How does a hydraulic bending machine work: description, types, characteristics. Hydraulic bending machine - modern bending equipment Setting up on a CNC bending machine

All models of hydraulic press brakes manufactured by YuUMZ LLC can be equipped with various numerical control systems (CNC) by order of customers. CNC Press Brake (CNC Press Brake) allows you to carry out bending, which on a conventional bending machine takes a very long period of time or it is impossible to do it at all. CNC systems for press brakes are now very numerous from various manufacturers, ranging from the simplest, controlling only two axes X And Y up to systems that control the 9 axes of the press and allow the operator to make adjustments to the work directly during the bending process.

The photo shows the control panels of various CNC systems from the simplest to models with 2D and 3D visualization on the screen.

The most popular CNC sheet benders control 3 axes: Y1-Y2-axes of the slider and X-axis of the backgauge. Metal bending on a CNC press brake is much more accurate and takes much less time, since the CNC system avoids such errors as underbending or bending of the product, automatically rearranges the back stops to the required parameters in height, depth and width. The CNC system on the press brake monitors and controls the movement of the slider - in two axes, the movement of the back gauges - in six axes (when the press brake is equipped with the appropriate back gauge), as well as the operation of the bombing system (table deflection compensation system) - the axes of the press brake are shown on figure.

All modern CNC systems for press brakes have in their functionality:

Database of materials and tools;

Possibility to enter new material bending parameters data;

Automatic calculation of the coordinates of all axes for each operation and the optimal bending sequence, the ability to change this sequence manually;

Automatic calculation of the developed length of the part;

Possibility of simple adjustment of the bending angle by entering the obtained angle after the first bend;

Sufficient memory to store the programs used;

Ability to add a new tool;

Graphical display of the sequence of bends, the possibility of graphical input of the dimensions of the resulting part have models with 2D and 3D visualization on the controller screen.

The presence of these functions on the CNC bending machine allows the operator to quickly enter and calculate programs directly on the CNC minimal cost time to prepare them. The absence of them complicates the work, increases the time spent on preparing control programs and performing test bends.

The CNC press brake (CNC press brake) allows you to produce a very accurate bend with optimal time and energy consumption and - what is important in the first place - the high quality of the resulting product!

Technical consultants will help you choose the necessary CNC press brake manufactured by YuUMZ LLC.

Description of some models of CNC controllers:

Compact controller DELEM DA-56 provides convenient programming through two-dimensional graphic design CNC DELEM (Holland). The use of stored tools makes it easy and quick to set up the machine and carry out test bending.

The CNC controller is equipped with touch buttons. The program automatically calculates the positions of all axes and the bending sequence and displays the tool and workpiece on the display.

In the process of controlling the machine, the operator, using the DA-56 control program, has the ability to graphically simulate the process of bending the workpiece. The basic control functions of the machine are the control of the axes Y1, Y2, X. The second axis of the backgauge can be R/Z or X2.

The CNC controller is designed with the latest technology and is flexible and easy to use.

The color TFT LCD display and the modern interface gives the user the possibility of quick orientation in the program and a convenient process of setting parameters.

Characteristics:

• 2D graphic programming
• Color screen 10.4” LCD TFT
• Determination of the bending sequence
• Axial length calculation
• Part convexity control
• USB interface for peripherals
• Auxiliary frequency converter and AC regulator
• Processor 200 MHz
• Memory 32 MB
• Product and tool memory 2 MB
• Economical housing design

Data sheet:

• 7 program levels
• Drawing numbering: 20 alphanumeric characters
• Program repeatability: 9.999
• Number of program steps: max. 99 (consecutive)
• Step repeatability: max. 99
• Measurement: millimeters / inches
• Counting of machined parts
• Memory function in case of power failure
• Error reporting system
• Enclosure with built-in control panel
• Programmable deceleration of the axes
• Source material programming
• Tool programming

Count:

• Tool safety distance
• Bending forces
• Allowance for bending
• Bulge adjustments
• Axial length
• Lower bombing force
• Tool Collisions
• Angle corrections

Interface:

• Bidirectional DNC RS-232C

Axes control:

• Unipolar frequency converter control
• Two speed axis control for AC motor
• Control of axes Y1, Y2, X, Z

