Press Brake Operation Manual (Training PDF)

Attention all mechanics and engineering enthusiasts! Have you ever wondered about the ins and outs of operating a press brake machine? In this blog post, we’ll dive into the world of press brakes, exploring their functions, safety considerations, and maintenance tips. Drawing from the expertise of seasoned professionals in the field, we’ll provide you with valuable insights to enhance your understanding and proficiency in using these powerful machines. Get ready to level up your press brake game!

Table Of Contents

Introduction to the Press Brake Operation Manual

We strongly recommend that all users and operators read this press brake operation manual thoroughly before using the press brake machine. This manual is intended for specialized and qualified personnel and comes with diagrams and all the necessary documentation to lift, move, and place the machine, as well as instructions for safe use and maintenance.

Available Control Systems

You can scroll directly to the bottom of the page to download the PDF version of the operation manual for the following press brake control systems:

  • Estun: E21, E200P, E200+
  • CybTouch: 8, 12
  • Esa: S630
  • Delem: DA41, DA52S, DA53T, DA58T, DA66T, DA69T

Important Information

Please note that all information contained in this manual is accurate at the time of printing. However, our company reserves the right to modify and improve specifications without prior notice.

Installation and Maintenance

To ensure proper performance, it is important to install the press brake as instructed and to conduct regular inspections and maintenance services. Any incorrect or irresponsible usage can result in irreparable damage to the machine and compromise the safety of the operator.

Liability Disclaimer

We are not responsible for any improper services, modifications, or connections made by unauthorized personnel.

By following the guidelines and recommendations outlined in this manual, you can ensure the safe and efficient operation of your press brake machine.

Further Reading:

Press Brake Functions and Range of Work

1.1 High-Efficiency and High-Precision Bending

The press brake is designed to deliver high efficiency and precision in bending metal sheets. The opening size of the V-groove on the lower dies is typically 8 times the thickness of the sheet, and it should be adjusted accordingly for sheets of varying thickness. Different types of upper and lower dies can be used to bend a variety of workpieces, as illustrated in Fig. 1.

bend a variety of workpieces
Figure 1

1.2 Structural Integrity and Safety Features

The press brake is constructed from steel plate fabrication, providing sufficient strength and rigidity. The hydraulic drive system of the machine prevents serious overload operation accidents that may occur due to changes in sheet thickness or incorrect selection of the lower die cavity. This machine also offers stable performance, ease of operation, and reliable safety.

To ensure high precision, the connection to the upper die is equipped with a compensation device. This device compensates for deflection of the worktable and slider during bending. Additionally, the mechanical block is equipped with an oil cylinder to ensure accurate fixing when the slider reaches the bottom dead point, maintaining consistency in bulk production.

1.3 Hydraulic and Electric Control

The press brake is equipped with both hydraulic and electric control systems, allowing the slider’s travel to be freely adjusted. This feature makes it convenient for trial and adjustment with an inch operating criterion.

1.4 Technological Advancements and Performance

This press brake is technologically advanced and boasts dependable performance, making it one of the ideal shaping devices. It is widely used in industries such as aviation, automobile, shipbuilding, and machinery due to its high production efficiency.

1.5 Operating Conditions

  • Temperature: The working temperature range for the press brake is 5~38℃.
  • Environment Moisture: The relative moisture should be between 20~80% RH.
  • Vibration and Interference: The machine should be kept far away from powerful vibrations and electromagnetic interference.
  • Environmental Conditions: The operating environment should be free from pernicious and corrosive gases, and dust.

Installation of press brake

Lifting

When lifting the press brake for transportation or positioning, it is crucial to use a crane with sufficient lifting capacity to prevent the risk of the press brake falling. Follow these guidelines to ensure safe lifting:

  • Use Two Steel Rope Slings and Shackles: Utilize the appropriate lifting holes located at the top of the machine.
  • Adequate Steel Rope: Ensure the steel rope is of adequate size to lift the weight of the press brake. The length of the rope should be sufficient, as its weight-carrying capacity decreases when the angle between the ropes widens (refer to Fig. 2).
Press Brake Operation Manual

Fig.2

Transport

When transporting the press brake, consider the following:

  • Weight Distribution: The majority of the press brake’s weight is concentrated in the front. Ensure the top ram is fully lowered during movement or transportation.
  • Loading onto a Truck: Position the rear of the machine as close as possible to the side of the vehicle. Secure the press brake to the truck using steel ropes to prevent any movement during transit.

