e for electronic Press Brakes

Transcription

1 E-Brake T E-Brake T H-Brake B-Shear & M-Shear e for electronic Press Brakes Safan B.V., Kwinkweerd 11, NL-7241 CW Lochem, P.O. Box 96, NL-7240 AB Lochem Tel.: +31 (0) , Fax: +31 (0) , info@safan.nl, Website: E1005.E

2 The E-volution in sheet metal working A head start with the SAFAN E-Brake Since the introduction of the first servomechatronic press brake the SAFAN SMK developments at SAFAN have continued. The patented drive system has been optimized, the electronics refined and the range of applications considerably expanded. The extensive work on the further development of the SMK has now resulted in the first all electronic Because the SAFAN E-Brake electronic press brake has been developed as an integral new concept, it combines a whole range of unique advantages compared to the conventional hydraulic press brake. The SAFAN E-Brake sets new standards in terms of ergonomics, efficiency, economy and ecology. Its proven reliability and optimum performance have been demonstrated by means of extensive testing under the severest and most demanding circumstances. press brake: the SAFAN E-Brake. With capacities up to 0 T and a 4100 mm working length, the SAFAN E-Brake is the advanced alternative to the conventional hydraulic press brake. The SAFAN E-Brake signals the start of the irreversible electronic evolution in sheet metal working. Because, to put it in one word, the advantages are: E-normous! Which is good news for you as a manufacturer of sheet-metal products, particularly in staying ahead of the competition. The SAFAN E-Brake concept is built around the completely new servo-electronic drive based on the pulley principle. It results in a very even distribution of forces, such that in 98% of cases no crowning table is required. Similarly, an entirely new generation of electronics and software makes operation and control extremely fast, easy and precise. The SAFAN E-Brake also incorporates further advances in ergonomics, including the user-friendly Touch Screen control. Cycle times are shorter, the working range has been increased, the possibility of mistakes reduced, in brief, a vast improvement in productivity. 4 2 "Survival of the fittest" requires that you maintain your technological edge - and preferably increase it. After all, standing still means losing ground. The SAFAN electronic evolution helps you make a great leap forward. The SAFAN E-Brake combines all of the above with a pleasantly low noise level, an energy consumption that is reduced by up to 50%, an integrated safety system and a high degree of environmental responsibility. 3 5

3 E for even bending E for efficiency With the SAFAN E-Brake you obtain the most Increased performance in less time. No The electronic control has been developed by dimension) of 690 mm. The SAFAN E-Brake accurate and constant bending angle along the full range problem at all with the electronic efficiency of the SAFAN itself and uses a new generation of increases efficiency even further through a of the machine, without the need for crowning. The unique SAFAN E-Brake press brake. The mechatronic electronics and software. This results in unique and innovative backgauge system. patented pulley drive in the top beam produces a very even drive in the top beam alone, already saves a lot of very short response and delay times, The system can be put to optimum use and immediate distribution of forces. time because it requires far fewer settings. yielding bending speeds of up to mm/sec. across the entire range of the machine and The effectiveness and precision of the is very accurate thanks to an electronic A balanced combination of powerful electric servo motors, fixed and moving pulleys, and technology that SAFAN are able to offer a 5 year warranty on the mechanical drive system, when SAFAN E-Brake are increased even further by its digital drive incorporating a closed- control system (± 0.02 mm). The system is modular in both its construction and in its Main drive system with 2 servo motors specially developed belts make it possible to combined with an annual service contract loop system and vector control technology. options. The backgauge is very distinctive handle over 0 tonnes. The flexible belts, The cycle times are also much shorter than because the beam extends across the full which are only 3 mm thick and 50 mm The special construction of the SAFAN E-Brake for conventional press brakes, partly due to width of the machine. (resp. 100 mm) wide, are reinforced with also contributes to the even absorption of large the fast backgauge. steel wires and coated with hard forces. The O-frame acts as a single unit and Special hinged backgauge pins are standard, polyurethane. This advanced technology has deformation is kept to an absolute minimum. Smaller bending work is no problem either, allowing a maximum sheet size of a 1000 been extensively tested in the demanding It is more stable, stronger and produces less thanks to the narrow construction of the top mm and the R-axis is adjustable from the elevator industry. So reliable is the deformation than a conventional C-frame. and lower beams. The working range is front of the machine using a handwheel. Backgauge with X-, Z1+Z2-, R- and Delta X-axes. extremely large with a maximum top beam stroke of 290 mm and a Qmax (daylight The backgauge has a very high positioning speed of 350 mm/sec. Standard backgauge The new SAFAN E-Brake is further optimised to take maximum advantage of the high acceleration and other favourable servo-motor characteristics. For this reason, our E-Brake is not only very fast in the rapid approach stage, but also throughout the entire cycle. We demonstrate this by manufacturing a specimen product (see illustration on right) on an E-Brake. As a comparison the product was also produced on a conventional press brake. SAFAN E-Brake: sec 4 4 E-Brake Conventional Conventional: 28 sec 5 5