Secondary functions:

• Error and Fault Detection Program
• Control language selection
• Dialog Messaging
• Help in the on-line system
• Optoisolated Input/Output

ESTUN E200- the controller is specially designed for press brakes and guillotines with the most modern electronic technologies to control the backgauge and punch movement.
Easily switch between various functions, friendly interface, convenient operation, and a large amount of information on the screen is available for the user to easily program, parameter setting and automatic processing operations are easier, more convenient and faster.
With Estun's patented motion control technology and CAN BUS interface to connect to Estun's own EDC series in an AC servo system, performances are fully reproduced.
Selectable menu language between: English / Chinese, selectable measurement system between: inch / mm meet the different requirements of customers from different countries.
The controller has passed rigorous EMC testing and has been CE certified and approved by TUV Rheinland Group in Germany.

Main technical characteristics:
Bright LCD display, 240 x 128
One-sided positioning ball screw backlash elimination
Choice of measurement system: inch / mm
Position compensation
Remembering the position of the punch
Automatic search for landmarks and remembering the position
Enough storage space for 40 programs
Multi-step programming 25 blocks (steps) per program
Possibility to choose between: English menu or Chinese
Control: X-axis backgauge, and Y-axis travel
Setting automatic work and rapid traverse
Bend counter
Easy force setting
Possibility of multi-stage programming during automatic program operation, and continuous positioning
In the event of a power failure: remembers the position of the program and the parameters of the sensors and the position of the punch
Single and joint positioning of axes
Fixing screw gap
Automatic datum search
Automatic system that prevents the backgauge from colliding with the workpiece
Automatic location correction
Saving data in memory after turning off the power

Sheet bending machines equipped with a numerical control (CNC) complex provide high quality metal deformation. This is achieved by a certain algorithm of actions, which is determined by the program embedded in the CNC.
The hardware-software complex includes controllers and a control console. This allows you to significantly reduce the possibility of marriage, since the bend of the metal sheet is performed the first time. The touch screen allows you to track the progress of the bend at all stages. The operator who manages the complex has the ability to set and monitor the accuracy and correctness of the operations performed.

Working principle of CNC bending machine

The action of CNC bending machines of various types, in principle, is no different. On our website, we described the functionality of such equipment in an article. It is only necessary to emphasize that without a computer, using only gear systems traditionally used in mechanics, it would not be possible to achieve such high synchronism and accuracy in the operation of individual units. And, as a result, such high rates of labor productivity and quality of finished products.

Listogib "DURMA ADR-25100".

Features and advantages over other types of sheet benders

In addition to the advantages mentioned in the above article, two other advantages of using CNC on this type of equipment should be highlighted:

• high injury protection;
• fast equipment setup.

Trauma protection

Trauma protection is provided by a safety system that serves to protect the operating personnel.

The mandatory mechanical attributes of the system include various fences (nets, covers, etc.) and some mechanical devices. For example, it is possible to set the machine in motion (the beginning of the lowering of the traverse at the speed of "free fall") only by simultaneously pressing two "Start" buttons spaced from each other (by the width of the arm span). In this case, both hands will be occupied, and the possibility of injury will become impossible. "Craftsmen" (most often equipment adjusters), in order to reduce labor intensity, fixed one button with something and often injured their hands.

The introduction of CNC made it impossible to use this "invention". This happened due to the development of a laser control device, which checks, during operation, the presence of foreign objects (including human hands) in the working area of ​​the bending machine.

The device works as follows. Laser beams form a "control plane" at a distance of 3...5 mm from the working tool. If, when the traverse moves down, any object appears in the “control zone” and at least one beam is crossed, the safety system will immediately stop the beam and the entire machine.

Listogib "PUMA 400-40".

Quick hardware setup

In the CNC computer organization production process carried out work program. All the parameters necessary for the processing of parts are entered in the form of variable data, which the main program uses to set up in each specific case.

Thus, the reconfiguration of the machine is for the operator to change the hard drives and load them from the control panel. Only when switching to another product, when the punch and die need to be replaced, does the equipment adjuster start working.

"Cons" of using CNC benders

Cons two:

• high cost of equipment - it increases by the cost of "electronic brains";
• highly educated staff required. The operator must not only have a good knowledge of metalworking, but also be "on you" with computer technology.

