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Press brakes are essential for creating everything from intricate automotive parts to sturdy architectural pieces. At the heart of each press brake structure lies major parts like a bed or lower beam, a ram or upper beam, and the vital punch and die that do the heavy lifting. Each type of press brake, whether powered mechanically, pneumatically, hydraulically, or by servo-electric means, shares the same mission: to transform metal with unmatched accuracy. This precision ensures that every bend meets your exact specifications, crucial for maintaining quality and efficiency in your projects. In this article, we’ll focus on exploring the main components that make press brakes so effective, discuss the common types, and offer practical tips for troubleshooting and maintenance to keep your machine in top shape.
Main components of a press brake
- Frame: This rigid structure, often C-shaped, is the backbone of the press brake, providing essential support to all major parts and maintaining stability during operations.
- Ram (Upper Beam): Positioned vertically, the ram moves to press the punch into the metal, playing a crucial role in the bending process.
- Bed (Lower Beam): Acting as a stationary platform, the bed holds the die and is critical for the alignment and support of the workpiece.
- Side Housing: These are vertical plates that form the sides of the press brake, crucial for the overall rigidity and stability of the machine.
- Hydraulic or Mechanical Mechanism: Depending on the type of press brake, this mechanism applies the necessary force for bending. Hydraulic brakes may use synchronized cylinders, while mechanical brakes might employ a crank/flywheel system.
- Electrical System: Including motors, drives, and control panels, this system powers and controls the machine’s motions and functions, ensuring smooth operation.
- Tooling System (Punches and Dies): These components actually shape the workpiece during each bend, with punches and dies that must be precisely manufactured to meet specific bending requirements.
- Back Gauge System: Essential for precision, this system helps in positioning the workpieces accurately before each bend.
- Crowning Mechanism: This component offsets any deflection in the beams, which is vital for maintaining uniform bend angles across the width of the workpiece.
Press Brake Parts and Components
- Power Source: The hydraulic system’s power source is generally an electric motor connected to a hydraulic pump, transforming electrical energy into hydraulic pressure. This setup is fundamental in circulating the hydraulic fluid under pressure throughout the system. The power rating of the motor, typically measured in kilowatts (kW), is calibrated to meet the maximum bending requirements of the press brake. Some press brakes are equipped with multiple pumps or incorporate variable-frequency drives to optimize energy consumption and adapt to different operational demands. Ensuring the motor has sufficient capacity is crucial for smooth operation and longevity of the hydraulic components.
- Hydraulic Pump: The hydraulic pump stands as the cornerstone of the hydraulic system, responsible for pressurizing the fluid and delivering it to the cylinders that drive the ram. Depending on the required pressure and precision, different types of pumps such as gear pumps or piston pumps are utilized. Gear pumps are suitable for moderate pressures, whereas piston pumps are preferred for higher pressures and more precise control over the fluid flow. In more sophisticated systems, variable-displacement pumps adjust the flow rate based on the demand, enhancing the system’s efficiency. Regular maintenance, including checks for leaks, abnormal noises, or temperature spikes, is vital to ensure the pump’s reliability and effective performance.
- Valves: Hydraulic cylinders are the muscle of the hydraulic system, converting fluid pressure into mechanical force that moves the ram. Key features include (1)Synchronization: Typically, two cylinders work in tandem, positioned on either side of the press brake to ensure even force distribution and precision in the bend (2)Types of Cylinders: Single-acting cylinders provide force in one direction—downward—while double-acting cylinders can apply force in both the downward and upward movements, offering enhanced control over the bending process (3)Maintenance: Keeping cylinder seals intact and ensuring proper alignment are vital to prevent leaks and uneven pressure, which could lead to faulty bends and reduce machine efficiency.
- Hydraulic Circuit: The hydraulic circuit is a network of hoses, pipes, and fittings that manages the flow of hydraulic fluid from the pump to the cylinders and back. Efficient circuit design is vital for (1)Minimizing Pressure Drops: Ensuring smooth transitions and consistent fluid flow without significant losses (2)Incorporating Key Elements: Such as accumulators for storing pressurized fluid and coolers to regulate fluid temperature, both of which help in stabilizing the hydraulic function across various operations (3)Maintenance: Regular inspections are crucial to avoid leaks and wear, ensuring reliable and uninterrupted press brake operation.
- Lubrication and Cooling System: To prevent overheating and reduce wear on moving parts, a well-maintained lubrication and cooling system is essential. This system includes (1)Hydraulic Fluids: These fluids do more than transmit force; they also lubricate the system and help dissipate heat generated during operation (2)Cooling Units: Often integrated within the system, such as heat exchangers or fans, maintain optimal fluid temperatures, typically below 70°C, to prevent thermal degradation of the hydraulic fluid.
- Filter Element: Keeping the hydraulic fluid clean is paramount, as contamination can lead to severe damage to the hydraulic components. Filters in the hydraulic system remove particles like metal shavings, dust, and moisture. Regular replacement and inspection of filter elements ensure the longevity and reliability of the hydraulic system, maintaining the precision and efficiency of the press brake operations.
