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Boosting Press Brake Safety: Laser Protection Explained

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Press brakes are equipment with a high risk factor, invariably leading to numerous occupational injuries, particularly when handling small workpieces or during dual operations. Injuries such as crushed fingers and arms are common.

So, why do occupational injuries occur during the bending process?

Boosting Press Brake Safety Laser Protection Explained

The main reasons include operator negligence, weak safety awareness, inconsistent rhythm between setting workpieces and stepping on the foot switch, and lack of focus due to fatigue.

Post-injury, operators may experience a severe impact on their quality of life and work; businesses may need to pay substantial compensation, and with injured workers on sick leave, production gets delayed, leading to business losses.

By installing a specialized laser safety protection device on the press brake, operators’ safety can be effectively ensured, preventing injuries and accidents before they happen.

The main components of the press brake’s laser safety protection device include a transmitter, receiver, controller, transmission line, and mounting bracket.

There are four main models: MSD, DSP, DSPAP+MCS, and DSPAPEX+MCSEX, as shown in Figure 1. This article primarily introduces the DSP five-point laser safety protection device.

Figure 1: Model of Safety Protection Device

Features of the DSP Five-Point Laser Safety Protection Device

The DSP five-point laser safety protection device, which complies with CE standards and reaches a safety level of CAT IV, protects a maximum distance of 15m.

Installed on the upper crossbeam or slider, it forms a block-shaped protection zone around the bending knife tip, protecting the front, middle, and back areas.

As the upper die moves synchronously with the protection zone, it ensures that any object beneath the high-speed descending upper slider enters the DSP-generated protection zone before touching the knife tip, thereby preventing occupational injuries.

The response time of the press brake after installing the DSP five-point laser safety protection device is 5ms, and the speed transition point is 5mm+ the stop distance, as shown in Figure 2.

Figure 2: Schematic Diagram of Speed Conversion Point

Additional features include a slow-down shield function and stop-distance detection function (mechanical).

Three Modes of the DSP Five-Point Laser Safety Protection Device

The DSP five-point laser safety protection device offers three selectable modes, as shown in Figure 3, with the protection zone diagram shown in Figure 4.

Figure 3: Three Modes
Figure 4: Schematic Diagram of Protected Area

Mode 1: In this mode, all depicted front, middle, and back areas totaling five laser protection monitoring functions are activated, as shown in Figure 5.

Figure 5: All Laser Protection Monitoring Functions Activated

Mode 2: In this mode, only the middle area, with a total of two laser protection monitoring functions, remains active, protecting the bending area, as shown in Figure 6.

Figure 6: Two-Point Laser Protection Monitoring Function Activated in the Central Area

Mode 3: In this mode, all depicted front and middle areas, with a total of four monitoring functions, remain active, protecting the operator and bending areas, as shown in Figure 7. This mode is suitable when the backgauge moves over the die.

Figure 7: Four-Point Laser Protection Monitoring Function Activated in the Front and Central Areas

Installation Bracket of the DSP Five-Point Laser Safety Protection Device

The standard installation bracket types for the DSP five-point laser safety protection device are shown in Figure 8, but custom brackets can be made according to the mechanical structure and application scenarios of the customer’s onsite equipment.

Figure 8: Conventional Support Bracket Type

If the press brake uses side pull plates or frequently replaces dies during operation, a customizable sliding bracket can be used. If the mechanical compensation of the press brake interferes with the motor, the bracket crossbeam can be extended, generally to 300-350mm.

If the lower beam structure of the press brake is irregular, a transition block and extended crossbeam may be needed. A flip bracket can also be used based on actual conditions. Customized bracket versions are shown in Figure 9.

Figure 9: Customized Support Bracket

Analysis of the Effect of Installing the DSP Five-Point Laser Safety Protection Device on the Press Brake

Taking the Amada HYB equipment as an example, as shown in Figure 10, we have conducted an efficiency analysis.

Figure 10: Installation of Safety Protection Device on Amada HYB Equipment

For customers pursuing efficiency, if the original speed transition point is set relatively low, such as within 4mm, we use 4mm as a reference. If the DSP five-point laser safety protection device is installed under the press brake, the efficiency impact per cut is within 0.1s.

If installed on the upper slider, due to the slider’s own stop distance, the efficiency impact per cut is within 0.5s. While the impact on efficiency is negligible, the safety factor reaches 100%, effectively preventing occupational injuries.

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