Listogib «TURBObend-rung-01».

Popular Models

The most popular are the following models of CNC bending machines:

• sheet bending machine brand "DURMA" model "ADR-25100";
• sheet bender brand "TURBOBEND" brand "Rung 01";
• machine "PUMA 400-40"

You can buy a bending machine .

Hydraulic bending machine is used in various manufacturing enterprises for bending sheet metal using a cold method with strict observance of the specified bend angles.

1 How did hydraulic bending machines come about?

Initially world industry produced sheet benders of mechanical and manual type. They were simple and reliable in operation, had a simple design and did not require excessive costs for their production. It is clear that it did not provide the proper bending accuracy, and for its use it was necessary to apply considerable physical force. The mechanical equipment also had a lot of shortcomings:

• high degree of vibration and noise during operation;
• low quality of manufactured products;
• increased risk of injury to the plant operator;
• high consumption of electrical energy;
• Difficulty in the need for readjustment of machines.

Simultaneously with mechanical bending presses metal blanks began to use pneumatic equipment. It was operated quite limitedly, since for the operation of such units it was necessary to supply compressed air to them through a special line. And the load force that they could provide was relatively small.

A real breakthrough in sheet metal bending was the appearance in the middle of the 20th century of hydraulic presses, which were distinguished by low electricity consumption, high level work safety, almost impeccable reliability and excellent quality of manufactured products.

In recent years, the standard hydraulic press brake has undergone many changes. Nowadays, it is equipped with innovative devices and mechanisms that greatly facilitate the procedure for bending metal blanks. These include the following devices and developments:

• graphical user interface that allows program management machine independently determine and set the bending sequence;
• adjustment equipment electronic devices traverse speed;
• protecting the operator from injury;
• bending angle control indicators.

It is possible to list the modern additional equipment installed on hydraulic sheet benders for quite a long time. We will talk about many special mechanisms and intricacies of using CNC bending machines, describing their popular brands.

2 General information about plants and how they work

The described equipment is usually used in production in the following situations:

• to obtain ideal products in terms of quality and accuracy;
• as one of the stages of the process of industrial processing of metal blanks with a thickness of 3.5 millimeters;
• for quick and inexpensive bending of metal sheets with a thickness of less than 3.5 millimeters;
• when performing bending operations of the same type of products (when tool settings do not need to be changed too often).

Listogib on hydraulics happen stationary and mobile. The former are used in one place, they can process large volumes of metal. And the second, mobile, is allowed to operate at different facilities. As a rule, they are purchased by small manufacturing companies. At the same time, both the first and the second ones operate on the energy of hydraulic cylinders, which eliminates the need for efforts on the part of the operator of the bending machine.

The essence of the operation of the described equipment is to provide the specified values ​​of the stroke (working) of the traverse of the installation and the required effort. A traverse is a rigid steel beam. Devices for specific bending modes are mounted on it, taking into account the characteristics of the workpiece being processed.

The traverse moves under the constant control of special linear sensors. Usually two pieces are installed on sheet benders (one "follows" the right side of the beam, the other behind the left), which guarantees the uniformity of the traverse. On most bending machines, in addition, a rear programmable stop is mounted. It allows you to get a bent metal edge with certain geometric values.

Sheet benders on hydraulic cylinders today are considered indispensable in the production of materials for hull construction, electronic products, appliances and household appliances, Vehicle and special vehicles. They are also necessary for the manufacture of bent products used in machine and machine tool building. When installing additional mechanisms, hydraulic sheet bending machines process cylindrical and conical surfaces of various diameters without any problems.

3 Algorithm for bending metal on sheet benders with hydraulic cylinders

The technology for processing sheet metal blanks on the equipment in question does not have any particular difficulties. At the same time, it ensures maximum productivity of sheet benders and high safety of work.

In general, the process of bending blanks on the units of interest to us is carried out in seven stages:

Bending machines with additional mechanisms can, of course, function with some additional steps. But the bending of metal products itself is performed exactly according to the described algorithm.

