e for electronic Press Brakes - Ferret

E-Brake 25 - 100 T
E-Brake 150 - 200 T
H-Brake B-Shear & M-Shear
Safan B.V., Kwinkweerd 11, NL-7241 CW Lochem, P.O. Box 96, NL-7240 AB Lochem
Tel.: +31 (0)573 222 222, Fax: +31 (0)573 252 057, E-mail: info@safan.nl, Website: www.safan.nl
E102005.E
e for electronic
Press Brakes

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The E-volution in sheet metal working
Since the introduction of the first servo-
mechatronic press brake – the SAFAN SMK
– developments at SAFAN have continued.
The patented drive system has been
optimized, the electronics refined and
the range of applications considerably
expanded. The extensive work on the
further development of the SMK has
now resulted in the first all electronic
press brake: the SAFAN E-Brake.
With capacities up to 200 T and a
4100 mm working length, the SAFAN
E-Brake is the advanced alternative to
the conventional hydraulic press brake.
The SAFAN E-Brake signals the start
of the irreversible electronic evolution
in sheet metal working. Because, to
put it in one word, the advantages are:
E-normous! Which is good news for you
as a manufacturer of sheet-metal products,
particularly in staying ahead of the competition.
"Survival of the fittest" requires that you maintain
your technological edge - and preferably increase it. After
all, standing still means losing ground. The SAFAN electronic
evolution helps you make a great leap forward.
A head start with the
SAFAN E-Brake
Because the SAFAN E-Brake electronic press brake has
been developed as an integral new concept, it combines
a whole range of unique advantages compared to the
conventional hydraulic press brake. The SAFAN E-Brake
sets new standards in terms of ergonomics, efficiency,
economy and ecology. Its proven reliability and optimum
performance have been demonstrated by means of
extensive testing under the severest and most demanding
circumstances.
The SAFAN E-Brake concept is built around the completely
new servo-electronic drive based on the pulley principle.
It results in a very even distribution of forces, such that in
98% of cases no crowning table is required. Similarly, an
entirely new generation of electronics and software makes
operation and control extremely fast, easy and precise.
The SAFAN E-Brake also incorporates further advances
in ergonomics, including the user-friendly Touch Screen
control. Cycle times are shorter, the working range has
been increased, the possibility of mistakes reduced …,
in brief, a vast improvement in productivity.
The SAFAN E-Brake combines all of the above with a
pleasantly low noise level, an energy consumption that is
reduced by up to 50%, an integrated safety system and
a high degree of environmental responsibility.
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E for even bending
With the SAFAN E-Brake you obtain the most
accurate and constant bending angle along the full range
of the machine, without the need for crowning. The unique
patented pulley drive in the top beam produces a very even
and immediate distribution of forces.
A balanced combination of powerful electric
servo motors, fixed and moving pulleys, and
specially developed belts make it possible to
handle over 200 tonnes. The flexible belts,
which are only 3 mm thick and 50 mm
(resp. 100 mm) wide, are reinforced with
steel wires and coated with hard
polyurethane. This advanced technology has
been extensively tested in the demanding
elevator industry. So reliable is the
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technology that SAFAN are able to offer a 5 year
warranty on the mechanical drive system, when
combined with an annual service contract
The special construction of the SAFAN E-Brake
also contributes to the even absorption of large
forces. The O-frame acts as a single unit and
deformation is kept to an absolute minimum.
It is more stable, stronger and produces less
deformation than a conventional C-frame.
E-Brake Conventional
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E for efficiency
Increased performance in less time. No
problem at all with the electronic efficiency of the
SAFAN E-Brake press brake. The mechatronic
drive in the top beam alone, already saves a lot of
time because it requires far fewer settings.
Backgauge with X-, Z1+Z2-, R- and Delta X-axes.
The electronic control has been developed by
SAFAN itself and uses a new generation of
electronics and software. This results in
very short response and delay times,
yielding bending speeds of up to 20 mm/sec.
The effectiveness and precision of the
SAFAN E-Brake are increased even further
by its digital drive incorporating a ‘closed-
loop’ system and vector control technology.
The cycle times are also much shorter than
for conventional press brakes, partly due to
the fast backgauge.
Smaller bending work is no problem either,
thanks to the narrow construction of the top
and lower beams. The working range is
extremely large with a maximum top beam
stroke of 290 mm and a Qmax (daylight
dimension) of 690 mm. The SAFAN E-Brake
increases efficiency even further through a
unique and innovative backgauge system.
The system can be put to optimum use
across the entire range of the machine and
is very accurate thanks to an electronic
control system (± 0.02 mm). The system is
modular in both its construction and in its
options. The backgauge is very distinctive
because the beam extends across the full
width of the machine.