Installation

Foundation of Press Brake:

To ensure the proper operation and stability of the press brake, the surface it will be placed on must be firm and stable. Follow these steps:

  • Concrete Foundation: If necessary, prepare a concrete foundation suitable for the specific ground conditions. Refer to the detailed foundation drawing provided below.

Technical Specifications:

  • Space Requirements: Ensure there is adequate space around the machine for maintenance work and special tasks. There should be sufficient space on either the left or right side of the press brake, equal to the length of the machine, to facilitate tool changing operations.
  • Rust Guard Removal: All exposed surfaces of the machine are coated with rust guard, which can be easily removed with kerosene or solvent.

Leveling

Proper leveling of the press brake is essential for its correct operation. Follow these steps to ensure the machine is level:

  • Horizontal Leveling: Place a spirit level on the machine table to check horizontal leveling.
  • Vertical Leveling: Place the spirit level on the machine table again to check vertical leveling.
  • Adjustments: Make any necessary adjustments by adjusting the leveling bolts located in the feet of the press brake.

Electrical Diagram and Operation Instructions for Press Brake

Electrical Connection and Initial Setup

  1. Check Machine Nameplate and Wiring:
    • Verify the nameplate details of the press brake.
    • Ensure all wiring is intact and in good condition.
  2. Power Connection:
    • Connect the press brake to the facility’s power source.
    • If the facility’s power does not meet the machine’s requirements, contact your electrical supplier.
  3. Safety Measures:
    • Ensure the incoming power is fused to allow full disconnection for repairs.
    • Connect the incoming power to the RST clamps in the control cabinet.
  4. Electrical Drawings:
    • Refer to the attached electrical diagrams for specific controller configurations.

Here are the drawings:

Operating the Press Brake Machine

Initial Power-Up

  1. Power Connection:
    • Connect the three-phase power lines to the inlet terminals in the electric box.
    • Plug in the foot switch socket located under the box.
    • Close the power switch QF and the door of the electric box.
    • The lighting of lamp HL1 indicates the machine is powered on.
  2. Motor Direction Check:
    • Start the oil pump motor using button HL2 on the operation panel.
    • Observe the motor’s direction; if incorrect, change the phase of the inlet lines (do not alter internal lines).
    • Restart the oil pump motor.

Jog Mode Operation

  1. Jog Mode Activation:
    • After a few minutes of normal operation, turn SA2 to jog mode.
    • Step on the foot switch “up”; the ram will rise and stop when the switch is released.
    • To raise the ram further, continue stepping on the foot switch until it reaches limit switch SQ1 and stops.
    • To lower the ram, step “down”; the ram will drop quickly, then slowly due to limit switch SQ2, adding pressure.
    • Release the foot switch to stop the ram.

Single Travel Mode

  1. Single Travel Mode Activation:
    • Turn SA2 to “single time”.
    • Step on the “down” foot switch; the ram will descend quickly, then slowly with pressure, and finally rise to the upper limit switch SQ1.
    • Adjust the working time of time relay KT1 to meet bending pressure requirements.
    • Adjust the pressure-keeping time of time relay KT2.

Continuity Mode

  1. Continuity Mode Activation:
    • Turn SA2 to “continuity”.
    • Step on the foot switch to repeat the single travel mode.
    • Adjust the circulation waiting time using time relay KT1.

Safety Note

  • The above steps should be performed by specialized personnel.
  • For safety, press brake machines with CE certification do not have a continuity mode.

The Hydraulic System of a Press Brake

Clean the Hydraulic Oil

Maintaining the cleanliness of the hydraulic oil is essential for ensuring the optimal performance and longevity of the hydraulic system in a press brake. Here’s a detailed guide on how to clean the hydraulic oil and the oil tank:

  1. Preparation:
    • Before starting, ensure the press brake is turned off and the hydraulic system is depressurized.
    • Gather necessary cleaning materials: clean towels (avoid using cotton as it can leave fibers), cleaning gasoline, and tools like a stick or bamboo wrapped with a towel for hard-to-reach areas.
  2. Removing the Oil:
    • Remove the cover of the oil tank carefully.
    • Loosen the leaking plug or brake valve to drain the dirty oil completely from the system.
  3. Cleaning the Tank:
    • Wipe the bottom and sides of the tank with a clean towel.
    • Use cleaning gasoline to wash the tank thoroughly.
    • For corners and hard-to-reach areas, wrap a towel around a stick or bamboo and wipe these areas meticulously.
    • If there is dirt accumulated at the welding seams or other difficult spots, use a tool like a rolling pin to clean these areas.
  4. Drying the Tank:
    • Ensure the tank is completely dry by wiping it with a clean towel.
    • Replace the cover of the tank once it is clean and dry.

