What is a Hydraulic, Hybrid, and All-Electric Press Brake?

With the recent advances in technology as a whole, the past decade has also brought about significant improvements far as press brake machines are concerned. All the new upgrades made to the conventional press brake system have made many buyers curious about the available options in the market. Here is a simple explanation of the popular types of press brake machines that are hot right now to help you get a basic idea of all of them.

Importance of press brakes

A properly functioning press brake system is a crucial piece of equipment for any kind of industry involving sheet metals and associated processing. Hence, it is very important to take all necessary factors into consideration beforehand and analyze them properly before deciding upon your press brake machines.

Hydraulic press brakes

When compared to your primitive mechanical brakes, hydraulic brakes are definitely safer because of their automaticity. The hydraulic press brake machine available right now come with high levels of flexibility and are known to be highly customer friendly. They are manufactured so as to comfortably meet the specific needs of a user by providing various degrees of options and settings which can be adjusted with ease.

How do they work?

The basic principle behind the working of a hydraulic press brake is the power obtained from a hydraulic motor, which is then applied in the form of a force onto the sheet metal. This force then compresses the metal into a die, thus forming the desired shape. The entire process is fully automatic and highly accurate and precise. This is why many renowned manufacturers choose these press brake systems as their machine of choice.

The bending device and die

The bending device per se is the stamping process. Here, the metal is literally stamped on the template or die, where it is cast into the given shape. The force applied further helps in shaping it as per the cast. The die itself is the major determinant of the shape of your metal pieces or sheet metal. The vibration-free nature of the current hydraulic press brake machines allows for high levels of accuracy with your metal shaping process.

Benefits of hydraulic press brakes

The usage of hydraulic press brake systems has benefitted many firms and industries greatly regarding several aspects involved in metal manufacturing and related sectors. Here are a few significant ones worth mentioning.

  • They are great energy-saving options.

Most of the modern hydraulic press brake systems come with built-in energy-saving times and pump mechanisms.

  • Can sustain high levels of power.

The industries working with bigger metal parts require huge amounts of energy, which can easily extend over 250 metric tonnes. Hydraulic machines tend to be a better option in such cases.

Hybrid press brakes

As the name subtly hints, the hybrid press brake is a machine that combines the best features of both hydraulic and all-electric press brake machines. Unlike hydraulic press brakes, hybrid machines do not have any gear pumps, but they operate with the assistance of hydraulics in the process of metal bending. 

Similar to the all-electric counterpart, they help work in a more environmentally friendly manner. They turn off on their own when not in use.

Parts of a hybrid press brake

To understand the functioning, it is important to first have an idea about how the machine is structured. The basic outline of a hybrid press brake system is composed of the following parts.

  • Machine frame:

The frame itself is further inclusive of left and right columns, oil tanks, working tables, and cylinders for when the crowning system is used. Along with this, there are other supportive parts as well. The crowning system is mainly for the compensation of the work deflection which is prone to occur in the working table. 

 

This is important to make the working table produce pre-deformation which is used to track the movements of the slider. These movements are then studied to control the angle change of the workpiece along with control of the bending length and tolerance range.

  • Sliding block:

It is composed of the left and right cylinders connected and secured together with the help of bolts, along with the system comprising of the piston rod and slider joined with the spherical blocks and screws. This block is in association with the frame through the guide rail. On moving the slider, the position data acquired is instantly fed to the CNC system. Then, the measures help in proper control of the output flow of the electro-hydraulic valves and the synchronization.

  • Crowning table:

It helps in ensuring the parallel fixation of the working table and sliding block throughout the process.

  • Light curtain:

It is an electrosensitive protective measure to ensure safety.

  • Bending angle laser detection device:

In most cases, it is software-mediated and helps in improving productivity and quality.

  • Bending mold and clamping:

It has two parts, the upper bending punch, and the bottom die.

  • Front support and back gauge:

The font support is a standard part of the working table, while the back gauge is a floor standing independent structure.

  • Hydraulic system:

It is similar to the hydraulic press brake, but a simpler version.

  • CNC control system:

This is in charge of all the calculations and corrections.

Benefits of a hybrid press brake

As was mentioned earlier, a hybrid press brake holds all the good stuff from both hydraulic and all-electric press brake systems. However, they cannot be employed in industries that work with high energy levels which exceed 250 metric tonnes. They are highly sustainable and environmentally friendly, unlike hydraulic systems which do not possess any auto shutting down mechanisms.

All-electric press brakes

The currently available electric press brake systems are the most effective and modernized edition of all press brake machines in history. Apart from simply making the process more effective and promoting fast functioning and manufacturing, they have also shown great progress in the aspect of the overall safety of the working as well. They are also highly accurate when compared to relatively older methods of functioning.

How does it work?

