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Angle Measurement System IRIS PLUS

BENDVISION

BendVision is an extension of our image processing technology that provides real-time analysis of the bending process. The technology is incorporated into the existing hardware of the IRIS Plus optical guarding system so that no extra components are required, resulting in an efficient and cost-effective solution for press brake manufacturers.

BendVision processes images of the press brake tools and material during the bending process and transfers a range of information to the CNC via SmartLink including raw and processed images as well as live angle data during bending. The press brake manufacturer can use real-time BendVision data to enable a wide range of customised functions and processes. These functions and processes are co-developed with Lazer Safe and the press brake manufacturer.

BendVision for angle measurement

BendVision technology provides a range of real-time angle measurement data that includes the inside and outside angles of the material, average angle, material warp angle, material spring back angle for various material types, thickness and grain direction, plus end of relaxation angle once the bend has been completed.

Iris Plus Angle Measurement System
Iris Plus Angle Measurement System

BendVision for angle measurement

BendVision technology provides a range of real-time angle measurement data that includes the inside and outside angles of the material, average angle, material warp angle, material spring back angle for various material types, thickness and grain direction, plus end of relaxation angle once the bend has been completed.

BendVision for angle control

The ability for the CNC to receive BendVision angle data opens up a wide range of possibilities for real-time angle control. Instead of just confirming angles are within tolerance, the CNC can use the live angle plus a measured spring back angle to control the bending depth for flexible active and dynamic angle control solutions.

Iris Plus Angle Measurement System
Iris Plus Angle Measurement System

BendVision for angle control

The ability for the CNC to receive BendVision angle data opens up a wide range of possibilities for real-time angle control. Instead of just confirming angles are within tolerance, the CNC can use the live angle plus a measured spring back angle to control the bending depth for flexible active and dynamic angle control solutions.

BendVision for tool recognition and confirmation

Raw and processed BendVision image data can be utilised in advanced tool recognition and confirmation processes. Live images of the punch and die can be compared with reference images that are stored in the CNC. Tool recognition and confirmation can be use for an array of functions including tool damage prevention if the programmed tools do not match the tools that are physically installed on the machine.

Iris Plus Angle Measurement System
Iris Plus Angle Measurement System

BendVision for tool recognition and confirmation

Raw and processed BendVision image data can be utilised in advanced tool recognition and confirmation processes. Live images of the punch and die can be compared with reference images that are stored in the CNC. Tool recognition and confirmation can be use for an array of functions including tool damage prevention if the programmed tools do not match the tools that are physically installed on the machine.

Active Angle Control (AAC)

Iris Plus Angle Measurement System

Active Angle Control is designed for single parts or small batch production. During operation the bend is briefly paused prior to reaching the programmed angle while real time images are processed to calculate the material spring back. The bend is resumed and the spring back calculation is then used to automatically control the bending depth. After decompression, the final angle is automatically confirmed before proceeding to the next bend. Active Angle Control is a highly accurate angle control process that ensures spring back is calculated for each individual bend to achieve the correct angle.

Iris Plus Angle Measurement System
Iris Plus Angle Measurement System

Active Angle Control (AAC)

Iris Plus Angle Measurement System

Active Angle Control is designed for single parts or small batch production. During operation the bend is briefly paused prior to reaching the programmed angle while real time images are processed to calculate the material spring back. The bend is resumed and the spring back calculation is then used to automatically control the bending depth. After decompression, the final angle is automatically confirmed before proceeding to the next bend. Active Angle Control is a highly accurate angle control process that ensures spring back is calculated for each individual bend to achieve the correct angle.

Dynamic Angle Control (DAC)

Dynamic Angle Control is ideal for high speed processing of volume production parts. When the first part is formed, Active Angle Control is first initiated to automatically calculate the spring back of each individual bend in the part. After spring back is calculated and recorded for the first part, then Dynamic Angle Control is activated. Dynamic Angle Control uses real time angle data plus the recorded spring back value to automatically and accurately control the bending depth, with the final angle automatically confirmed after decompression before proceeding to the next bend. Dynamic Angle Control is a high speed process that ensures accuracy and consistency between parts with no delay to the bending operation.