Choose the Hydraulic Oil

Selecting the appropriate hydraulic oil is crucial for the efficient operation of the press brake. Consider the following guidelines:

  1. Viscosity:
    • The mark value of hydraulic oil indicates its average viscosity at 40°C.
    • For higher working pressures and temperatures, and slower working speeds, choose a higher grade hydraulic oil.
  2. Recommended Oil:
    • ISO VG46: This antiwear hydraulic oil has an average viscosity of 46 mm²/s at 40°C and is suitable for most operating conditions.
    • ISO VG32: Use this oil if the machine operates at temperatures below 5°C for extended periods.
  3. Temperature Considerations:
    • Avoid operating the machine at very low temperatures (below -5°C). If necessary, allow the machine to idle to warm up the oil.
    • An oil heater can be added to the circuit for extremely low temperatures.
    • Under normal conditions, the oil temperature should not exceed 70°C. Install an oil cooler if required for special conditions.

Fill the Oil

Properly filling the hydraulic oil is essential to maintain the system’s performance:

  1. Cleanliness:
    • Ensure the oil used is clean.
    • Tighten the nut of the air filter and fill the oil through the filter.
    • If using filling equipment with a filter, you can open the cover of the oil tank and fill it directly.
  2. Oil Level:
    • Observe the oil gauge. When the ram stops at the Top Dead Spot, the hydraulic oil should fill about 80% to 90% of the tank’s inner space.
  3. Removing Air Bubbles:
    • Make the machine work by idling first and then at the maximum stroke to remove any air bubbles in the hydraulic circuit.

Hydraulic Diagram

For a comprehensive understanding of the hydraulic system, refer to the provided hydraulic diagram. This diagram will help in external system analysis and troubleshooting.

Standard Control Equipment

5.1Start buttonTo start the main motor running and Control circuit.
5.2Stop buttonTo stop the main motor running and Control circuit.
5.3Auto/Manual Mode Selector SwitchSelect the working mode
In the Auto mode-The ram will rise automatically when Preset pressure is reached and the dwell time is up.
In the Manual mode-Lowering and rising of the ram is by pressing the foot pedal.
5.4Foot pedalPush and hold to command lowering the ram to reach bending point, release when the ram is moving up in AUTO mode.
Press to command lowering the ram and press to command raising the ram in Manual mode.

Starting the Press Brake Machine

Pre-Start Checks

Before starting the press brake machine, it is crucial to perform several checks to ensure safe and efficient operation:

  1. Clean and Grease Guideways: Ensure that the guideways are free from debris and properly lubricated to facilitate smooth movement.
  2. Inspect Hydraulic System: Check for any leaks in the hydraulic system. Leaks can lead to inefficiencies and potential hazards.
  3. Check Oil Level: Verify the oil level on the level gauge located at the side of the tank. This should be done with the top ram in the fully raised position. If necessary, top up the oil to the required level.
  4. Motor Rotation Direction: Observe the direction of the cooling fan to ensure the motor is rotating correctly. The fan should rotate clockwise, or in the direction indicated by the arrow. If the rotation is incorrect, switch two wires in the supply line. Ensure the motor runs by inching while making this adjustment.

Turning the Machine On

  1. Main Switch: Turn on the main switch to power the machine.
  2. Selector Switch: Switch the selector to the “Auto” mode.
  3. Main Motor: Press the green button to start the main motor.

Turning the Machine Off

When the press brake is not in use for a few hours, it should be turned off to conserve energy and maintain safety:

  1. Select Manual Mode: Switch the machine to manual mode.
  2. Descend the Ram: Press the down pedal to lower the ram, bringing the top tool as close to the V-die as possible.
  3. Stop Button: Press the stop button to halt the machine.
  4. Main Switch: Turn off the main switch to completely power down the machine.

