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PressBrakeControls.pdf

PressBrakeControls.pdf

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PRESS BRAKE CONTROL SYSTEMSPRESS BRAKE CONTROL SYSTEMS
Rockford Systems, Inc.
www.rockfordsystems.com
sales@rockfordsystems.com
FAB 
145
(Continued on next page.) 
INTRODUCTION
Press brakes are one of the most difficult machine tools to safeguard because of their general purpose-type use in indus-try. General purpose means a press brakecan be used to bend from very small partsto very large parts. Production runs onthese machines can be one part to thou-sands of parts. With this type of operation,press brakes must be versatile. Today, with advanced technology, it is now possible for industry to safeguard press brakes and maintain the same levels of productivity when the employer (user)considers all components in the press brake system. A complete safeguardedsystem includes, but is not limited to, thetype of press brake, the safeguard itself,tooling to be used, size, shape or configu-ration of workpiece, material handling,production, maintenance, and any antici-pated future needs.
OSHA STANDARDS
Under OSHA, press brakes are cited for noncom-pliance in accordance with 29 CFR 1910.212— Machine Guarding, which specifically requirespoint-of-operation safeguarding. All machines fallunder this same regulation where it states: “thesafeguarding shall be in conformity with any appropriate standard.” Some states may havetheir own rules and regulations for press brakes.
ANSI STANDARDS
 There are several references available on press brake safety; however, most industries use the ANSI (American National Standards Institute)B11.3 standard. This standard can be purchased by contacting:
 ANSI
 American National Standards Institute, Inc.25 West 43rd Street, 4th Floor New York, New York 10036Phone: (212) 642-4900Fax: (212) 398-0023 www.ansi.org
OR 
 AMT
 The Association for Manufacturing Technology 7901 Westpark DriveMcLean, VA 22102Phone: (703) 893-2900Fax: (703) 893-1151 www.amtonline.org
OR 
GLOBAL ENGINEERING
15 Inverness Way East Englewood, CO 80112 Toll-Free: 1-800-624-3974http://global.ihs.com
TYPES OF PRESS BRAKES
 There are three basic categories of press brakes:
1.Part-Revolution
 —Mechanical-Friction Clutch —Air Clutch (Single- or Two-Speed)
2.Hydraulic (Down-Acting and Up-Acting)3.Hydra-Mechanical
Each one of these press brake types is discussedon subsequent pages in this section. There arealso servo-drive (electric) press brakes that can besafeguarded. Please consult the factory.
POINT-OF-OPERATION HAZARD
Fortunately, most press brake operations do not require the operators to place their hands or any part of their body into the point-of-operation haz-ard; however, exposure to point-of-operationinjuries still exists. Because of this exposure, theoperator(s) must be safeguarded from point-of-operation hazards. Best safety practice is whenoperators are
never
required to put their hands or any part of their body in the point of operation at any time. Sometimes as the workpiece bends up,a hazard may be created between the part and thefront face of the slide. When this happens, be surethe operators do not place their fingers on the topor sides of the material, but support the materialfrom underneath.
HELPERS
Many times two or more operators are feeding andretrieving workpieces from press brake dies. Theemployer may describe one person as an operator and one person as a helper; however, a helper is
 
PRESS BRAKE CONTROL SYSTEMSPRESS BRAKE CONTROL SYSTEMS
Rockford Systems, Inc.
Call Toll-Free 1-800-922-7533
Fax 815-874-6144
146
FAB 
 This introduction and subsequent pages in thiscatalog will provide information on safety require-ments in these areas.
SAFEGUARDING
Press brake safeguarding can be accomplished by using one of the following safeguarding
devices
:
1. Presence-sensing device (pp. 45-73)2. Two-hand control device (p. 74)3. Pullback device (p. 77)4. Restraint device (pp. 78-79)5. Hostage control device (pp. 148-149)
PRESENCE-SENSING DEVICES
Of all the recognized point-of-operation safeguardingdevices for press brakes, the light curtain is the most  versatile for short- to long-run operations and for small to large workpieces. Proper use of this deviceprovides protection for all operators and passersby inproduction modes of operation. It also minimizesoperator resistance to using safety devices. A muting feature, most commonly used with press brakes, allows the light curtain to be bypassedduring the nonhazardous portion of a press brakestroke. This is generally from
1
 ⁄ 
4
" or less above the workpiece to the bottom of the stroke and back tothe top of the stroke. Blanking of beams or the useof float blanking are also popular options for press brake applications; however, these options must  be closely supervised and discouraged whenever possible. When applying light curtains, they must bemounted at a safe distance according to the for-mulas found on page 46.
HELPERS (continued)
considered an operator when exposed to any point-of-operation hazards. Each operator must  be safeguarded and have his/her own set of oper-ating controls for cycling the machine such aspalm buttons or a foot switch.
METHODS FOR CYCLING AND SETUP
SEQUENCE OR HIGH/LOW OPERATION
 When there is a concern about whip-up actionof material, or positioning of a part, the sequenceor high/low speed-change mode of operation isused. Sequence is accomplished by stopping theslide on the downstroke (on down-actingmachines) just above the workpiece, then com-pleting the downward part of the stroke in a slow,controlled speed. In the high/low mode, the slidedoes not stop; when selected, it goes into a slower speed for bending the workpiece.
SINGLE STROKE
In the single-stroke mode, the machine slide willdescend through the workpiece and return auto-matically to stop at the beginning of the cycle. In a high production situation, with certain workpieces,machines are usually single-stroked (cycled) rather than operated in the sequence or high/low mode. The controls offered in this catalog allow the opera-tor to inch on the downstroke in the single-stroke,sequence, and high/low modes, on both mechani-cal and hydraulic press brakes.
INCH/SETUP
 When the inch mode of operation is provided onpress brakes, it must be used for setup only.
Never
operate a press brake in the inch mode for production operations.
PRESS BRAKES USING POWER PRESS TOOLING
If mechanical or hydraulic press brakes use presstooling (i.e., conventional or unitized dies) for stamping parts, please refer to pages 103-129 for mechanical press control box and component selection, and pages 172 and 173 for air cylinder selection (mechanical-friction clutch press brakesonly), or pages 130-142 for hydraulic press control box selection.
BASIC SAFETY REQUIREMENTS
 When updating press brakes to comply with the indi-cated safety standards, there are five basic require-ments that must always be considered. They are:
1. Safeguarding (pp. 7-86)2. Controls (pp. 153-185)3. Disconnects (pp. 193-197)4. Starters (pp. 193-197)5. Covers(user to provide)
Light Curtain
 