Dynamic Angle Control (DAC)

Dynamic Angle Control is ideal for high speed processing of volume production parts. When the first part is formed, Active Angle Control is first initiated to automatically calculate the spring back of each individual bend in the part. After spring back is calculated and recorded for the first part, then Dynamic Angle Control is activated. Dynamic Angle Control uses real time angle data plus the recorded spring back value to automatically and accurately control the bending depth, with the final angle automatically confirmed after decompression before proceeding to the next bend. Dynamic Angle Control is a high speed process that ensures accuracy and consistency between parts with no delay to the bending operation.

Angle control processes

These are two examples of angle control processes that can be implemented in the CNC system through the development of supporting software.

Specifications

IRIS
IRIS PLUS
Optical protection functions
Optical imaging functions
Maximum recommended optical range
8 metres
4.5 metres
Optical sensor
Camera
Digital Image Sensor
Digital Image Sensor
Frame rate / frequency
17ms / 59Hz
Selectable 5ms / 200Hz or 10ms / 100Hz
Data resolution (sensor)
0.01 degrees
Measurement technology
Type
Integrated Intel® image processor
Integrated high-speed
Intel® image processor
Memory depth
Records up to 10 seconds
(2000 images) of bend data per cycle
Measurement accuracy
Up to +/- 0.25 degrees
Measurement rate synchronised with frame rate
Selectable 5ms / 200Hz or 10ms / 100Hz
Imaging technology
Bend Speed Management
BendVision

Optical Imaging Technology

IRIS and IRIS Plus optical systems incorporate an integrated real-time image processor that is contained within the receiver unit. Our optical imaging technology provides greater flexibility for press brake manufacturers by combining high-performance optical protectionwith real-time image processing capabilities.

As combination systems, both IRIS and IRIS Plus models provide high performance optical protection while the tools are closing at high speed, then once the bending process starts, the image processing functions take over. During bending, the systems take and process images in real-time and transfer live data to the CNC system via SmartLink. As the image data processing system is completely contained within the IRIS and IRIS Plus receivers, no additional processing hardware or software is required.IRIS and IRIS Plus optical imaging is a flexible technology platform that allows press brake manufacturers to utilise the real-time image data to develop and implement a wide variety of advanced functions and processes in the CNC system. The optical imaging technology requires supporting CNC system software that is co-developed and customised for each manufacturer.

Optical imaging functions

Bend Speed Management (BSM)

Iris Plus Angle Measurement System

The European press brake standard EN12622 mandates that bending speed be restricted to 10mm/s. This speed restriction provides a general level of safety by managing the speed at which the material facing toward the operator moves during bending. However in the machinery directive and EN12622 there are clauses that provide a basis for faster bending speeds with wider V dies, provided certain operations can be properly monitored. In the CNC system the manufacturer can set a faster bend speed for larger width V dies and to facilitate a safe condition for faster bending, the Bend Speed Management process provides automatic monitoring of the speed at which the material facing the operator moves through its bending arc.

To do this, IRIS and IRIS Plus systems process real-time images of the bending process to calculate the angular velocity of the moving sheet and measure the speed at which the part is being formed. If the angular velocity with a wider V die is sufficiently less than the speed when using narrower V dies then a faster bending speed is permissible. This calculated speed is compared with the die width programmed in the CNC and if within the angular velocity threshold, enables the machine to continue bending the material at a speed greater than 10mm/s.

Bend Speed Management continuously monitors the bending process so in the event the angular velocity exceeds the maximum threshold or the operator selects an incorrect die width then the bend is stopped then continues to be completed at 10mm/s. Bend Speed Management* is available with both IRIS and IRIS Plus.
*Supporting software development is required for the CNC system.

Iris Plus Angle Measurement System
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