The electric press brake systems are completely free from any form of hydraulic support and run entirely on electricity. That being the case, they are relatively eco-friendly and offer greater levels of safety and accuracy. This is all thanks to the recent advances and progresses in the field of mechanics and so.

In the electric press brake system, the movable part is solely operated by electricity rather than any form of direct force, which is the case in hydraulic systems. This is brought about with good precision with the help of several in-built attachments and software control.

Benefits

With such high degrees of innovation and automation, these devices greatly decrease production costs. They also help reduce production costs, as well as energy expenditure. As a result of the above, they are considered to be highly economical options when compared to the others in the line.

Conclusion

Finding a press brake machine that suits all aspects of your work and industry along with the general expectations can vary with every firm or business. So make sure to spend enough time on appropriate research and thought before buying your press brake system and machine.

Servo Electric Press Brake Troubleshooting Principle

After crossing a significant number of running hours, your bending machine is prone to damage and problems. This is completely unrelated to the quality provided by the manufacturer. Rather, think of it as additional investment into your project, which is sure to result in significant benefits and profits in the long run. Managing these problems at the beginning is definitely better than letting them grow into something that can compromise the work process and quality.

Think simple

Sometimes, the solutions for all your trouble are right in front of your eyes. This is very true in the case of most heavy machinery and even our home appliances. If you encounter any problem with your press brake that you do not completely understand, simply try restarting your machine. Though this might not work every time, it can still save you from a significant amount of time lost on thought and services to check the machine.

You can just keep this method as a final check before making the call to your maintenance or service technicians. All you have to do is switch off your device completely and let it stay that way for a few seconds, draining all the circuits of any power. Then, restart your brake.

Basic measures

As a first and foremost approach, the program already present is tried to be adjusted with an older program. This is a good way to help you understand what is wrong when your machine stops working abruptly when it was apparently fine before a few cycles of work. By switching your machine back to a program that you know was working fine, you avoid unnecessary troubles with device management services. 

Common problems and troubleshooting methods

There are a few issues that have been reported commonly by the users of Electro servo press brakes but have very simple solutions. Here are a few such examples to help you deal with such minor inconveniences easily.

Device fails to start

Sometimes, the press brake machine simply does not switch on at all, without any previous inconvenience or sign of trouble. In this case, you will have to check these basic things.

  • The proper open or ON state of the main disconnect switch is pretty basic.
  • Check for a blown transformer fuse. Replacing a blown fuse might be a very easy solution.
  • Check if there is a tripped central motor thermal overload delay. You can reset this as required. 

Primary motor overload

The main control of this lies at the thermal overload relay. Thermal overload delay is responsible for protecting your machine from damage due to overload and constraint. Rectify the problem which is causing this overload, and you are good to go.

Uneven bending

It should be pretty obvious to you when your machine is not bending perfectly with the usual level of accuracy. You can start by checking the proper alignment of the machine grossly, along with the secure nature of the screws in the shaft. In case of any loose screws, simply tighten them with the appropriate toolkit.

You should also check your machine for any visible damage or signs and extensive wear and tear. Any machine that has worked for a significant time frame can produce inaccurate bending. Make sure to get your machine checked by professionals and replace any parts when required, and do not compromise.

This is important because any compromise you make as far as your machine is concerned will directly reflect on the overall quality and accuracy of your work and bending. 

When your RAM is not traveling down

Your electro servos press brake should have properly functioning RAM. In the case of a blown transformer fuse, your press brake RAM might not be able to come down. In that case, you will have to check the coil using a voltmeter. If there is no energizing, your coil needs replacement. Otherwise, in the case of energizing without shifting the valve, a service might suffice.

When RAM does not return to the top

In this situation, you should check if your device is in the RUN position. Alternatively, you can check for a broken solenoid coil or if the main relief valve is not spaced appropriately. 

Your RAM failing to stop at any fixed position is different from both the above conditions. In the former case, the Top-of-stroke limit switch most probably requires replacement.

RAM parallelism

An improper setup of the parallels of the RAM might twist the RAM off parallel and damage the tools, along with many other complications. There are many steps that are useful in keeping good parallelism in your device.

  • Make a few uniformly sized metal squares out of a suitable thickness.
  • Put one of those in from each end of the lower die along with the grain, while the material is going the same direction on the metal cut out.
  • Put the machine in JOG. Then take the RAM down to lower levels and crank down the lower limits as you hold the down button. Carry on with this until the sheet metal coupons are bent approximately at 45 degrees Fahrenheit.
  • Then, allow your RAM to back up and then insert two new sheets.
  • Bring the RAM down to stops.
  • Slide the metal sheets and compare their bending. The overall objective is to have the pieces of sheet metal with an equal bend. A good way to measure this bend is with the help of a micrometer.
  • You can easily make any future adjustments and changes to the micrometer with the help of the right side, while you touch up the other side with simple spray paint.

