Press Brake Setup & Installation Guide

The installation cost for a press brake setup is the highest.

No materials are created throughout the setup, and the number of expenses keeps growing as the longer setup continues. The quantity of finished, accurate items you can create in a particular amount of time determines a press brake’s effectiveness and profit margins. Because less time is spent on creating parts if the setup is too time-consuming, the price of each part rises.

Making a lot of components with a similar setup is the sole method to lower the cost per component on old hardware. Each operator should strive to master all the quick-setup techniques to produce more components for less cost.

This can be facilitated by employing a standard setup technique, which will also significantly improve the effectiveness of your press brake.

Analyze The Sketch

Operators must be fully versed in their components. A revision of the design might not be required if the pieces have already been manufactured, but eventually, the operator must be aware of:

  • Type of material and density.
  • Dimensions and tolerances for flanges.
  • Angles necessary and angle tolerances.
  • Inside the arc of an angle.
  • Blank size.

In the absence of any of this data, the supervisor will be required to make an educated assumption. The part now runs the danger of being inaccurate. An important initial step is to have detailed drawings.

Tooling Selection

The sketch is used to select the tooling. There are a few options available to you: air bending, bottom bending, coinage, or customized usage.

For instance, if the layout calls for a bottoming tool and the inside arc length is equivalent to the metal density.

For that specific type of machinery, you should use tooling which is least as precise as what the tool maker recommends. No matter how precise the press brake installation is, worn equipment cannot create correct products.

Calculate Tonnage

Operators should have little trouble estimating the necessary tonnage.

Regarding air bending, there seem to be tonnage graphs available. A reasonable calculation for bottom bending is nearly three times the tonnage of an air bend. About eight times as much air bend tonnage is needed for coining. The supplier will offer tonnage estimates for customized application tooling. Never try a bend before determining the required tonnage and comparing it to the tonnage provided.

Choose The Press Brake

If your shop has just one press brake, you can skip this step. If you have more than one brake, make sure the one you choose is the most appropriate for the task at hand.

A tons-per-inch limit is located in the center of press brake machines. Multiply the length across the lateral panels by 0.6 to find the tonnes per inch for the brake then start dividing the machine tonnage with your estimate.

The highest tonnage in the center of the machine shouldn’t be higher than 25 tonnes for a 12-in.-wide item. A condensed overload is produced by exceeding 25 tonnes over 12 inches. This is a poor decision because it could harm the ram permanently. When using a tonnage control, both manual and CNC, make sure to only use the quantity necessary to twist the part and not to go over the tonnage threshold in the middle.

Additionally, keep in mind that overloading a press brake is only permitted while bottoming, coinage, or utilizing specialty tooling for air bending.

Choose A Tooling Position

You might be able to complete the task off-center if the required tonnage surpasses the focussed weight limit in the system’s center.

Nevertheless, you should first confirm that your press brake’s supplier permits off-center loading for proceeding. Working off-center is acceptable so long as you stay within the manufacturer’s guidelines.

Set Up The Tooling

Assemble the tooling and line up the top and lower tools to create the bend after determining the tooling placement on the bed.

The task in the setting process that requires the most funds and duration is tool installation.

You will be required to release your brake’s mechanical clamping bars just slightly to put the tools into place if it comes with them. The bottom tool (die) should be installed first and left loose for a while. Reduce the ram to a position that is roughly 1/4 inch higher than the punch’s vertical position just above the die.

Now position the punch so that the tang is behind the clamping rods and move it onto the die. In this process, the die is bearing the punch’s mass. Regardless of whether there is a security label on the punch, use the same approach.

Descend the ram to place the punch and position the die, then snugly compress the clamping bars along a tang. The clamp rods and die set screws should then be tightened.

This process is made simpler and faster by employing a hydraulic press brake for tooling, and it is even more effective when snap tooling is used. All press brakes can be retrofitted with either of these functionalities.

Create A Press Brake Programme

The brake must be appropriately configured to make the bend regardless of whether it is manual or CNC. Even though manual programming may need some experimentation, CNC machines can typically be automated extremely rapidly.

Programming takes the second-longest amount of time during setup.

The fact that some operators lack the necessary training could be one factor in why programming takes so long. Operators devote a lot of time to learning how to use the brakes, but they rarely devote much effort to program development. Coding a CNC brake requires much less time than setting a manual model, but both mechanical and CNC systems require sufficient knowledge of the subject. You may need to find someone who has knowledge on different types of machinery such hybrid press brake and electric press brake

Now You Can Run The Parts

You are prepared to operate high-quality parts after the correct setup. Don’t count on everything being flawless though. A testing and evaluation process will be established by your supervisor for the components you are producing.

Remember your setup technique and use it for each new element you create. Your setup period will quickly go down, and your precision will noticeably increase.

How To Setup And Install Electro Servos Press Brake

Press brakes are tools that are used to bend and work with metal pieces and sheets. Press brakes are essential tools in the heavy industry and fabrication industries because of this capability.