Upper and Lower Tool Setting

(Check out the drawings of press brake toolings)

Proper alignment of the upper and lower tools is essential for accurate bending operations:

  1. Tooling Drawings: Refer to the drawings of the press brake toolings for guidance.
  2. Clean Surfaces: Ensure that the V-die base and table surfaces are clean to avoid any misalignment or damage.
  3. Lower System Pressure: Turn the pressure-regulating knob counterclockwise to lower the system pressure.
  4. Set Mechanical Depth Stop: Adjust the mechanical depth stop to the lowest position, either manually or electrically.
  5. Manual Mode: Select the manual mode and press the down pedal to lower the ram until the top tool is as close to the V-die as possible.
  6. Align Tools: Adjust the V-die tightening bolts to align the upper and lower tools accurately.
  7. Tighten Bolts: Once alignment is correct, securely tighten all the V-die tightening bolts.
  8. Raise the Ram: Press the UP pedal to raise the ram.

Additional Recommendations

  • Regular Bolt Checks: Regularly check the fixing bolts of the tool clamp to ensure they are secure.
  • Tool Storage: Store the tools on a rack near the press brake to prevent damage to the top tool.
  • Tool Capacity: Be aware of the maximum capacity force for each tool to avoid overloading and potential damage.

Tools Change Procedure for Press Brake

Top Tool Change Procedure

  1. Switch to Manual Mode: Turn the mode selector to manual.
  2. Lower the Ram: Lower the ram as near to the V-die as possible.
  3. Power Off: Turn the machine off.
  4. Loosen Tool Clamp: Loosen all the fixing bolts of the tool clamp.
  5. Remove the Tool: Remove the top tool from the side of the machine.
  6. Mount New Tool: Slide the new top tool in from the same side.
  7. Tighten Tool Clamp: Tighten all the fixing bolts of the tool clamp.
  8. Power On: Turn the machine on and ensure the mode selector is on manual.
  9. Seat the Top Tool: Lower the ram to seat the top tool in the V-die while reducing the system pressure by turning the pressure-regulating knob counterclockwise to prevent damage to the tool.
Press Brake Operation Manual

Lower Tool Change Procedure

  1. Unscrew Tightening Bolts: Unscrew all the tightening bolts to free the V-die.
  2. Switch to Manual Mode: Change the mode selector to manual.
  3. Power On: Turn on the machine.
  4. Lower the Ram: Lower the ram as close to the V-die as possible.
  5. Hook the V-die: Hook the V-die onto the ram at both ends using the appropriate chains.
  6. Raise the Ram: Raise the ram by stepping on the UP pedal to a height where the V-die can turn.
  7. Turn the V-die: Turn the desired V-die to face up.
  8. Lower the Ram: Lower the ram by stepping on the DOWN pedal so that the die rests on the machine table and the chains can be unhooked.
  9. Center the V-die: Center the V-die with respect to the top tool.
  10. Lock the V-die: Lock the V-die in place by tightening the bolts.

Front Support Arm Adjustment

The press brake comes standard with two front support arms. These support arms are used to hold the plate in place during the bending process. They can be adjusted vertically and along the length of the press brake. The support arms usually need to be adjusted when using a different size bottom tool or bending a larger or smaller size plate.

Press Brake Operation Manual

Safety Precautions

DANGEROUS!

  • If the punch and die are not placed correctly, do not start the machine at any time.
  • Do not insert your hands or any part of your body into the space between the punch and die as it is extremely dangerous.

Mechanical Depth Stop Setting

When working with a press brake, it is crucial to handle the mechanical depth stop setting with care to avoid any potential damage to the machine. Here are some key points to consider:

  1. Avoid Adjustments with Ram Down: Never attempt to adjust the mechanical depth stop setting when the ram is in the down position. Doing so can cause unnecessary damage to the machine due to the pressure and positioning of the components.
  2. Determines Bending Angle: The depth setting is essential as it determines the bending angle of the sheet metal. Accurate depth settings ensure precise bends and high-quality finished products.
  3. Manual or Electrical Settings: The mechanical depth stop can be adjusted either manually or electrically, depending on the design and capabilities of the press brake. Manual adjustments typically involve physical manipulation of the stop, while electrical adjustments may be controlled via a user interface or control panel.