4 Capacity with the E of enormous SAFAN E-Brake 150 T-3100 and 0 T-4100 The success of the SAFAN E-Brake with a pressing force up to and including 100 tons has received a logical follow-up: the extension of the SAFAN E-brake into the segment involving greater pressure forces and longer working lengths. The new 150 and 0 ton models now make it possible to profit from the unique advantages of the innovative E-Brake technology when bending heavy and long products. Proven technology constitutes a further improvement on this SAFAN s servo-electronic technology has technology, one that is resulting in groundbreaking performances. Customers are been proving itself all over the world since The SAFAN E-Brake concept therefore full of praise, especially about the much shorter cycle times, more advantageous use of energy and substantially lower costs for maintenance in comparison with traditional hydraulic press brakes. Based on this extensive practical experience, SAFAN has effectively adapted the technology and construction to the segment involving weights up to 0 tons and work lengths up to 4 metres. In addition, a strong point of the construction is the level foundation. Heavy-duty back gauge with full range of operation The SAFAN E-Brake and the SAFAN E-Brake are both equipped with a heavy-duty sized CNC-controlled backgauge system that is equipped with two ball screws and play free ballscrew linear guides. Even in this regard, the SAFAN E-Brake concept offers a unique advantage: the backgauge can be used over the entire working length of the machine. The standard backgauge is equipped with a CNC controlled X axis and two backgauge fingers that can be manually moved along the bending line (Z axes) as well as adjusted in height (R axis). The fingers are provided with interchangeable stops. The backgauge system can be optionally fitted with CNC controlled R and Z axes and a dx axis. It is also possible to fit a fully 3D backgauge with X1, X2, Z1, Z2, R1 and R2 axes. Rollenaandrijving d.m.v. 2 servomotoren. Various interchangeable backauge stops