However, previous press brake machine types were notorious for making loud bangs and needed a lot of power to get results. Better options were required that would deliver similar or superior benefits with the least amount of resource usage and pollution-causing emissions due to growing environmental concerns.

The invention of the servos electric press brake was made to satisfy these demands.

Servo-Electric Press Brakes: How Do They Work?

We’ll move on to studying the functions of an electro servos press brake knowing that we have a good understanding of what it is. Understanding a machine’s workings is crucial since you can then set up the machine effectively.

The die and the punch are typically the two major parts of press brake machines whose motion produces the intended effect. While the punch in some variants is stationary and its die is mobile, in other versions the punch is stationary but the die is created to shift in opposition to it.

In both methods, the appropriate metal or substance is sandwiched among the fixed and moving parts, which are powered by electricity. To manipulate the metal as needed, the die may be altered and connected with a variety of orientations and forms.

Hoisting The Machine

The bending brake is generally hefty in the front but lighter in the back due to a high center of gravity. Therefore, it is important to be mindful of the center of gravity to prevent equipment turnover.

Clean Up

The rust prevention oil should be removed from the working components before managing a hydraulic press brake.

As long as you don’t use a dissolvent wash on the machine, you’re free to use gasoline and coal oil to clean the parts.

To ensure machine stability, silk strands should be employed at a slightly inclined angle.

Horizontal And Vertical Leveling

Lay the device out horizontally on the underlay. Once all of the machine’s components, including the electrical ones, are securely connected, the accuracy adjustment can be made.

The method is:

  • A slider block should be placed on the top dead spot.
  • Put a gradienter upon the opposite wings of the slider blocks with an accuracy of 0.05mm/m.
  • Make vertical level adjustments
  • To correct the horizontal plane, place a gradienter in the center of the workbench with an accuracy of +0.05mm/m.

The bottom screw throughout this operation also needs to be securely linked.

After using it for two days straight, the level needs to be checked and adjusted again.

Connect The Electric Components

Inspect the hydraulic pump position following the connecting of the electrical switch (electrical sections: R, S, T, and PE). Alternate the two-phase lines right off the bat if the alignment is incorrect.

The electrical box’s bottom can accommodate the cable entryway.

Verify the voltages are compatible and allow an electrical expert or a professional following the handbook to guide the person who is connecting the machine’s electricity.

Operating

The top crossbeam of electro servos press brake installation is sliding intermittently toward the motion of the control valve, with the amount of displacement being measured by rasters on both ends of the machinery.

Two valve gates inside both left and right fuel tanks are controlled by the DNC. Its top crossbeam could be made to shift directly into the upright direction if necessary by the servo, and the amount of mobility is determined by the latest recorded pulse frequency.

Each fuel tank in the hydraulic equipment has its independent feedback signal, together with both the servo valve and the refilling nozzle, which receives the message from the DNC processor and passes it over to the hydraulic force data, and regulates the motion of the valve.

Axis Of The Gauge

The back gauge would be implemented by a plain guide and a ball bearing drive shaft, which is made up of a light source that extends through one side of a device toward the other, and thus the rear gauge’s guide is installed on both sides of the device body. A straight gauge can be driven by a servo engine, and the portion is moved using DNC.

The operator must be aware of the rear gauge’s location because if it passes through the region of the mold, the equipment will be harmed. The Z-axis may only be adjusted manually from the system’s back. To avoid hitting the bottom die, you should be cautious while setting the back gauge.

Choosing A Top Punch For A Press Brake

The choice of the upper die must also take into account the compression power and the burthen limit, which should not be exceeded.

Additionally, the user has the option of selecting unique tooling; however, they must be aware of the differences in the burthen versus normal tooling.

The device’s technician should follow the precautionary principles when in a hazardous region.

To prevent safety hazards, you must put the NC steering key and start switch to “axes stop” before fitting the higher and lowers dies.

Starting Up

Here are some guidelines to keep in mind before you start the press brake and some tips if you get stuck.

  • Before commencing, make doubly sure there will be no irreparable harm.
  • The mechanical tool needs to be in a secure and usable state for operation, and all guards and safety measures must be in place.
  • Avoid any potentially hazardous operations in terms of safety.
  • If a fault shows up, shut down the machine immediately and fix it.
  • Fixing problems must be taught by more qualified or experienced individuals.
  • Generally, inspect the equipment from the exterior if there seems to be breakage or a defect, then report it and, if required, shut it down.
  • The user should study the instruction manual thoroughly.

End Note

Every industry has benefited from new technologies and devices, which has enabled them to make great strides. You must understand and stay current on these newest technologies as business owners if you want to make the most of them.

Consequently, you must understand how to set up a press brake properly if you work in the industrial sector or own a fabricator company.

5 Characteristics of Hybrid Servo CNC Press Brake Machine

The field of metal bending underwent a transformation when the press brake machine was developed.

Engineers working on press brakes continued to improve both hydraulic and electric press brakes eventually someone had the brilliant idea to merge the advantages of both of them into a single hybrid machine. Hybrid hydraulic-electric press brakes also called “servo press brakes,” employ hydraulic force to propel the ram and therefore employ AC servomotors to regulate the ram’s angle of motion.

