Something You Must Know About All-Electric Servo Press Brake Machine

The CNC system of the all-electric servo press brake machine adopts a high-end CNC system development platform and advanced special algorithms and motion control algorithms for sheet metal bending sex detection.

High-End Design

• High-grade modeling design

CNC system adopts high-grade industrial style luxury panel design, 17-inch large-screen LCD display, and touch screen, the interface display is clear at a glance.

• Two-dimensional graphic programming function Servo Press Brake

The system has two-dimensional graphic programming/display/simulation functions, the operation is intuitive, and the bending collision can be warned in the simulated bending.

• Direct programming function Servo Press Brake

The system also has a direct programming function. It is most convenient to use a direct programming function for simple bending. It is only necessary to simply input several parameters such as the back file and angle of each process to perform bending processing. Servo Press Brake

High-Speed And High-Precision Control

The numerical control system of this all-electric servo press brake adopts a high-speed acceleration and deceleration algorithm and trajectory look-ahead algorithm, to ensure good bending accuracy and soft motion characteristics. So that high speed and high precision are effectively integrated! Servo Press Brake

1. High speed: The maximum fast forward speed of the Y axis is 300mm/s, and the maximum working speed is 100mm/s.
2. High precision: The magnetic scale with 5um resolution and the double-loop control of the high-digit encoder are used, and the repeated positioning accuracy is ±3um.
3. Processing consistency: avoid the influence of oil temperature change on the consistency of the bending workpiece. Servo Press Brake

Intelligent Safety Light Curtain Monitoring

The CNC system of the all-electric servo bending machine intelligently determines the dangerous area and Safe area to protect the safety of operators. This design solves the defects of the special safety light curtain for bending machines commonly used in the market and can protect the safety of operators during the bending process without affecting the work efficiency. Servo Press Brake

All-Electric Servo Press Brake Technical Indicators And Functions

• Y1/Y2 adopts grating scale or magnetic scale feedback full closed-loop control mode, precise positioning control, repeat positioning accuracy of ±3μm!
• The intelligent safety light curtain monitoring ensures the safety of operators, and has authorized patents, which are unique!
• Intelligent tool load monitoring ensures tool safety; Servo Press Brake
• Five-wire touch screen, high reliability and service life of more than 10 million times, the operation process is simple and fast;
• Rich and diverse programming methods: direct programming mode and two-dimensional graphical interactive programming mode are optional for customers;
• Automatic calculation function of bending pressure, alarm prompt when the pressure exceeds the limit range; Servo Press Brake
• “Direct” calculation function of the back gauge position: According to the relative size and plastic deformation of the sheet metal, the back gauge position is directly calculated according to the neutral layer;
• Angle intelligent compensation function: According to sheet metal process parameters such as sheet metal material characteristics, die size, material thickness, bending angle, etc., combined with the angle calculation model of the CNC system, any sheet metal only needs one trial bending, and it can be automatically compared according to the angle deviation. Yes, it can be officially produced.
• Arc continuous bending function;
• Mould parameter library: establish a mould parameter library for customers, which is convenient for customers to quickly call parameters for sheet metal bending;
• Password protection function

Advantages of All-Electric Servo Press Brake Machine

With the advancement of technology and the increase of labor costs, the current sheet metal processing, especially the bending processing equipment, has higher and higher requirements for processing efficiency and product quality, and in recent years, the country’s requirements for environmental protection have become higher and higher.

In recent years, the maturity and cost reduction of high-power, high-torque servo motors, and drive technologies have promoted more and more applications of related electric servo drives. The CNC bending machine widely used in the sheet metal industry has opened a new trend of pure electric servo main drive to replace the hydraulic main drive. The tonnage and output of pure electric servo CNC bending machines are increasing.

• Significant energy saving

One of the advantages of pure electric servo drive technology is that the input power of the motor is proportional to the load power, the power consumption is large when bending, the power consumption is small when the slider moves up without load, and basically, no power consumption is consumed when the slider stops.

However, the main motor and hydraulic pump of the hydraulic servo bending machine continue to run even if the slider does not work, consuming electricity. In addition, the mechanical main transmission efficiency of pure electric servo bending machine is more than 95%, the hydraulic transmission efficiency of hydraulic servo bending machine is below 80%, and the efficiency of hydraulic system components is lower after aging and wear.

Taking a 100t bending machine as an example, according to the work of 8 hours a day, the power consumption of the main engine of the pure electric servo bending machine is about 12kW·h/d, while the power consumption of the hydraulic system of the hydraulic bending machine is about 60kW·h/d. The servo bending machine saves about 80% of energy.

• Environmentally friendly and pollution-free

The pure electric servo bending machine does not use hydraulic oil, and there is no trouble in replacing hydraulic oil and hydraulic components, so there is no hydraulic oil leakage during the replacement, replacement process and the daily system of the system, and there is no waste oil treatment and pollution.