RAM Timing

After a proper setup of parallelism, you will have to correct the timing of your RAM appropriately. You should ensure that the RAM on both sides is operating and descending at a uniform pace. This is a simple task, done with the following steps.

  • Put your machine in the RUN position.
  • Without taking your eyes off the indicator lights on the back of the control box, cycle your machine twice or thrice. Check for the time when both lights blink simultaneously. This is indicative of proper timing and synchronization. 
  • If the above was not exhibited, try adjusting or loosening your lock nuts and knobs.
  • Put both the adjustment knobs to stops and tighten your lock nuts. Check your indicator lights again after cycling your machine a couple of times.
  • Correct the adjustment knob corresponding to the light with the delay for about a quarter turn. Cycle your machine and observe the light again.
  • Repeat this step again if your problem still persists. Once you fine-tune your machine to perfect synchrony of lights is achieved, lock the locknuts.
  • In case your indicator lights worsen on adjustment, put the current knob at the resting position and try the above steps with the other knob.

Conclusion

With all the above troubleshooting methods and ways to resolve simple problems, along with a good amount of knowledge about the possible troubles your machine might face, you will be able to figure out a good way to work out any issue. All this info will help you decide if you will have to repair, replace, or retrofit your Servos electric press brake.

Bend Angle Measurement Systems For CNC Press Brakes

It is very important to get the measurements and angles perfectly with the press brakes because anything less would compromise the features as well as the quality of the end product. By using laser-assisted bend angle measurement devices, the exact and accurate bending angle for CNC press brakes can be determined with zero contact. 

How they work

The most important property of such devices is that they can be easily attached to the press brakes without making any modifications to the tools. But still, you will have to alter the height of your bench for proper installation of the set-up. In short, the bent part should have a side flange with no counter bends and a side flange with an appropriate length.

These devices can be used at even very high tonnages and have no die opening limitations per se.

Different types of bend angle measurement systems

Currently, there are two highly trusted and accurate measures that are used by renowned firms for bend angle measurement and angle correction. This includes methods that make use of a predominantly laser-based technique like the LaserCheck, and the laser transmitter-receiver sets, which are the Iris Plus bending angle measurement systems.

Both of these methods are highly accurate and automatic. They require no technical input or assistance from the workforce and are completely self-sufficient. Apart from just covering whatever is on their checklist, that is, angle measurement, they also provide active correction and accuracy check of the measured angles while also taking care of the compatibility and data sharing processes.

Laser-assisted bend angle measurement systems

With a fully automated process, these systems calculate the exact bending angle of the material in question with unbelievable accuracy and precision. In order to measure the bending angle, the projection of the laser beam from the metal surface is measured using the CMOS camera. Secondly, the angle made by the laser and the camera’s viewing axis determines another distance.

Lastly, the angle between the sensor and the metal sheet is calculated using the above measurements. By using a second sensor on the opposite side, you get the bending angle. Most of our Accurl laser bending angle measurement systems work by this principle.

Laser transmitter and receiver set 

The necessary devices and goods for the same include the transmitter and laser receiver systems, inclusive of a high-speed digital camera and an image data processing system. They are then set up according to the upper beam of the press brake. With the appropriate technological assistance, this system provides real-time angle measurement data, which covers several intimate aspects.

The clear details of the inside and outside angles, average angle, material warp, and material spring-back angle are given, along with several other angles like the thickness and direction of the grain, etc.

Benefits of using an automated bend angle measurement system

Firstly, these bend angle measurement systems for press brakes are completely automatic and can function smoothly with zero manual assistance. It takes care of all necessary adjustments, including height compression and automatic angle correction. With such high-quality systems, you are provided with a die width of up to 60mm,  instant image transfer, and a significantly big measurement range of 0 to 180 degrees.

These systems provide real-time measurement of the bend angles while calculating the force reduction and spring back simultaneously. 

Conclusion

To sum up, the most important take-home message here is that the serious process of bend angle measurement, which is crucial for the proper functioning of your press brakes, can be easily managed with the usage of such high-quality measurement systems. You can find more detailed information on the same with great details across the internet,

 

What are the different types of CNC control system units?

As someone looking for the different types of CNC control system units, you should know what it actually is and how it functions. Simply put, the abbreviation CNC is short for Computer Numerical Control. In the case of most programs, the CNC control system is in charge of managing the motion and speed of the machine tools used in everyday industrial processes. This is why they are often referred to as CNC control systems.

 

The general structure of a CNC machine

As far as the basic outline goes, here are a few unavoidable components of the CNC machine that you should know about for a better understanding of how the different types of the machine function.

