E-Brake from Safan produces the pressing force by means of synchronised electric motors which transfers via belts and pulleys to the beam.
This drive principle brings many advantages: no problems with hydraulic oil, low energy consumption as well as higher productivity.
Since Safan introduced Mechatronic Press brake, its patented drive system has been optimised, the electronics refined and the range of applications expanded.
Productive bending depends less on the theoretical speed of the beam than on the times between the bends. An efficient Press brake machine must therefore optimise these functions and not just the beam speed.
When a product requires several bends it is common practice to operate the machine at its fastest beam speed.
Between the bends, the component is turned and inserted as required for each fold.
More time is lost between the bends by handling, the change over time between fast and slow points of the beam and the back gauge positioning speed.
With safety on the one hand and the well-known inertia of Hydraulic systems on the other hand being the major limiting factors.
The solution is the E-Brake Mechatronic Press Brake from Safan.
The control of the electric motors used in the machine is the basis of this innovative system.
The principle of the system is a pulley-block, which pulls the top beam of the press against the effect of laterally arranged return springs into the die, and applies the pressing force evenly along the length of the machine.
In 98% of cases no crowning table is required. When rolling the belt up, the driving motor pulls the beam downward into the die.
The return springs strained during the bending procedure return the beam to its initial position.
The E-Brake is available from 25 to 200 ton pressing force and lengths from 1250 to 4100 mm. Depending upon the size and power requirements, the number of pairs of pulleys varies.
In the large machine four pulley-block arrangements with their own drives and nine pairs of rolls each are present. With this machine a 100 mm wide belt is used.
The belts are made from the same 3mm thick wire-strengthened material coated with polyurethane that is also used extensively in elevator systems.
The drive is provided by Lenze electric motors. The 4m machine with 200 ton pressing force requires a total output of 22 KW. The force is distributed evenly over 36 rolls attached to the upper beam.
The framework of the E - Brake forms an “O” which is naturally more rigid than the usual C-frame of Hydraulic machines. The back gauge is also distinctive because it extends across the full width of the machine.
Cycle times are 30% faster than conventional press brakes are offered by the E-Brake Mechatronic press brake:
Safan’s own electronic control system ensures short response and delay times resulting in bending speeds of up to 20mm/sec.
The high acceleration and other servo motor characteristics mean not only fast approach speed but also a seamless change over to bending speed.
Working at high speed without risk is achieved via the active safety system built into the touch screen control.
The safety light curtain is programmable directly from the touch screen with innovative settings to maximise productivity whilst maintaining a safe operating environment.
This programmable light curtain also has features that give you the opportunity to move the upper beam and back gauge into the next step without using the foot pedal. This means that the machine is already in its next position while handling the sheet.
The combination of these features delivers typical cycle times 30% faster than conventional press brakes.
The absence of hydraulics means no seals, no pressure valves etc. resulting in less downtime and lower maintenance costs, furthermore the Safan E- Brake uses less energy than Hydraulic machines because the motors only operate when the beam is actually moving.
The new range of Safan’s Mechatronic Press brakes is available from Sheetmetal Machinery.