The new brakes made use of an engine, rotor, and unconventional gear to power a ram and contort denser plate material, but they did not replace hand-powered metal press brakes. As a result, completely new fields of manufacturing were made possible. Additionally, as the press brake system advanced over time, increased control and accuracy were added in addition to steadily rising bending power.

Hybrid brakes are far more effective than conventional brakes because they typically require less hydraulic energy and because the hydraulics don’t always operate as they do in conventional brakes. There is no need for hydraulic positional valves, hence there is no space available for valve adjustments. Furthermore, hybrid press brake functioning is surprisingly quiet due to the minimal hydraulic use.

Hybrid press brakes provide reduced production costs due to their decreased power usage, keeping them cheaper for long-term use when compared to their completely hydraulic equivalents.

Going further we’ll discuss 5 main characteristics of press brakes machines.

1. Environmental Protection

Let’s start by examining the benefits of hybridized servo-driven CNC press brakes for reducing energy consumption and minimizing environmental impact. The most sophisticated dual servo pump management system on the planet powers the dual press brake. The conventional servo proportional valve and management technology is replaced by the servo pump. Compared to conventional hydraulic systems, this motor solution uses less space, hydraulic fluid, and power. The quantity of hydraulic oil consumed is only approximately a third or even a fifth of that of conventional hydraulic equipment since the dispersion of fluid is essentially on-demand but without throttle loss. Actual energy savings are possible.

2. Energy Efficient

In addition to energy savings and ecological sustainability, the benefits of hybrid servo CNC press brake machines extend to power utilization and energy conservation are more striking. Since the technology only consumes the power needed mostly by the press brake within every stage and all of the force from the workstation is decreased and compensated, a hybrid press brake has remarkably better energy cost-effectiveness compared to the conventional compression gear mode. It may be decreased by greater than 75%, it may even be down to just 5% of many other systems that are in power-saving mode. The success of this system depends on its location control precision of 5 m. The usage of multiple gearing pumps lowers the overall machine’s noise level. The noise level never exceeds 60 decibels regardless of whether the machine is operating at its greatest speed. The malfunction rate is significantly decreased, and the susceptibility to oil quality is decreased.

3. High Performance

The hybrid servo-driven CNC press brake performs exceptionally well in regards to maximum productivity. Its slider’s or the component’s positional correctness is equal to or even greater than that provided by the proportional valve controller design. The slider’s repeat placement accuracy is 0.01mm following the testing process, with the greatest precision being 0.005mm. To maintain bending precision, its no-load and operating speeds can be raised by 15% to 25% while especially in comparison to a standard CNC press brake machine. The returning velocity can be enhanced by greater than 50%. The production of sheet metal has substantially increased due to the improvement in working speed. This is because of its superior hydraulic system. The fluid temperature may also be maintained at a constant level with the extended quick reciprocal operation. A 38-degree Celsius interior heating is present. The temperature of the liquid doesn’t quite rise above 50 degrees Celsius. Fuel leakage danger is decreased, steadiness is improved, and the lifespan of hydraulic equipment and valves is extended.

4. Automated Operations

In contexts of software features, hybrid servo-driven CNC press brakes can easily and quickly pick tools, determine initiatives, bend robotic arms autonomously, detect lasers electronically, provide input and recognize monitoring results conveniently, among other things. Normal press brakes can also automatically compensate. A hybrid press brake has been able to operate in a manner that is truly autonomous as compared to anti-collision management. The setup is also less confusing since it doesn’t require complicated assembly processes like engines, fuel injection systems, storage cleaning, pipes, etc., which might increase the effectiveness of user installation. Economically and practically speaking, it is better. The previous motor, oil injector, oil chamber, and hydraulic valve switch are retained, along with labor expenses for cleanup and complex pipeline placement. Energy utilization and hydraulic oil requirement are also significantly reduced. The device and it function flawlessly together to create a true automated chemical plant. So even the workplace computer system can be used by the personnel to finish the entire arrangement, slicing, manufacturing, distribution, and completed supplier process, and even then it can take some time and constant labor.

5. Synchronization

A servo motor is used in the hybrid servo-driven CNC press brake, which is attached to a two-inbuilt gear pump. Both press brake and outgoing fluid stream of the fuel pump are regulated by the CNC technology by regulating the velocity of the servo engine. To manage the slider’s placement precisely, the two canisters are synced to move more quickly and efficiently. The press brake could be attached without the use of oil thanks to the operational program’s direct correlation to the oil fuel tank. This eliminates the need for a transitional pipeline link. The setup is simple, which reduces contamination and other issues while conserving energy and protecting the climate. In the area of industrial production artificial intelligence, multifunctional CNC press brake has already attained Industry 4.0 requirements. It’s a top-of-the-line CNC press brake. It will undoubtedly hold a significant position within the press brake group and within China’s industrial production sector while having a part to play.