 

1. The input devices are used for the proper input methods of the part program into the CNC machine itself. Most commonly, the industries make use of three different input devices, which are the punch tape reader, magnetic tape reader, and the computer, via RS-232-C communication. This is subject to variation depending upon the specific endeavors and concerns pertaining to individual companies.

2. The machine control unit or the MCY in short. This is referred to as the heart of the machine, and it is definitely a very apt nickname. This part of the CNC system is responsible for all the mainstream controlling activities demonstrated by the machine per se. The general functions can be listed as follows.

  • Reading the coded information which is being fed
  • Decoding the coded info
  • Implementation of complex techniques like interpolation for the generation of axis motion commands
  • Reception of feedback signals for position and speed pertaining to each drive axis
  • Implementation of auxiliary control functions inclusive of coolant, spindle on and off, tool change, and more

3. Machine tools are an essential component of the toolkits for CNC control units. These machine tools are seen to be controlled on the X and Y axes, while the spindle is being controlled on the Z-axis.

4. The driving system, includes amplifier circuits, drove motors, and ball lead screws.

5. Feedback systems, act as transducers or sensors, thus forming a measuring system of sorts. These transducers include both positions and speed-specific ones and are dedicated to continuously monitoring the position and speed of the cutting tools in question.

6. Display unit, which shows all the required data and commands which are being fed into the control system.

Different types of CNC control systems

Along with the constant progression of CNC systems and their utilization within the renowned industries, there has been quite an amount of research and thought put into the field. This led to the development of a wide range of machines, which differ extensively either in their general functioning or their specific direction of work. That being said, industrialists, these days are provided with a wide variety of CNC control systems to choose from. Here are a few of the most popular ones in the market as of now, with a brief explanation of their working and advantages.

 

1. Motion type CNC 

Motion type CNC control system units are further divided into two main types, which are

  • Contouring systems

These machine tools are known to work in a continuous path where they focus on cutting the material presented to them and following its contour as such. Their basic functioning is inclusive of processes like luke milling, lathe, and routing machines. These contouring machines function through the simulatory movement of the tool and work positions. Both the position f the machine as well as the product are controlled by the control system.

  • Point to point control systems

In this case, both the workpiece and the tool are kept in a  constant position while the tool performs its required duty. The major members of such machines which function through point-to-point mechanisms include drilling machines, tapping machines, boring machines, and more. By not moving the pieces unnecessarily in between the work process, these machines ensure safe and proper completion of work and minimize the margin for error significantly.

2. Loop control CNC systems

This part of the classification further branches into two depending upon the looping system involved in the procedure.

  • Closed-loop systems

This type of CNC control system works through a process that has feedback from the control system sent to the actual and programmed input. This is why it is referred to as a closed-loop system. In this case of a CNC control system working under the servo mechanism, the feedback can be possibly measured through either analog or digital systems. With such closed-loop systems, you achieve high levels of power and accuracy thanks to their extensive capability and monitoring.

  • Open-loop systems

Here, the instructions are sent into the control via the input device, which is then converted to the signals by the controller. These converted signals are then sent to the servo amplifiers to energize the motors.

3. Number of axis type CNC control systems

This is a rather extensive segment of the CNC control system classification and is inclusive of 5 sub-classes of highly competent machine systems. The only thing varying in these devices is the number of axes which is clear from the name itself. However, this difference is all it takes to create notable changes in how it can complement your business specifically.

 

Putting it plainly, one can safely assume that the number of axes in which your CNC machine works should be a direct reflection of the requirements and expectations you would like to be fulfilled by your CNC control system. This is subject to great degrees of variation with every process in the industrial and business sector.

  • Two-axis control system

These machines allow you to access only 2 axes. A good example would be the lathe machine, where work is done only on the X and Y axes.

  • Two and a half axis control system

Though these machines possess three axes, movement is still not possible in all three of them. In these cases, the X and Y axes are firstly in position while the third axis comes into effect later.

  • Three-axis control system

As the name simply suggests, these machines work across three axes, mostly the X-axis, Y-axis, and the Z-axis simultaneously.  They work with high levels of accuracy and precision and are limited to simple jobs and straightforward applications.

  • Four-axis control system

Along with the three common axes, an additional rotation axis known as the B-axis comes into play. This machine could either be a vertical machine or a horizontal machine.

  • Five-axis control system

They are three-axis machines with additional rotational axes in both Y and Z directions, alternatively called the A and B axes. Such machine systems get improved access to the undercuts and deep pockets.

 

Conclusion

To wrap things up, there are a few very important basic things to keep in mind while you choose your CNC systems. Though it might seem like a trivial task, picking an appropriate CNC control system can affect your overall functioning greatly. Hence, be sure to spend a good amount of time into effective thought and research regarding the machines and devices you would like to purchase beforehand. Doing so, you will be able to notice visible changes in your overall productivity and work efficiency because perfectly suited hardware often has significant positive changes in a firm.