Pressure Setting

The pressure setting on a press brake is vital for achieving the desired bend without damaging the material or the machine. Here are the factors and considerations for setting the bending pressure:

  1. Bending Chart: Typically, a bending chart is fixed on the side of the machine, and a copy is often enclosed with the machine documentation. This chart provides essential information for setting the correct bending force.
  2. Factors Affecting Bending Force:
    • Plate Thickness: The thickness of the plate directly influences the required bending force.
    • Width of Die Opening: The width of the die opening, often calculated as 8 times the plate thickness, also affects the bending force.
  3. Calculating Bending Force: The required bending force can be calculated using a formula provided in Table 1. This formula and the values in the table are based on carbon-steel plates with a tensile strength of Qb=450KN.
    • For stainless steel plates, multiply the P value from the table by 2.
    • For aluminum plates, multiply the P value from the table by 0.7.
  4. Tonnage Calculator: For more precise calculations, you can use a specially designed tonnage calculator for press brakes. This tool helps in determining the exact force required based on the material and bending parameters.
press brake bending chart

> Press Brake Tonnage Calculator

Parallelism Control and Setting for Press Brake Ram

Ensuring the parallelism of the ram in a press brake is crucial for achieving precise and consistent bends in sheet metal. The parallelism is typically controlled by a solid anti-torsion bar linked to both side oil cylinders. Here is a detailed guide on how to control and set the parallelism of the ram:

Factory Calibration

The top ram of the press brake is calibrated parallel to the V-die at the factory. However, over time and with usage, re-calibration may become necessary to maintain accuracy.

Steps for Re-Calibration

  1. Locate the Torsion Bar Linkage:
    • Find the torsion bar linkage connected to the top ram on the rear (left side) of the machine.
  2. Loosen the Screw:
    • Identify the screw (M8/M10) on the torsion bar.
    • Loosen this screw to allow for adjustment.
  3. Adjust the Torsion Bar:
    • Use the appropriate spanners to turn the outer flat piece by 15° to 30°.
    • You can turn it either clockwise or anti-clockwise, which will rotate the eccentric pin inside.
  4. Tighten the Screw:
    • After making the adjustment, tighten the screw (M8/M10) securely.
  5. Check Parallelism:
    • Perform a test bend to check the parallelism of the top ram.
    • If the ram is still not parallel, repeat the adjustment process.
  6. Repeat if Necessary:
    • Continue the procedure until the desired accuracy is achieved.

Tips for Accurate Adjustment

  • Use Precision Tools: Ensure you are using calibrated tools for measurement and adjustment to maintain high precision.
  • Perform Multiple Test Bends: It may take several test bends to achieve perfect parallelism. Be patient and make small adjustments.
  • Document Adjustments: Keep a record of the adjustments made for future reference and maintenance.

Press Brake Troubleshooting

Press Brake Machine Cannot Start

  1. Check Incoming Power Supply: Ensure that the machine is receiving the correct voltage and current as specified by the manufacturer. Verify that all connections are secure and there are no power supply issues.
  2. Check that Emergency Stop is Released: Confirm that the emergency stop button is not engaged. If it is, release it and reset the machine.
  3. Check for Broken Fuses: Inspect all fuses in the electrical panel for continuity. Replace any blown fuses with ones of the correct rating.
  4. Check Transformer Output: Verify that the transformer is outputting the correct voltage. If the output is incorrect, the transformer may need to be replaced.

Ram Could Not Be Lowered

  1. Check Foot Pedal Cable for Possible Broken Wire: Inspect the foot pedal cable for any signs of damage or broken wires. Replace the cable if any issues are found.
  2. Check the Limit Switch: Ensure that the limit switch is functioning correctly. Test the switch with a multimeter to verify its operation. Replace if faulty.
  3. Check Motor Rotation: Confirm that the motor is rotating in the correct direction. Incorrect motor rotation can prevent the ram from lowering. Adjust the wiring if necessary.
  4. Check the Micro-Switch Inside Foot Pedal: Verify that the micro-switch inside the foot pedal is operational. Test it with a multimeter and replace it if it is not functioning properly.