• Fast slider speed and high production efficiency

The response speed of the servo motor is faster than that of the hydraulic servo. Take the 100t pure electric servo bending machine developed by Kaifeng CNC as an example. Tonnage hydraulic press brake slider return and fast down speeds are below 120mm/s, and the working speed is 10mm/s. The hydraulic servo bending machine is affected by the environment and the heat of the hydraulic system, and needs to be preheated or stopped to dissipate heat; once the hydraulic system is faulty, the technical requirements for troubleshooting are high and the time is long. The pure electric servo bending machine has few components and a low failure rate, and these problems do not exist fundamentally.

Therefore, the processing efficiency of a pure electric servo bending machine is nearly 1 times higher than that of the hydraulic bending machine of the same tonnage.

• High bending accuracy

The bending speed of the pure electric servo bending machine can be adjusted. It can be bent according to different thicknesses, different materials, and different bending lengths, and a more suitable bending speed can be set to improve the bending accuracy and maintain high productivity. The deflection compensation shaft of the pure electric servo bending machine adopts the VILA structure compensation device, and the bending accuracy is higher.

The bending angle error of the hydraulic bending machine is within ±1°, and the main driver of the servo bending machine is driven by the servo motor to drive the screw, and the transmission accuracy is higher. It is good to ensure that the bending angle error is within ±0.5°.

• Low maintenance cost

The hydraulic oil of the hydraulic bending machine needs to be replaced regularly; pumps, valves, and seals are prone to failure and damage, and the hydraulic system is prone to pollution, and it is difficult to find and eliminate faults. Once the hydraulic system is polluted, it will be difficult to clean the system and will cause environmental pollution. The drive system of the pure electric servo bending machine is simple, there is basically no maintenance cost, and only regular lubrication is required.

The design and manufacture of the pure electric servo bending machine aim at high bending precision, high operation efficiency, and high reliability. The finite element analysis of the bed and the slider is carried out, and the rigidity of the bed and the slider is optimized and strengthened.

According to the analysis of pure electric servo bending machine and hydraulic bending machine in terms of energy consumption, environmental protection, processing efficiency, processing accuracy, and cost, the conclusions are as follows.

Comparison of hydraulic press brake and pure electric servo press brake (take 100T press brake as an example, based on 8h work a day)

• Energy consumption

The power consumption of hydraulic bending is about 60kw.h/d, and the power consumption of a pure electric servo bending machine is about 12kw.h/d.

• Environmental protection

Hydraulic bending machine has the possibility of pollution, pure electric servo bending machine has no possibility of pollution-free.

• Processing efficiency

The slider return and fast down the speed of the hydraulic press brake are below 120mm/s, and the working speed is 10mm/s; the slider return and fast down the speed of the pure electric servo press brake are as high as 200mm/s, and the working speed is 0-20mm/s.

• Machining accuracy

The error of the bending angle of the hydraulic press brake is within ±1°, and the angle error of the pure electric servo press brake is within ±0.5°.

• Cost

The cost of hydraulic press brakes is slightly lower, and the cost of pure electric servo press brakes is slightly higher.

A servo press brake, also known as a servo-electric press brake, is a specialized type of press brake used in metal fabrication and manufacturing. It differs from traditional hydraulic press brakes in that it employs a servo motor-driven system for bending metal sheets and plates. Servo press brakes offer several advantages, including high precision, energy efficiency, and reduced maintenance compared to their hydraulic counterparts.

Here are some key features and benefits of a servo press brake:

Servo Motor Control: Servo press brakes use electric servo motors to control the movement of the ram (the part responsible for bending). This precise control allows for highly accurate and repeatable bends.

High Precision: Servo press brakes are known for their exceptional precision and repeatability. The servo motor can precisely control the ram’s speed and position, resulting in tight tolerances and consistent part quality.

Energy Efficiency: One of the significant advantages of servo press brakes is their energy efficiency. They only consume electricity when actively bending the material, reducing overall energy consumption and operational costs.

Quiet Operation: Unlike hydraulic press brakes that can be noisy due to hydraulic pumps and fluid flow, servo press brakes operate quietly, making them suitable for environments where noise levels need to be minimized.

Faster Setup: Many servo press brakes are equipped with user-friendly CNC control systems that streamline setup and programming. Operators can easily program and store bending sequences, reducing setup times and increasing productivity.

Reduced Maintenance: Servo press brakes have fewer moving parts compared to hydraulic press brakes, leading to lower maintenance requirements and less downtime. They do not require hydraulic fluids or frequent fluid changes, reducing the risk of leaks and environmental concerns.

Versatility: Servo press brakes are versatile and can be used for a wide range of bending applications, from simple bends to complex profiles. They are suitable for bending various materials, including mild steel, stainless steel, aluminum, and more.

Safety Features: Just like hydraulic press brakes, servo press brakes are equipped with safety features to protect operators. These features may include safety light curtains, interlock systems, and emergency stop buttons.

Environmental Friendliness: Servo-driven systems are considered more environmentally friendly because they do not use hydraulic fluids, which can be hazardous to the environment if not managed properly.

Improved Control: The CNC control system on a servo press brake allows operators to precisely control the bending process, monitor bending parameters, and make adjustments as needed to achieve the desired results.

Servo press brakes are gaining popularity in the metal fabrication industry due to their precision, energy efficiency, and ease of use. They are particularly well-suited for applications that require high-precision bending, intricate profiles, and where energy costs and environmental concerns are important considerations.

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