Special hinged backgauge pins are standard,
allowing a maximum sheet size of a 1000
mm and the R-axis is adjustable from the
front of the machine using a handwheel.
The backgauge has a very high positioning
speed of 350 mm/sec.
The new SAFAN E-Brake is further optimised to take maximum advantage of the high
acceleration and other favourable servo-motor characteristics. For this reason, our E-Brake is
not only very fast in the rapid approach stage, but also throughout the entire cycle.
We demonstrate this by manufacturing a specimen product (see illustration on right) on an
E-Brake. As a comparison the product was also produced on a conventional press brake.
SAFAN E-Brake: 20 sec
Conventional: 28 sec
Main drive system with 2 servo motors
Standard backgauge
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Capacity with the E of enormous
SAFAN E-Brake 150 T-3100 and 200 T-4100
The success of the SAFAN E-Brake with a
pressing force up to and including 100 tons has
received a logical follow-up: the extension of the SAFAN
E-brake into the segment involving greater pressure
forces and longer working lengths. The new 150 and
200 ton models now make it possible to profit from the
unique advantages of the innovative E-Brake technology
when bending heavy and long products.
Proven technology
SAFAN’s servo-electronic technology has
been proving itself all over the world since
1995. The SAFAN E-Brake concept
constitutes a further improvement on this
technology, one that is resulting in ground-
breaking performances. Customers are
therefore full of praise, especially about the
much shorter cycle times, more
advantageous use of energy and
substantially lower costs for maintenance in
comparison with traditional hydraulic press
brakes. Based on this extensive practical
experience, SAFAN has effectively adapted
the technology and construction to the
segment involving weights up to 200 tons
and work lengths up to 4 metres.
In addition, a strong point of the
construction is the level foundation.
Heavy-duty back gauge with
full range of operation
The SAFAN E-Brake 150-3100 and the SAFAN E-Brake 200-4100
are both equipped with a heavy-duty sized CNC-controlled backgauge
system that is equipped with two ball screws and play free ballscrew linear
guides. Even in this regard, the SAFAN E-Brake concept offers a unique
advantage: the backgauge can be used over the entire working length of
the machine.
The standard backgauge is equipped with a
CNC controlled X axis and two backgauge
fingers that can be manually moved along
the bending line (Z axes) as well as adjusted
in height (R axis). The fingers are provided
with interchangeable stops.
The backgauge system can be optionally
fitted with CNC controlled R and Z axes and
a dX axis. It is also possible to fit a fully 3D
backgauge with X1, X2, Z1, Z2, R1 and R2
axes.
Rollenaandrijving d.m.v. 2 servomotoren.
Various interchangeable backauge stops
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SAFAN TS1 in Run mode.
E for ergonomic
Electronic operation and control by means of a
Touch Screen is a typical SAFAN innovation. With its
Touch Screens, SAFAN has set a new standard for
press brake controls.
The SAFAN TS1 control is the most simple
and effective Man/Machine Interface
available at present; and a shining example
of the electronic evolution in sheet metal
working. The control is PC based and runs
under Microsoft Windows ® .
An intelligent feature of the SAFAN TS
control is that it only displays those buttons
that are required at the particular stage of
operation. The system is so simple that it
makes bending sheet metal almost literally
child’s play. The adjustable height of the
control unit ensures optimum ergonomics
for any operator, whether short or tall.
A standard accessory is a 100 MB Ethernet
UTP network connection that opens up
unlimited possibilities. The instructions from
the SAFAN TS control are sent to a central
processor, which in turn activates the
various axes by means of a so-called
CAN-BUS (Control Area Network). The
advantage of this system is that the
electronics are of a modular construction,
requiring fewer components. This means a
high degree of flexibility and compatibility, as
well as great reliability.
The system can be programmed very quickly
and accurately thanks, among other things,
to a "self-learning" database of materials,
tools and previous (corrected) bendings.
The standard SAFAN TS1 control uses a
numerical bending-parameter entry and
representation.
SAFAN TS3 control
Options for graphic programming
Options for graphical programming
and representation
By extending the Touch Screen control with bending simulation software and a keyboard,
SAFAN now offers advanced graphic applications that further boost efficiency.
The optional TS2 and TS3 controls use Delem software, but can also be connected to external
packages such as SomaBEND (Radan).