- Control System: The control system is the central intelligence of a press brake, typically featuring CNC (Computer Numerical Control) or NC (Numerical Control) units. This system interprets data from various sensors to manage the ram movement and back gauge positions effectively, adjusting the bending angles according to the operator’s input. Operators input data such as part geometry, material thickness, and desired bend angles into the control system, which then calculates and executes the necessary actions. Advanced control systems can store multiple bending programs, which enhances repeatability and reduces setup time for future jobs. Additionally, real-time feedback from linear scales or encoders helps in making precise adjustments to the ram’s position, compensating for any mechanical deflections known as springback, thus ensuring the accuracy of each bend.
- Motors and Drives: Motors and drives are fundamental components that supply the power needed for the various movements of a press brake. Electric motors are responsible for driving the hydraulic pumps that power the ram and also for moving the back gauge, which positions the metal sheet accurately. In servo-electric press brakes, servomotors are used for directly actuating the ram movement via mechanical linkages like belts, pulleys, or ball screws, offering high precision and energy efficiency. Drives control the speed and torque of the motors, adapting the power output to the operational demands. The use of Variable Frequency Drives (VFD) can further enhance energy efficiency by adjusting the motor speeds based on the load, reducing electrical consumption and wear on mechanical components.
- Electrical Panels and Wiring: Electrical panels are the hubs where various electrical components such as circuit breakers, relays, and contactors are housed. These panels distribute power throughout the press brake and protect the system from electrical overloads. Organized and clearly labeled wiring within these panels is crucial for efficient troubleshooting and maintenance. Moreover, these panels often include PLCs or CNC controllers, which interact with the machine’s user interface, providing a centralized control point for operators. Regular inspections are necessary to ensure there are no loose connections or signs of overheating, which could lead to machine failures. Additionally, enclosures are used to protect sensitive electronics from environmental contaminants like dust and metal shavings, which could impair their function.
- Human-Machine Interface (HMI): The Human-Machine Interface (HMI) serves as the critical point of interaction between the operator and the press brake. Modern HMIs typically feature intuitive touchscreens that facilitate easy navigation and allow operators to input bending parameters swiftly. They display essential diagnostic information and monitor production metrics such as bend angles and cycle times. The ability to store and retrieve preprogrammed part sequences not only reduces errors but also decreases setup times significantly. Additionally, some HMIs incorporate advanced functionalities like 2D or 3D bending simulations, which help in visualizing the final product shape and identifying potential collision points before actual production begins. This level of interaction ensures that operators can achieve high productivity levels while maintaining precise control over the bending process.
- Custom Tooling: Custom tooling is developed to meet specific project requirements, especially when standard tools cannot accommodate the unique shapes or precision needed. This adaptability is crucial for specialized applications in industries requiring high precision, such as aerospace and automotive sectors.
- Front Support Arms: Front support arms are essential for handling large or heavy sheets of metal during the bending process. These arms, which can be adjusted along rails on the bed for various part sizes or shapes, help stabilize the material, preventing sagging or shifting that could affect the bend’s accuracy. They are equipped with features like adjustable stops or rollers that aid in smoothly feeding the workpiece into the machine. By supporting the material effectively, these arms enhance the precision of bends, improve safety for operators, and minimize the risk of damage to the workpiece or machine.
- Crane Arm: The crane arm, also known as a swing arm or pendant arm, plays a crucial role in the ergonomics and functionality of press brakes. It is typically used to mount a control panel or small control box, which pivots freely to allow operators to move the interface closer during setup or while performing bend checks. This flexibility not only enhances accessibility but also supports the weight of the panel without compromising stability. By allowing adjustments to be made with minimal effort, the crane arm significantly reduces operator fatigue and facilitates quicker reprogramming or adjustments, thus streamlining the workflow.
- Foot Pedal: The foot pedal is a key ergonomic feature in press brakes that enables hands-free operation of the bending cycles. This allows operators to concentrate more effectively on material handling and alignment. The pedal may feature multiple stages—light pressure activates a slow approach, while full pressure initiates the bending stroke. Many systems also integrate emergency stops within the pedal design, providing operators with the ability to quickly react to unsafe conditions. The option for wireless or tethered foot pedals helps minimize the presence of cables on the shop floor, thereby enhancing safety and organizational efficiency.
- Linear Scale: Linear scales are essential for maintaining precision in press brakes. They are responsible for measuring the position of the ram or back gauge in real-time, which is crucial for providing feedback to the CNC or control system. Often installed on both sides of the press brake, these scales ensure there is no tilt or uneven movement that could impact the bending process. High-precision linear scales, which can achieve accuracies within microns, are vital for maintaining consistent bend angles over multiple cycles. They play a critical role in automatically correcting any variations in part dimensions or minor deflections during the process, ensuring uniformity and consistency in the final products.
Adange
- High dynamic for higher productivity of the machine.
- Compliance with EU Directives.
- Lower energy for a green Machine.
- Energy efficiency of up to 35 % compared to conventional systems.
- Operating cost is min due to low energy consumption. Thus, it gives advantages to the user with high efficiency & low operation cost.
The machine working video: https://www.youtube.com/watch?v=ANXpBnVXfgU&t=33s