We know that almost all sheet metal processing enterprises will use sheet metal bending machine.
But the technical workers who have operated the press brake machine all know that whether it is the ordinary press brake, or the CNC press brake, whether it is the large and heavy workpieces in the switch cabinet and elevator door industry, or the small workpieces in the kitchen utensils and air conditioning industry, whether it is the workpieces mainly produced in batch or the single workpieces mainly customized, using the press brake machine is both brain consuming and laborious.
Therefore, in the current sheet metal processing industry, there is such a phenomenon that no one is willing to be the press brake operator.
Even if it is just apprenticeship, and the enterprises provide higher wages than CNC punch technical workers, few people are willing to go to bending positions.
As a result, CNC panel bending machine “came into being.”
This post analyzes and introduces the CNC panel bending machine with reference to the press brake machine.
Panel bender & press brake features
CNC panel bending machine is different from press brake machine in principle, and has better guarantee in bending accuracy and sheet protection.
At the same time, the tool replacement is more intelligent and convenient, and the requirements for the level of operators are also greatly reduced.
Bending principle of panel bender and press brake
The press brake controls the bending angle by adjusting the downward stroke of the top punch.
At the same time, when bending, because the short side is on the inside, the operator needs to hold up most of the material on the outside, and during the bending process, the operator needs to hold the plate to follow its upward movement.
When bending large workpieces, two or more employees are needed.
When there are bending demands in different directions in all bending processes of an edge, it is necessary to turn over manually and repeatedly.
The working principle of the panel bender is to place the sheet on the worktable, press down the edge press beam to fix the sheet, and turn up or down the beam to realize bending.
In all the bending processes of one edge, manual positioning, auxiliary positioning and turning are no longer needed.
Bending accuracy and consistency
(1) Dimensional accuracy.
The dimension precision controlled by the press brake is the short side dimension precision of the back stop positioning. After the bending is completed, the error is accumulated to the bending dimension of the next process, so that the accumulated error is concentrated on the final forming dimension.
The dimension precision controlled by the panel bender is that the outside edge is taken as the positioning datum for each folding, and the controlled dimension error is only concentrated on the first folding, which has no influence on other dimensions.
(2) Angle accuracy.
On the press brake, the bending angle is controlled by the downward stroke of the top punch, which is related to the material thickness.
In the panel bender, the bending angle is directly controlled, and the material thickness has little effect on it.
The dimensional accuracy of each side of the press brake is guaranteed by the back stop positioning, and the accuracy is inconsistent due to various external factors;
The angle is determined by the position of the ram. The positioning accuracy of the ram control and the hot and cold conditions of the hydraulic system have a significant impact on the angle accuracy.
The positioning accuracy and angle processing of the workpiece are completely controlled by the servo motor of the press brake, and the consistency of the size and angle processed can be well guaranteed.
Scratch protection of sheet metal
When the press brake is working, the material will move relative to the plate. If the plate surface is not protected, the indentation will be left.
At the same time, when one side needs to achieve a variety of processing technology or bending large workpiece, it needs to turn over and move many times, which will inevitably produce scratches in the process.
When the panel bender is working, there is no relative movement between the pressing beam die or the bending beam die and the plate, which can avoid the surface scratch.
When there are many kinds of processing technology on one side or large workpieces need to be bent, because the sheet metal is horizontally placed on the worktable for processing, after the first positioning, all the processing on one side of the workpiece can be completed, and the surface scratch can be completely avoided.
Because the bending die is directly used to achieve the fixed folding line and angle forming parts, when bending different materials, different thickness, different angles and even special structures, it needs to change the tool or the machine to process step by step;
When there is a need for edging or the bending process affects the bending (Fig. 1), the same workpiece needs multiple sets of dies with different lengths to complete the processing.
At this time, it is necessary to replace and readjust the mold, or even replace the machine tool.
Fig. 1 Bending workpiece affected by sequence
The panel bender uses two sets of molds to control the bending line fixation and angle forming respectively. By automatically adjusting the spacing between the two sets of molds, the angle forming of different materials, different plate thickness and different R angle can be realized;
For hemming, bending with arbitrary angle, bending arc, etc., different control programs can be called, and the processing requirements of the workpiece can be easily realized through the cooperation of two sets of dies of pressing and bending;
In the process of bending, if the die length needs to be changed, it can be automatically switched by adjusting the program at any time, and there is no need to debug after the die is replaced.
The programming and operation of the press brake have higher requirements on the technical level of bending workers, especially for the workpiece with complex folding process.
The program of panel bender can be programmed off-line by programming software.
Through the import of 2D or 3D graphics, with the help of simple drag and drop settings, the machining code can be generated automatically
In the programming process, it can also automatically prompt bending interference.
When the program is copied into the panel bending machine through the network cable or U disk, the operation of the machine becomes a simple matter of pushing buttons and loading and unloading.
Industry application advantages of CNC panel bender
Whether it is industries like switch cabinets, elevator door panels and other industries with large workpieces and heavy workpieces, or industries with small workpieces and light workpieces such as kitchen cabinets and air conditioners, they are paying close attention to the panel bending machine.
According to the preliminary statistics, the CNC panel bender has been applied in many industries, such as switch cabinet, elevator, household appliances, kitchen cabinet, medical and so on.
The following is to share the application advantages of the widely used switch cabinet industry and cabinet industry.
Switch cabinet industry
The characteristics of switchgear products (Fig. 2) are large, heavy and dangerous, and there are certain precision requirements for the final forming dimensions.
Fig. 2 Switch cabinet parts
If the conventional bending machine is used for processing, at least two operators are required to carry the workpiece and bend the iron plate one by one according to the speed of the bending machine, which has high requirements for workers and unstable error control.
Coupled with heavy workload, daily production capacity is greatly limited, and there will be great security risks.
The panel bender only needs one person to operate, cooperate with automatic loading and unloading, put the workpiece flat on the working platform, automatically carry out edge-changing and folding processing, and the process will not be affected by human factors and produce precision deviation.
In general, the panel bending machine is not only time-saving and labor-saving, but also safe and efficient.
Cabinet products (Figure 3) is characterized by relatively thin sheet, but the processing requirements are more complex.
Fig. 3 Cabinet product parts
When bending with the press brake machine, it is necessary to check the unfolding size of the parts according to the contents of the drawing. After confirming that there is no error, it is necessary to select the appropriate tool for tool setting and matching, and then program according to the requirements.
This process requires a high level of work experience for workers.
In addition, due to the need for round edge wrapping and special process, if the press brake is used, it needs to change multiple sets of tools or machines, which is time-consuming and laborious.
The panel bender only needs to read the sheet metal size and forming size, and the reasonable folding program is automatically generated by the programming software.
The universal bending tool of panel bender can reduce or even save the time of changing the bending tool. For the kitchen utensils with many special process requirements, it can easily complete the processing, and finally fold the workpieces that meet the requirements more quickly and economically.
Development prospect of panel bender
With the characteristics of automatic production in the whole process, CNC panel bender not only has great application advantages when compared with multiple sets of press brakes alone, but also can realize automatic production by connecting with punch press, laser cutting machine and other machine tools, and even can be used with intelligent management software and multi row material warehouse, so as to provide customers with a full set of solutions for intelligent chemical plants.
In the face of the current problems of “difficult employment” and “expensive employment”, intelligent and efficient automatic production line can greatly reduce the requirements of labor quantity and experience in production, and customers can obtain higher production capacity and income through lower labor cost.