Bending Angle Not Even on Entire Bend Length

  1. Worn Off Upper Tool or Lower Tool: Inspect the upper and lower tools for wear and tear. Replace any worn tools to ensure consistent bending angles.
  2. Machine Table Surface and the Underside of the V-Die is Dirty: Clean the machine table surface and the underside of the V-die. Dirt and debris can affect the precision of the bend.
  3. Top and Bottom Tools Not Properly Aligned: Check the alignment of the top and bottom tools. Misalignment can cause uneven bending angles. Adjust the tools to ensure they are properly aligned.
FailureReasonsTrouble removal
The system doesn’t work without pressure1. Negative rotation of the motorChange the rotation direction of the motor
2. Main overflow valve blockedClean main overflow valve
3. Electromagnetic valve does not workCheck electric and electromagnetic coils
Ram Slider cannot riseValves jammedClean electromagnetic valves
Slider declines automaticallyValves jammedClean electromagnetic valves
Normal rising and dropping but there’s no force in bendingValves jammedClean electromagnetic valve
Leaking in components, pipe fittings and oil cylinderSealing pieces are aging.Change sealing rings

Maintenance of Press Brake

General Guidelines

  1. Read the Manual: Ensure that anyone operating or maintaining the press brake thoroughly reads and understands the manual. Strict adherence to the instructions is essential for achieving optimal results.
  2. Designated Operator: Assign a designated person to the machine. Operators must have a working knowledge of the machine’s operation and safety protocols.

Bending Force and Load Distribution

  1. Nominal Force: The bending force applied to the workpiece must not exceed the nominal force of the press brake.
  2. Mold Lifespan: To extend the lifespan of the molds, avoid damaging them by improper bending width, especially when bending narrow sheets. Reduce the working pressure appropriately in such cases.
  3. Bending Load: For every 630mm length, the bending load should not exceed 400KN.
  4. Load Centering: Ensure that the sheets being bent are centered on the machine to maintain accuracy. Uneven loading can compromise both the workpieces and the machine.
  5. Side Bending: If a workpiece must be bent on one side only, the load should not exceed one quarter of the nominal force. Perform bending on both sides to balance the load.

Hydraulic System Maintenance

  1. Oil Change Schedule:
    • Change the hydraulic oil after the first month of use.
    • Subsequently, change the oil every 2000 working hours.
  2. Oil Temperature: Maintain the oil temperature between 15-60°C. If the temperature exceeds this range, install a cooler.
  3. Oil Type: Use antiwear hydraulic oil ISO VG46# (average viscosity of 46mm²/s at 40°C). For operations below 5°C, use ISO VG32#.
  4. Oil Level and Quality:
    • Regularly check the oil level in the tank.
    • Use oil that meets the specified characteristics.
    • The mark value of hydraulic oil corresponds to the average viscosity at 40°C.
  5. Oil Filter:
    • Regularly clean the oil filter by rinsing and brushing in a solvent.
    • Replace the oil filter when cleaning is not possible or if it is damaged.
    • Use the same grade of oil filter when replacement is necessary.

Lubrication

  1. Lubrication Points:
    • Regularly check lubrication points.
    • Lubricate with high-quality grease on a weekly basis.
    • For parts exposed to wear without lubrication points, lubricate twice a week.
  2. Lubrication Diagram: Refer to the lubrication diagram for specific details on lubrication points.

Electrical Maintenance

  1. Electrical Terminals:
    • Regularly inspect all connections in the main panel and electrical switches.
    • Tighten screws as necessary.
    • Replace any faulty fuses and signal lights.

Mechanical Parts Inspection

  1. Monthly Checks:
    • Ensure the torsion bar bearing is properly secure.
    • Check that slides are not worn off.
    • Verify that cylinder rods are properly secure.
    • Ensure the top ram is properly secure.

Maintenance Accessories

  1. Availability: Keep maintenance accessories on hand at all times.
  2. Post-Repair Precision: After any heavy repairs, ensure the machine’s precision meets factory standards.

Special Conditions

  1. Low Temperature Operation: Avoid using the machine at very low temperatures (below -5°C). If necessary, let the machine run idle for a while. An oil heater can be installed if needed.
  2. High Temperature Operation: Under normal conditions, the oil temperature should not exceed 70°C. An oil cooler may be required under special conditions.

Recommended Hydraulic Oils

  • FIAT-HTF 46
  • ENERGOL HLP 46
  • ESSO NUTO H46
  • SHELL-TELLUS S46
  • TOTAL-AZOLLA 46

Safety Ensuring and Press Brake Machine Main Construction

Introduction

This section provides guidelines for ensuring the safety of personnel and equipment when operating a press brake machine. While it is tailored to specific requirements, it can also serve as a reference for other machines.

Safety Equipment

To ensure the safety of personnel and equipment, various safety mechanisms have been integrated into the press brake machine. Operators must not alter, remove, or disable any safety equipment.

Light Beam/Laser Beam

The machine can be equipped with a light beam or laser beam, depending on customer requirements. These beams form a light curtain that, when interfered with, activates the safety module. This prevents the ram from moving downwards, thereby protecting the operator from potential injury.