We add that the processing of workpieces on sheet benders with hydraulic cylinders is described by three main parameters - the working length of the machine, the power of the developed load on the part, the productivity per certain time, as well as several additional characteristics (the distance between the racks of the unit, the speed of performing work operations, the amplitude with which the traverse can move, and others).

4 Machine LGSG-28 - brief description

Press LGSG-28 Lipetsk plant for the production of profile bending special equipment is very popular with Russian companies, which are engaged in the production of different and corners, as well as other products for the construction industry. This unit is capable of processing at the highest level of efficiency sheet metal up to 3 mm thick and up to 2.5 meters long.

• slight noise during operation;
• elementary management;
• an excellent ratio of functionality and cost;
• low consumption of electrical energy;
• the ability to perform bending in manual and fully automatic modes;
• sufficiently high versatility.

LGSG-28 develops a bending force of up to 20 tons, provides a bending angle of up to 105 degrees. The overall dimensions of the machine are 280 by 80 by 200 centimeters with a weight of about 2 thousand kilograms. This equipment allows you to get a minimum bend at the level of four centimeters.

It must be noted that LGSG-28 breaks very rarely. But even in situations where it becomes necessary to repair it (replacement of components that have naturally failed), users have no problems with "updating" the machine. The Lipetsk plant produces in sufficient quantities a complete range of spare parts for its bending machine.

5 Overview of CNC press brakes

Hydraulic units for metal bending are now equipped with CNC systems. Such equipment is characterized by high accuracy and efficiency of work. Sheet bending machines of many well-known manufacturers from Europe are presented on the domestic market. We will tell you a little more about some companies and their products.

Listogibs of the Portuguese brand are considered popular Adira produced in the city of Porto. Russian enterprises purchase equipment series RN(models 16060, 30060, 40070, 50070, 60060, 110080, 135070, etc.), which is supplied with motors of different power (from 15 to 110 kW), bending speed (from 6.5 to 10 mm/s) and pressing force ( from 160 to 2000 tons). All of them are characterized by the following operational advantages:

• compact dimensions of hydraulic stations;
• stabilized monoblock strong traverse;
• the presence of two servo valves with automatic control;
• hydraulic and electrical overload protection;
• simple adjustment of the indicator of lowering the traverse and programming of all values ​​of the technological process without exception;
• high-performance numerical color controllers with Russification;
• powerful emphasis (rear) with four controlled axles.

Also well-known units under the brand MetalMaster(models 2563K, HPJ-k 1340, 2580, 32200) with many features, reliable hydraulics, modern instrumentation and construction of heat-treated welded components. These sheet benders are controlled by a numerical complex ESTUN, allowing you to perform step-by-step programming of any number of work operations in inch and metric coordinate systems.

Modern factory equipment in most cases necessarily includes a CNC press brake: such machines allow you to bend metal blanks quickly, accurately and at minimal cost, both time and financial. Among the products manufactured by DURMA (Turkey), experts recommend paying attention to the AD-R presses, which are distinguished by the versatility of operation and high precision performing operations.

Economic CNC Press Brake

DURMA brand products are designed for the widest range of customers, and therefore the company pays Special attention to reduce the cost of equipment that uses most in demand. It was within the framework of this program that Turkish designers developed the presses of the AD-R line.

CNC bending (bending) press DURMA:

• True innovation
• A combination of efficiency, affordability and simplicity
• The best ratio "complexity of work / cost of equipment" in the competitive range
• Intuitive CNC control
• Special design control box and software provide ease of setting up the operation of the equipment, and control will become possible even for untrained workers.
• Excellent bending quality, easy input of bending angle and other operations
• Rugged cast construction is the hallmark of DURMA equipment
• The work is simple and comfortable in all respects.
• Increased "clearance" and overall working space optimizes work with complex multiple bends
• Designed and produced for the low-price segment of the market, while complying with the "Premium" class
• practically has no restrictions on the complexity of the processed workpieces;
• has a high level of functionality;
• belongs to the category of highly profitable equipment;
• has an impeccable level of quality and all the necessary manufacturer's warranties.

