing precision or quality.
The key advantages of this technology—extended bending length, increased tonnage capacity, and production flexibility—make it an invaluable asset for metal fabricators working with oversized components. The sophisticated control systems that enable perfect synchronisation between machines represent the cutting edge of metal forming technology.
At Ursviken, we’ve refined tandem press brake technology through decades of engineering excellence. With over 135 years of industry experience, our approach to tandem press brake design focuses on precision, reliability, and seamless integration. Our tandem systems are custom-engineered to meet the exact requirements of each application, ensuring optimal performance for even the most demanding bending operations.
Want to learn more about our press brake solutions, including tandem configurations? Find out more about our Press Brake products and discover how they can enhance your metal forming capabilities.