5 E for ergonomic Options for graphic programming Electronic operation and control by means of a Options for graphical programming and representation Touch Screen is a typical SAFAN innovation. With its Touch Screens, SAFAN has set a new standard for By extending the Touch Screen control with bending simulation software and a keyboard, press brake controls. SAFAN now offers advanced graphic applications that further boost efficiency. The optional TS2 and TS3 controls use Delem software, but can also be connected to external The SAFAN TS1 control is the most simple unlimited possibilities. The instructions from packages such as SomaBEND (Radan). and effective Man/Machine Interface available at present; and a shining example the SAFAN TS control are sent to a central processor, which in turn activates the Moveable and adjustable support arms of the electronic evolution in sheet metal various axes by means of a so-called SAFAN TS1 in Run mode. working. The control is PC based and runs under Microsoft Windows. An intelligent feature of the SAFAN TS control is that it only displays those buttons that are required at the particular stage of operation. The system is so simple that it makes bending sheet metal almost literally child s play. The adjustable height of the control unit ensures optimum ergonomics for any operator, whether short or tall. A standard accessory is a 100 MB Ethernet UTP network connection that opens up CAN-BUS (Control Area Network). The advantage of this system is that the electronics are of a modular construction, requiring fewer components. This means a high degree of flexibility and compatibility, as well as great reliability. The system can be programmed very quickly and accurately thanks, among other things, to a "self-learning" database of materials, tools and previous (corrected) bendings. The standard SAFAN TS1 control uses a numerical bending-parameter entry and representation. Summary of SAFAN press brake controls TS1 TS2 TS3 Control type Description Features/representation Off-line control by TS1 SAFAN CNC Numeral product entry, - SAFAN TS software press brake control by means of Touch Screen - Delem Profile - numerical bending parameter - Delem VBend presentation - External software - symbols for sheet handling - SomaBEND (Radan) TS2 As TS1, but with As TS1 but also with: - SAFAN TS software graphical representation - graphical representation of - Delem Profile of the bending sequence 2D and 3D products - Delem VBend - External software - SomaBEND (Radan) TS3 As TS2, but with As TS2, but also with: - SAFAN TS software graphical programming - graphical product entry and - Delem Profile and representation of the representation by means of an - Delem VBend bending sequence additional keyboard - External software - SomaBEND (Radan) SAFAN has developed a range of support arms of modular construction for both light and heavy-duty sheet-metal work. This makes it possible to rapidly set up the correct solution for each application. An optimum combination of ergonomics and efficiency: moveable across the machine width fitted with brushes or hardened strip adjustable height fitted with (fine adjustment) front stops programmable height suitable for use with safety light screen. 4 8 SAFAN TS3 control 9 5

6 Bending with the E of E-Mate Servo-mechatronic bending aid... and the efficiency of SAFAN E-Bend angle measurement With the electrically-driven E-Mate from SAFAN, you prevent angle deviation when bending thin sheets with large dimensions. The bending aid provides the operator with a simple and ergonomic means to remain within set angle tolerances. It is often not easy for an operator to install a SAFAN bending aid. In most cases, position large sheets. Certainly during the it can be used by a single man to position return movement of the top beam, it is larger products. In brief, along with difficult work to keep everything in hand. accuracy, productivity is increased by the Instead of having a second operator provide SAFAN E-Mate, the best partner for your assistance, it is frequently more efficient to operator. In order to relieve the operator in the case of long, routine, heavy duty work, SAFAN has developed an extremely powerful and highly accurate bending aid. The bending aid supports and follows the sheet with great accuracy throughout the entire bending process. Quick, easy and reliable angle measurement can be essential to your bending process. The SAFAN E-volution also allows you to take the lead in this regard. Two SAFAN E-Bend systems, electronically linked to the SAFAN Touch-Screen control, increase your efficiency by enabling exact angle measurement and constant monitoring of angles Programming SAFAN E-Mate SAFAN E-Mate SAFAN E-Mate plus SAFAN E-Bend L The E-Bend L system is an angle management system that uses two laser sensors to make measurements. The two sensors are equipped with fastening magnets and are placed in pairs on the front and back of the standard bottom tool. During bending, the sensors project a laser beam on the sheet and measure the value of the angle in relation to the bending tool in use. The SAFAN E-Bend L enables the operator to keep the bent angle constant and to do so independently of differences in sheet thickness and rolling direction. SAFAN E-Bend M The E-Bend M system can be used as an angle management system and an angle measurement system. The SAFAN E-Bend M consists of two pneumatic sensors on a rail that can be programmed for any arbitrary position. Both sensors are in contact with the sheet during the bending cycle. Before the final angle is bent, the spring back of the sheet is measured. This measurement is used to make a correction, after which the definitive angle is bent. The measured values can be adopted for bending procedures in which the geometry of the product makes angle measurement impossible.