Summary of SAFAN press brake controls TS1 – TS2 – TS3
Control type Description Features/representation Off-line control by
TS1 SAFAN CNC Numeral product entry, - SAFAN TS software
press brake control by means of Touch Screen - Delem Profile
- numerical bending parameter - Delem VBend
presentation - External software
- symbols for sheet handling - SomaBEND (Radan)
TS2 As TS1, but with As TS1 but also with: - SAFAN TS software
graphical representation - graphical representation of - Delem Profile
of the bending sequence 2D and 3D products - Delem VBend
- External software
- SomaBEND (Radan)
TS3 As TS2, but with As TS2, but also with: - SAFAN TS software
graphical programming - graphical product entry and - Delem Profile
and representation of the representation by means of an - Delem VBend
bending sequence additional keyboard - External software
- SomaBEND (Radan)
Moveable and adjustable support arms
SAFAN has developed a range of support arms of modular construction for both light and
heavy-duty sheet-metal work. This makes it possible to rapidly set up the correct solution for
each application. An optimum combination of ergonomics and efficiency:
• moveable across the machine width • fitted with brushes or hardened strip
• adjustable height • fitted with (fine adjustment) front stops
• programmable height • suitable for use with safety light screen.
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Programming SAFAN E-Mate
Bending with the E of E-Mate…
Servo-mechatronic bending aid
With the electrically-driven E-Mate from SAFAN,
you prevent angle deviation when bending thin sheets
with large dimensions. The bending aid provides the
operator with a simple and ergonomic means to remain
within set angle tolerances.
It is often not easy for an operator to
position large sheets. Certainly during the
return movement of the top beam, it is
difficult work to keep everything in hand.
Instead of having a second operator provide
assistance, it is frequently more efficient to
install a SAFAN bending aid. In most cases,
it can be used by a single man to position
larger products. In brief, along with
accuracy, productivity is increased by the
SAFAN E-Mate, the best partner for your
operator.
SAFAN E-Mate SAFAN E-Mate plus
In order to relieve the operator in the case
of long, routine, heavy duty work, SAFAN has
developed an extremely powerful and highly
accurate bending aid.
The bending aid supports and follows the
sheet with great accuracy throughout the
entire bending process.
... and the efficiency of SAFAN E-Bend
angle measurement
Quick, easy and reliable angle measurement can
be essential to your bending process. The SAFAN
E-volution also allows you to take the lead in this
regard. Two SAFAN E-Bend systems, electronically
linked to the SAFAN Touch-Screen control, increase
your efficiency by enabling exact angle measurement
and constant monitoring of angles.
1 2 1 2
SAFAN E-Bend L
The E-Bend L system is an angle
management system that uses two laser
sensors to make measurements. The two
sensors are equipped with fastening magnets
and are placed in pairs on the front and back
of the standard bottom tool. During bending,
the sensors project a laser beam on the
sheet and measure the value of the angle in
relation to the bending tool in use.
The SAFAN E-Bend L enables the operator
to keep the bent angle constant and to do so
independently of differences in sheet
thickness and rolling direction.
SAFAN E-Bend M
The E-Bend M system can be used as an
angle management system and an angle
measurement system. The SAFAN E-Bend M
consists of two pneumatic sensors on a rail
that can be programmed for any arbitrary
position. Both sensors are in contact with
the sheet during the bending cycle.
Before the final angle is bent, the spring
back of the sheet is measured. This
measurement is used to make a correction,
after which the definitive angle is bent.
The measured values can be adopted for
bending procedures in which the geometry
of the product makes angle measurement
impossible.
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Side view
E for ecological and economical
Electronic evolution of the SAFAN E-Brake helps
you to run your business much more economically, while
maintaining environmental awareness for the future.
The absence of hydraulics means that the
problems associated with environmentally
harmful and risky oil are now things of the
past. Furthermore, your SAFAN E-Brake
uses much less energy, namely only when
the beam actually moves. This can result
in energy savings of 50% compared to
conventional hydraulic press brakes.
There is also no need to adjust the settings
of pressure relief valves – with the inherent
risk of mistakes and drift – nor are there
filters to be checked and replaced. The
absence of oil, tanks, pumps, seals, valves
and filters means that the servo-electronic
system is much more reliable than an
hydraulic one. And you will never again have
to face the inconvenience of a cold start.
Integrated safety
Working at lightning speed without risk:
SAFAN makes this possible with an active
safety system integrated in the control.
It uses a safety light guard that is
automatically controlled from the Touch
Screen.
In addition, the SAFAN E-Brake has another
built-in safety provision. The application of a
spring-return system means that in the case
of an accident the top beam will always
move upward.
Intergrated safety light guard
Automation as expertise
Labour is expensive, especially in Western Europe.
In the e-volution to a stronger competitive position,
automation is the answer. SAFAN is one of the pioneers
in this field, working together with partners in the areas of
robotics and software. SAFAN installed the first robotic
press brake in Europe as early as 1988.