Safety Grid

A safety grid is installed at the side and back of the machine to keep operators away from hazardous areas. This grid is connected to the electrical system via a safety switch. When the safety grid is opened, the electrical system is activated, rendering the machine inoperable.

Emergency Stop

Emergency stop buttons are strategically located at the handle control station and the hanging control station. In the event of an operational error or any other accident, pressing the emergency stop button will immediately halt all machine actions.

Hydraulic System

The hydraulic system is a critical component of the press brake machine. The falling of the ram poses a significant danger, which is mitigated by the inclusion of a safety lifting valve. The valve cores of both the exchange valve and the safety lifting valve are monitored. If any abnormality is detected in the valve cores, the monitoring signal will stop the electrical system to prevent injury from the falling ram. If the valve cores cannot be reset, the valve should be inspected immediately.

Troubleshooting

Normal operation of the press brake machine is safe when all safety protocols are followed. However, in the event of unusual accidents or during maintenance and repair, the following steps should be taken:

  1. Lock the safety grid.
  2. Push the emergency stop button located inside the uprights.
  3. Seek professional assistance.

If any body part becomes clamped by the punch or sheet, follow these steps:

  1. Push the emergency stop button.
  2. Inspect the situation carefully.
  3. Restart the machine only after ensuring it is safe to do so.
  4. Switch the operating mode to the “inch” position.
  5. Push the handle return button to retract the ram and free the clamped parts.

Overall Drawings of Press Brake

Here are the drawings:

Part No.NameQuantity
1Control panel1
2Bearing block2
3Torsion bar1
4Pendulum pole2
5Cylinder base block2
6Connect pole4
7Oil cylinder2
8Guide rail2
9Cylinder cover1
10Single Control Valve1
11Pipe connector1 set
12Pipe1 set
13Oil tank1
14Manometer box1
15Coupling1
16Gear Pump1
17Main motor1
18Level Gauge1
19Filter 4-501
20Filter 2501
21Close valve1
22FWMBM1set
23Saddle of travel switch1
24Travel switch2
25Pole of travel switch1
26Connecting plates16 sets
27Lower die1
28Upper punch1 set
29Press plate52
30Star handle4
31Motor of back gauge1
32Ball screw2
33Guide rail2
34Stop beam1
35Stop finger2 sets
36Foundation screw4
37Controller system1 set
38Electric system1 set
39Valve system1 set

Download the PDF File of the Installation & Operation Manual:

Don't forget, sharing is caring! : )
Shane
Author

Shane

Founder of MachineMFG

As the founder of MachineMFG, I have dedicated over a decade of my career to the metalworking industry. My extensive experience has allowed me to become an expert in the fields of sheet metal fabrication, machining, mechanical engineering, and machine tools for metals. I am constantly thinking, reading, and writing about these subjects, constantly striving to stay at the forefront of my field. Let my knowledge and expertise be an asset to your business.

You May Also Like
We picked them just for you. Keep reading and learn more!

6 Types of Press Brake Bending Process

Ever wondered how sheet metal is expertly bent into intricate shapes? This article explores six types of press brake bending processes—folding, wiping, air bending, bottoming, coining, and three-point bending. You'll…

Hydraulic Oil Used in Press Brake Explained

Ever wondered what keeps a CNC press brake running smoothly? The answer lies in the hydraulic oil. This essential fluid ensures optimal performance and longevity of the machine. Our article…

Press Brake’s Hydraulic Cylinder Repair Guide

Properly repairing the hydraulic cylinder of a press brake is crucial for maintaining machine performance and safety. The hydraulic cylinder typically consists of a piston, sleeve, piston rod, and screw.…

Press Brake Axis Explained (3, 4, 6 8-axis)

Ever wondered how a press brake achieves such precise bends? This article explores the fascinating world of press brake axes, revealing the secrets behind their roles and functions. Learn how…
Press Brake Stroke

How to Calculate Press Brake Stroke? (Tutorial)

Ever struggled with setting the correct press brake stroke length? Many operators do, often resorting to trial and error. This article demystifies the process, providing a clear formula to calculate…
MachineMFG
Take your business to the next level
Subscribe to our newsletter
The latest news, articles, and resources, sent to your inbox weekly.
© 2024. All rights reserved.

Contact Us

You will get our reply within 24 hours.