PRESS BRAKE CONTROL SYSTEMSPRESS BRAKE CONTROL SYSTEMS
Rockford Systems, Inc.
www.rockfordsystems.com
sales@rockfordsystems.com
FAB 
147
(Continued on next page.) 
STEP 1
 The operator inserts the workpiece into thepress brake die and supports it either withhis/her hands, on rails, or on a table.
STEP 2
 The press brake is activated by a foot switchor palm buttons.
STEP 3
If the light curtain is interrupted during the die-closing portion of the cycle, the press brakeslide will stop.
STEP 4
If the light curtain is not interrupted, thepress brake will continue its downstroke and will either:
1)
make contact with the work-piece and finish the single stroke in normalspeed (or in high/low speed if chosen), or 
2)
stop above the workpiece if in sequence mode.In the sequence mode, the workpiece may beinserted or positioned at this time and thenthe slide is reactivated to finish the stroke.
Note: The light curtain is muted once the die is a maximum of 
1
 ⁄  
" above the workpiece.
 When the light curtain is muted, it is auto-matically turned off or bypassed during the bending operation to permit the workpiece or operator’s hand to move through the plane of light without interrupting the cycle.
STEP 5
 The slide returns to the beginning of the cycle.
so the operator(s) must hold the palm buttonsdepressed until the slide reaches a point 
1
 ⁄ 
4
" or less above the workpiece. If either palm button is released, the slide stops. Both palm but-tons must then be released and reactuated to fin-ish the stroke. Two-hand control is usually arranged to provide this protection in the two-hand single stroke, sequence, or high/low mode of operation. See information below and on the next page for additional details on how two-hand con-trol and sequence mode of operation work.
LIGHTCURTAIN
SLIDEDIEBEDTOPOFSTROKEBOTTOMOFSTROKE1/4" MUTEPOINTBACKGAUGE
This illustration is of a down-acting press brake bending a workpiece with a light curtain used as the safeguard.
TWO-HANDCONTROL(TWO BUTTONS)SLIDEDIEBEDTOPOFSTROKEBOTTOMOFSTROKE1/4" SEQUENCESTOP OR LOW-SPEED POINTBACKGAUGE
STEP 1
By depressing the two run buttons, the oper-ator(s) initiate the press brake cycle.
STEP 2
 The operator(s) must hold the two run but-tons until the slide completes its downwardtravel to the workpiece or until the slidestops
1
 ⁄ 
4
" or less above the workpiece. If theoperator(s) remove one hand from the run buttons, the slide will stop. In the single-stroke or high/low mode, the slide will makeone complete cycle.
STEP 3
In the sequence mode, the slide will auto-matically stop at a preset position
1
 ⁄ 
4
" or lessabove the workpiece. This preset position isadjustable for different feed-line heights or material thicknesses.
STEP 4
If the workpiece is not already placed in thedie, it may be inserted at this time.
STEP 5
 The palm buttons or the foot switch is now reactuated, causing the slide to continuethrough the bottom of the cycle and auto-matically return at high speed to the begin-ning of the cycle.
PRESENCE-SENSING DEVICES (continued)How a Light Curtain Works as a SafeguardingDevice on Press Brakes:How Two-Hand Control Works:TWO-HAND CONTROLDEVICES
 Two-hand control, as a point-of-operation safe-guarding device for press brakes, is ideal for short-run job-shop operations. Workpieces can be from very small to very large.Each operator station is arranged with two guardedrun palm button assemblies. These buttons areusually mountedto the slide of the press brake;however, they can also be installed on a floor stand(see page 123) for more flexibility. Two-hand control provides protection against point-of-operation injury during the die-closingportion of the cycle. Two-hand control is arranged
Note: The controls illustrated provide the ability to inch the slide down with the palm buttons or foot switch in the sin- gle, sequence, or high/low mode of operation. By inching the slide down in these modes, the operator makes sure the upper die is going to bend the workpiece in the correct  position. This also avoids hazardous whip-up action of the workpiece when inching through the workpiece bend.
This illustration is of a down- acting press brake bending a workpiece with two-hand con- trol used as the safeguard.

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