Synchronized hydraulic bending press DURMA AD-R from the "economy" series has become a successful development of the AD-E model. The unit is designed for a wide range of customers who would like to minimize the number of control functions. IN new series presses, sheet processing is carried out according to the program, which is formed directly by the operator, who exercises subsequent control over its development. The main programmable operations are approach speed, return speed and working stroke. Yes, quality finished product increases significantly due to the elimination of deformations in the bend zone, if you set the mode of moving the slider up at low speed, followed by a stop and a transition to the standby state. When working with stainless steel and some other unusual materials, it is useful to program a slow shutter or delay. For these purposes, the CNC Easy controller is included in the standard set of AD-R presses.

All representatives of the DURMA AD-R family of hydraulic press brakes have three axes under CNC control: X - positioning of the backgauge, Y1 and Y2 - movement of the slider. The process of programming the controller is simplified as much as possible and is carried out from the control panel, due to which the time for manufacturing the part is significantly reduced. Having received the initial information about the dimensions of the product and the sequence technological operations, CNC independently calculates the bending angle, the initial and final positions of the slider and backgauge, as well as their movement along the axes.

At the request of the customer, the basic set of the AD-R press can be supplemented with a desktop deflection compensation system (automatic under the control of the controller or manual), a color graphic monitor connected to the CNC Easy and a scheme for determining the sequence of bending and sheet rotation operations.

Hydraulic presses of the DURMA-D series have automatic calibration, which makes it possible to manufacture precision products on them with a positioning accuracy of up to 0.05 mm. The hydraulics of the unit is equipped with components manufactured by Bosch, and its electrical part is built on elements from Omron, Telemecanique and Siemens.

Products with the DURMA trademark have gained popularity in Russia due to the highest responsibility of the manufacturer for the fulfillment of contractual obligations, modern system warranty and post-warranty service and the most optimal in its market segment the ratio of quality and price.

Key Standard Components
Top beam guides	Increased stroke, clearance and feed depth
Double guides increase the accuracy of the movement of the upper beam	The working space on the AD-R series machines has been increased, which greatly facilitated the work and reduced the time production cycle
Motorized X axis stroke controlled by CNC	Front support
The height of the backgauge (R-axis) is set manually. The positioning depth of the finger blocks is calculated by the CNC. Backgauge rollback is a standard feature to ensure positioning accuracy. Finger blocks move along linear guides on bearings	The front support is quickly mounted on linear guides and ball bearings, which allow you to easily move the workpiece in a horizontal plane.
Tool holder
Euroclamp Multi-V	Quick release clamp
This tool holding system allows for precise parallelism
Security systems comply with CE regulations
The machine can be equipped with additional safety systems in accordance with CE
	Durma CNC Easy Bend
	More effective and thorough control than in serial machines Training time 5 minutes More productive than analogues More cost effective than comparable machines Less service costs than serial machines Simplified screen with fewer buttons Easy to manage Does not require additional reprogramming Full control over all bending steps Instrument options are already stored in memory Ability to adjust the process USB interface Ease of upgrade
	Durma CNC Advantage
	Monitor with a diagonal of 19 cm with a 2-dimensional scan on the working screen Lightweight bend settings Automatic bend sequencing Complete calculation of dimensions and parts Safety system Offline software (programming and setting up the operation of machine components) Motorized table deflection compensation I/O control Tandem work USB interface for backing up and restoring programs, instrument settings, parameters Free Support 85 programs (up to 12 steps each) Provision on disk or other media
	DNC 880s - CNC 2D
	DNC 8805 - controller designed specifically for bending equipment It is used both on fully synchronized machines and on serial machines with a simplified control system with an electric or hydraulic motor. DNC 880s - Competitively priced performance benchmark in a compact design 25 cm color screen Displaying the bending process in real time on a 2D screen Windows XP is preinstalled for job and data management Communication with external devices via USB port for data backup. Over 20 languages ​​available

Specifications
AD-R series press brakes from 1250 mm. up to 3050 mm.

Specifications
AD-R series press brakes from 3700 mm. up to 6050 mm.

DURMA pursues a consistent policy of reducing the cost of the main types production equipment. The AD-R press line was developed by the company's designers as part of this program.

The vertical bending press has no restrictions on the complexity of the processed products, it combines high functionality and unconditional profitability. By selling equipment on the Russian market, DURMA offers its customers the best ratio of cost, quality assurance and comfortable trading conditions.