Automated
Production
Solutions from
SAFAN (APS)
Since then, SAFAN has become an
experienced specialist in the field of
automated bending cells. With Automated
Product Solutions (APS), SAFAN gives
this e-volution new impulse. SAFAN offers
integrated solutions for your production
process that go further than stand-alone
solutions can. Not only the robotised
loading, operation and unloading of the
bending cell but the entire routing of the
sheet-metal material through your machine
park can be automated.
With SAFAN’s APS, you remain flexible with
a view to new products or changes in your
production process. You are also flexible
in linking with external systems and in the
choice of your robotics. The SAFAN E-Brake
and SAFAN H-Brake are particularly well
suited to serve as the focal point of each
automated bending cell. SAFAN’s control
system operates on the Windows ® platform
and uses it to create a legion of possibilities
for links, networks, software packages and,
via the internet, remedies for any stagnation
in the unmanned production process.
SAFAN supplies complete, fully tested
programmes for both new and existing robot
cells. Of course, you can entirely outsource
the programming to SAFAN.
From advice and
consultancy to
turn-key
SAFAN makes the automation of sheet-
metal working simpler than you think. This
already begins with the convenience of
one contact person for the entire project.
Our APS consultants give you clear advice
on the complete range of possibilities, so
that you can make the best choice for your
production process.
SAFAN develops and realises turn-key
solutions for bending and cutting systems
with guaranteed cycle times. This allows
you to determine your costs per product.
Based on these fixed costs, the time needed
to recover investment can be accurately
established. With the aid of a simulation
model, you are given in advance a reliable
indication of the return on investment to be
expected.
APS
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Kilo Watt
SAFAN E-Brake energy consumption
On the SAFAN E-Brake, the main drive
motor is used only when the E-Brake has to
actually perform a movement. With a
conventional hydraulic press brake, the
hydraulic pump motor is running all the
time. The graph below only covers the time
kN
while the press brake is actually in
operation. During the standby time - which
can be as much as 90% on account of sheet
handling, conversion and intervals - this will
mean a further saving with the E-Brake up to
3000 kWh a year.
E-Brake
Conventional
Adapter
NSCL-basic
Adapter
NSCL-I+
Adapter
NSCL-II
Adapter
SAFAN
Adapter
American
Adapter
European
Segmented
European
Adapter
Q = 415 mm
Stroke = 115 mm
SAFAN E-Brake tool adapters
Q = 515 mm
Stroke = 215 mm
Q = 590 mm
Stroke = 290 mm
Q = 650 mm
Stroke = 290 mm
Q = 690 mm
Stroke = 290 mm
STANDARD 3.0.8080 3.0.8090 3.0.8130 3.08140
Table
OB-3
Table
OB/S-3
Table
European
Table
OB/EUR-1
Table
DD006
Table
DD006 incl. ty
Technical specifications SAFAN E-Brake
150-200T 25-100T
HS = High Speed
Pressure force in kN.
Maximum stroke
in mm.
Closing speed
in mm/sec.
Bending speed
max. in mm/sec.
Return speed
in mm/sec.
25-1250 250 115/215/290 110
110 4
20
25-1250 HS 250 290 180 180 7
40-1600 400 115/215/290 130
130 7
20
40-1600 HS 400 290 180 180 11
50-2050 500 115/215/290 110
110 7
20
50-2050 HS 500 290 160 160 11
65-2550 650 115/215/290 90
90 7
20
65-2550 HS 650 290 140 160 11
Motor Power in kW.
Weight in kg.
A in mm.
B in mm.
C in mm.
(Q=415/ 515/590 mm.)
C in mm.
(Q=650/690 mm.)
3250 2280 1250 2485 2585
3950 2630 1600 2485 2585
4750 3080 2050 2485 2585
5950 3580 2550 2485 2585
80-2550 800 115/215/290 90 20 90 11 6050 3580 2550 2485 2585
80-3100 800
115/215/290
90
20
90
100-3100 1000 75 75
Pressure force in kN.
Maximum stroke
in mm.
Closing speed
in mm/sec.
Bending speed
max. in mm/sec.
Return speed
in mm/sec.
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6350 4130 3100 2485 2585
150-3100 1500 300 100 20 100 22 11.400 4350 3100 2885 2885
200-4100 2000 300 75 20 75 22 14.200 5350 4100 2885 2885
Motor Power in kW.
Weight in kg.
A in mm.
B in mm.
C in mm. (Q=590 mm.)
C in mm. (Q=690 mm.)
Subject to modifications
E-003
SAFAN E-Brake 25 - 100 T
SAFAN E-Brake 150 - 200 T