Safan® E-Brake

The Evolution in sheet metal working

Since the introduction of the first servo-mechatronic press brake - the Safan SMK - developments at Safan have continued apace. 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 100 Tonnes and a 3100 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 make 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.

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 100 tonnes. The flexible belts, which are only 3 mm thick and 50 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 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 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.

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 a1000mm and the R-axis is adjustable from the front of the machine using a handwheel. The backgauge has a very high positing speed of 350 mm/sec.

The new 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.

E for ergonomic

Safan has set a new standard for press brake control and operating convenience. Electronic operation and control by means of a Touch Screen is a typical Safan innovation. The Safan Touch Screen 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 Touch Screen 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 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 Touch Screen 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) bending orders. The standard TS1 control uses a numerical bending-parameter entry and representation.

• 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 Radan.

• Mobile 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:

• mobile across the machine width
• adjustable height
• programmable height
• fitted with brushes or hardened strip
• fitted with (fine adjustment) location stops
• suitable for use with safety light screen.

• Servo-mechatronic bending aid

In order to relieve the operator in the case of lengthy, 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.

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 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 screen 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.

Another step further: Flexible Production Automation (FPA)

The e-volution in sheet metal working makes the automation of integrated bending cells even more attractive and effective than before. The Safan® e-Brake is particularly suitable for serving as the centre of each automated bending cell.

The possibilities for electronic and software connections with other systems are unlimited. The experienced FPA specialists at Safan can give you clear advice on the complete range of possibilities, enabling you to choose the options most suitable for your business.

• Turn-key solutions

In the field of Flexible Production Automation, Safan can provide you with all the support you require. You can count on customer-specific solutions that range from advice on adapting your existing systems, to realising turn-key automated bending cells including loading and unloading.

Safan® H-Brake

 

Safan products distinguish themselves in modern technology with a high quality and accuracy.

Safan supplies two types of press brakes, one with servo-mechatronic drive and one with servo-hydraulic drive. Both press brakes are used widely in the market and a standard feature is their high accuracy. The top beam has a repetition and adjustment accuracy of +/- 0.01 mm. The backgauge system has an adjustment accuracy of 0.01 mm and high repetitive accuracy by means of a closed loop arrangement.

Safan distinguishes itself through the H-Brake servo-hydraulic press brake

The servo-hydraulic press brakes all have the sturdy frame structure developed by Safan and they are machined on one of the 12-metre long milling machines in Safan's own workshop.
The independent measuring frames ensure a high repetitive accuracy of the top beam even with a one-sided load.
The hydraulic servo-valves together with the cylinders manufactured by Safan itself ensure a correct positioning and the proper amount of pressure for the required forces.
The frame has a large working width and the top beam guides have been equipped with maintenance-free wear-resistant material.
In addition the top beam has been made of high-quality steel making it possible to absorb higher surface pressures.
In order to obtain a variable daylight dimension (depending on the choice of tool) compensating rings are placed between cylinder and top beam.
A selection of ring thicknesses is available.
The front of the lower beam has been prepared in such a way that various accessories can be fitted direct on to the lower beam.
Deformation of lower and top beam and geometry deviation of the tool can simply be compensated by means of the adjustable intermediate beam supplied as a standard accessory.
The servomotor controlled backgauge adjustment, standard range is 550 mm up to 2250 kN, 1000 mm when exceeding 2250 kN, has been equipped with play-free straight guides and re-circulating ball spindles and up to 1500 kN it moves at a speed of 350 mm/sec and it is highly accurate +/- 0.03 mm.
The supports have been mounted on the inside of the side frame, which offers greater access.

On the backgauge beam a fixed and a fine-adjustment backgauge finger have been placed which can be moved by hand across the entire length of the backgauge beam.

Safan distinguishes itself through control options and programming possibilities
Generally speaking dedicated machine controls become obsolete very quickly due to the developments in this field.
As a reaction to this, in 1995 Safan decided to adopt PC based controls as standard; since that time hundreds of machines with this type of control have been sold.
The PC control (running under Microsoft Windows ®) does not have a keyboard but a so-called Touch Screen.
This improves the operation and the control is direct and prompt.
Because of its PC environment the Touch Screen control has a 12.1" T.F.T. colour monitor, Flash disk memory, (+/- 2000 programmes with an average of 5 bends, floppy disk drive and a network connection (100 MB Ethernet UTP).
The instructions from the Touch Screen are sent to a central processor unit, which in turn activates the various axes by means of a so-called CAN-BUS (Control Area Network).
Apart from the Y1 + Y2 and X axes (angle and backgauge) there are 10 other axes including 5 servo-axes (in all 13 axes).
An advantage of the CAN-BUS system is that the electronics are based on a modular construction (flexible) and that it requires fewer components.
This results in a high degree of compatibility and reliability.
The Touch Screen control contains a log which, when called up via the monitor, can read functions and positions.
It contains a database for 30 upper and 30 lower tools; products and experience data can also be generated by means of the database.
Time registration and automatic crowning calculation are standard features.
The numerical and alphanumerical keyboards supplied with the control are optional accessories as well.

The standard position for the above mentioned Touch Screen is on the right and it is mounted on the machine in such a way that the range of operation is very extensive.

This is the standard control and is referred to as: TS 1.

TS 3.

Above mentioned Touch Screen control can be extended by means of software and a separate keyboard enabling you to enter, programme and simulate 2D and 3D products graphically and subsequently you can start producing.

TS 2.

An intermediate form for the method mentioned above:
From another PC or where appropriate pre-processing station products are simulated graphically and consequently programmed and then sent to the workshop after which production can start.
In this case visualisation software (does not include drawing options) is needed in the workshop.
These programmes can be activated in the Touch Screen control by means of floppy disks or through a data network.

In the two cases described above Safan uses Delem and Radan simulation software.

The two options mentioned above can also be purchased at a later stage; after all it is a user-friendly PC.

Standard features:

• Removable table.
• Intermediate beam with safety key and wedge adjustment.
• Touch Screen control unit.
• 2 support arms.
• Top beam incline Y1 and Y2 (+/- 2.50 mm).
• Foundation plates.
• In the case of the CNCL-K: filled oil reservoir.

Optional accessories

• Servo controlled Z-axes.
• Servo centrally controlled R-axis in the case of the SMK.
• D-X axis controlled backgauge pin.
• Frame on the backgauge, if required with pneumatic height adjustment.
• Increase of daylight dimension and stroke.
• Laser angle-measuring system.
• Light guard protection systems.
• Closing or flattening tool.
• Pneumatically operated height-adjustable support arms.
• Hydraulic tool clamping.
• Different tool adaptions.
• Movable support arms.
• Contact backgauge fingers.
• Angle-independent CNC controlled bending aids.
• Segmented intermediate beam.
• Independently controlled R-axes (R1 and R2) from 2250 kN centrally controlled.
• Enlarged working width.
• Movable support arms, even outside machine range.
• Tool cabinet mounted on machine.
• CNC controlled crowning (various types).

Safan distinguishes itself through standard safety

Of course, Safan press brakes meet the CE standards.
Safan can extend this with light screen protection systems.
These systems have the advantage that top beam speeds can be increased without endangering the safety of the operator.
The application of these systems means that the two-hand operation is cancelled.
The standard maximum closing speed of the top beam without light screen protection system is 10 mm/sec.
Safan was the first to market an active safety system integrated in the control.
The operator determines the procedure by means of the Touch Screen; it is possible to store this procedure in the relevant programme step.
In many cases an even higher production can be achieved in combination with the one stroke - two stroke setting options of the light screen system.

The systems fully meet the pr EN 12622 standard.

Also See Safan Website