7 Automation as expertise system operates on the Windows platform and uses it to create a legion of possibilities Labour is expensive, especially in Western Europe. for links, networks, software packages and, In the e-volution to a stronger competitive position, via the internet, remedies for any stagnation E for ecological and economical automation is the answer. SAFAN is one of the pioneers in this field, working together with partners in the areas of in the unmanned production process. robotics and software. SAFAN installed the first robotic SAFAN supplies complete, fully tested press brake in Europe as early as programmes for both new and existing robot Electronic evolution of the SAFAN E-Brake helps you to run your business much more economically, while maintaining environmental awareness for the future. The absence of hydraulics means that the Integrated safety Automated Production Solutions from SAFAN (APS) Since then, SAFAN has become an cells. Of course, you can entirely outsource the programming to SAFAN. From advice and consultancy to turn-key APS problems associated with environmentally experienced specialist in the field of harmful and risky oil are now things of the Working at lightning speed without risk: automated bending cells. With Automated SAFAN makes the automation of sheet- past. Furthermore, your SAFAN E-Brake SAFAN makes this possible with an active Product Solutions (APS), SAFAN gives metal working simpler than you think. This uses much less energy, namely only when safety system integrated in the control. this e-volution new impulse. SAFAN offers already begins with the convenience of the beam actually moves. This can result It uses a safety light guard that is integrated solutions for your production one contact person for the entire project. in energy savings of 50% compared to automatically controlled from the Touch process that go further than stand-alone Our APS consultants give you clear advice conventional hydraulic press brakes. Screen. solutions can. Not only the robotised on the complete range of possibilities, so In addition, the SAFAN E-Brake has another loading, operation and unloading of the that you can make the best choice for your There is also no need to adjust the settings built-in safety provision. The application of a bending cell but the entire routing of the production process. of pressure relief valves with the inherent spring-return system means that in the case sheet-metal material through your machine risk of mistakes and drift nor are there of an accident the top beam will always park can be automated. SAFAN develops and realises turn-key filters to be checked and replaced. The move upward. solutions for bending and cutting systems absence of oil, tanks, pumps, seals, valves With SAFAN s APS, you remain flexible with with guaranteed cycle times. This allows and filters means that the servo-electronic a view to new products or changes in your you to determine your costs per product. system is much more reliable than an production process. You are also flexible Based on these fixed costs, the time needed Side view hydraulic one. And you will never again have to face the inconvenience of a cold start. in linking with external systems and in the choice of your robotics. The SAFAN E-Brake to recover investment can be accurately established. With the aid of a simulation and SAFAN H-Brake are particularly well model, you are given in advance a reliable suited to serve as the focal point of each indication of the return on investment to be automated bending cell. SAFAN s control expected Intergrated safety light guard 13 5

8 SAFAN E-Brake tool adapters Technical specifications SAFAN E-Brake SAFAN E-Brake T Kilo Watt SAFAN E-Brake energy consumption On the SAFAN E-Brake, the main drive motor is used only when the E-Brake has to actually perform a movement. With a conventional hydraulic press brake, the hydraulic pump motor is running all the time. The graph below only covers the time 4 14 kn while the press brake is actually in operation. During the standby time - which can be as much as 90% on account of sheet handling, conversion and intervals - this will mean a further saving with the E-Brake up to 3000 kwh a year. E-Brake Conventional NSCL-basic NSCL-I+ NSCL-II SAFAN American European Segmented European Q = 415 mm Stroke = 115 mm Q = 515 mm Stroke = 215 mm Q = 590 mm Stroke = 290 mm Q = 650 mm Stroke = 290 mm Q = 690 mm Stroke = 290 mm STANDARD OB-3 OB/S-3 European OB/EUR-1 DD006 DD006 incl. ty 150-0T T HS = High Speed Pressure force in kn. Maximum stroke in mm. Closing speed in mm/sec. Bending speed max. in mm/sec. Return speed in mm/sec /215/ HS /215/ HS /215/ HS /215/ HS Motor Power in kw. Weight in kg. A in mm. B in mm. C in mm. (Q=415/ 515/590 mm.) C in mm. (Q=650/690 mm.) /215/ /215/ Pressure force in kn. Maximum stroke in mm. Closing speed in mm/sec. Bending speed max. in mm/sec. Return speed in mm/sec Motor Power in kw. Weight in kg. A in mm. B in mm. C in mm. (Q=590 mm.) C in mm. (Q=690 mm.) Subject to modifications E-003 SAFAN E-Brake T