Are you looking for a comprehensive guide on how to safely operate and maintain a hydraulic press brake? Look no further!
In this blog post, we will cover everything you need to know about operating a hydraulic press brake, including important safety procedures, precautions, and maintenance tips.
Whether you are a seasoned professional or just starting out, this guide will provide you with all the information you need to ensure the safety of yourself and others, as well as the longevity of your equipment.
So, let’s dive in and learn how to operate a hydraulic press brake like a pro!
1. Operating procedures
- Follow the safety regulations for machine tool workers and wear the necessary protective gear.
- Check for any foreign objects on the front support frame, rear retaining frame, and ram and remove them if present to avoid potential safety hazards.
- Verify the alignment and stability of the upper and lower molds and check that each positioning device meets the processing requirements.
- Before starting, thoroughly clean the upper and lower production models and remove any foreign objects, such as iron ballast, from the notch to avoid damaging the models and affecting accuracy.
- Before starting, carefully inspect the motor, switch, wires, and grounding for any issues, and check that the equipment’s operating parts and buttons are in the correct position.
- If the upper ram and positioning shafts are not at the origin, run the procedure to return them to the origin.
- After starting the machine, allow it to idle for 1-2 minutes and move the ram through a full stroke 2-3 times. If any abnormal sounds or faults occur, stop the machine immediately, resolve the issue, and only continue operation after everything is normal.
- Select the correct die based on the plate thickness. Generally, the opening size should be 6-10 times the plate thickness, and for plates under 2mm, it should be 6-8 times.
- Have one person in charge of overseeing the operation to ensure close cooperation with the feeding and pressing personnel and to ensure that all personnel are in a safe position before sending the bending signal.
- When processing narrow broken plates, reduce the system pressure to avoid cracking the notch of the production model.
- Before bending, adjust the gap between the upper and lower production models to be equal.
- During bending, the person in charge of the operation should not place their hands in the production mold room and narrow, long, or small materials should not be supported by hand. Only bend one piece of material at a time and do not bend multiple pieces simultaneously.
- Check the oil level in the tank and refill with hydraulic oil of the same model if necessary. Start the machine and check for any issues with the hydraulic pipeline or oil pump.
- If an abnormality occurs, stop the machine immediately, investigate the cause, and resolve it promptly. Do not operate the machine with injuries, as it will worsen the problem.
- The person in charge of the operation must undergo specialized training and the company should assign a designated operator for the machine to ensure proper protection and maintenance.
- Compact the sheet material during bending to prevent warping and potential harm.
- Cut off the power supply when pressing the die and only do so after stopping the operation.
- When changing the opening of the variable lower die, do not allow any material to contact the lower die.
- Do not stand behind the machine tool while it is in operation.
- Do not fold plates at one end alone.
- If a mold issue is discovered during operation, stop and correct it. Do not make corrections by hand during operation to prevent injury.
- Do not bend thick iron plates, quenched steel plates, high-grade alloy steels, square steels, or plates that exceed the performance of the plate bending machine to avoid damaging the machine.
- Regularly check the alignment of the upper and lower molds and the indication of the pressure gauge.
- Before shutting down, place wooden blocks on the lower die below the oil cylinders on both sides and lower the upper ram onto the wooden block or lower the upper die to the bottom of the lower die opening.
- After work, turn off the oil pump and power supply.
- It is forbidden to fold over thick iron plates, quenched steel plates, high-grade alloy steels, square steels, or plates that exceed the performance of the plate bending machine.
- Ensure the safety of all personnel by following the proper operating procedures and guidelines at all times.
Precautions before operation:
- Before starting the machine, inspect the oil circuit, oil cup, and oil level according to the lubrication chart to ensure that the oil is of good quality and that the oil circuit is clear.
- Check that all parts are in good condition, that the upper and lower dies are in the correct position, and that the oil pump motor is operating normally.
- After starting the oil pump, run it under air pressure for 3 to 5 minutes and confirm that the equipment is functioning properly.
Precautions for operation:
- During operation, the workpiece being pressed should be positioned in the center of the upper and lower dies and parallel to them, and placed securely. No adjustments or repairs to the dies should be made during operation.
- When pressing long or large workpieces, two or more people should be involved to prevent the workpiece from dropping or deforming during the release of pressure. It is not allowed to clamp the ends of the workpiece being pressed.
- When changing or pressing the workpiece, it should be positioned in the center of the dies without any tilt. The upper die should be approached slowly to prevent the workpiece from popping out.
- Always check that the strokes of the two oil cylinders are consistent during operation and make adjustments or report for repair if necessary. If the oil cylinder piston shakes or the oil pump makes a loud noise, the air in the oil circuit must be removed.
- Regularly monitor the oil tank to ensure that the oil level is appropriate. If the oil level is too high, inspect the oil return pipeline and adjust the oil return valve. Overfilling the oil tank is strictly prohibited. The temperature of the working oil should not exceed 45°C.
- If the control valve, safety valve, or safety protection device fails, operation must not continue.
- The operator should secure the adjusting valve and pressure gauge after making any adjustments, and others should not move or adjust them.
- If the working pressure is too high, the valve should be checked and adjusted, and operation can only resume once the issue has been resolved.
- The upper die should not exceed its maximum stroke.
- No hands should be placed between the upper and lower dies during operation.
- Regularly check the machine’s travel to ensure the safety of the switch.
- Turn off the oil pump when adjusting the dies or performing maintenance to ensure safety.
Precautions for shutdown:
- Before shutting down the machine, the dies should be closed. Follow these steps to shut down: first turn off the working oil pump, then turn off the control power supply, and finally turn off the main power supply.
- After completing the work, clean the machine and surrounding workspace, and store the workpiece in the designated location.
1. Hydraulic oil circuit
a. Inspect the oil level of the oil tank once a week. If the level is below the oil window, add hydraulic oil.
b. The recommended hydraulic oil for this machine is ISO HM46 or Mobil DTE25.
c. The oil in a new machine should be changed after 2000 hours of use, and should be changed again after 4000 to 6000 hours of use. Each time the oil is changed, the oil tank should be cleaned.
d. The oil temperature in the system should be between 35°C and 60°C and should not exceed 70°C. If the temperature is too high, it can lead to deterioration and damage to the oil quality and components.
a. Whenever you change the oil, the filter should be either replaced or thoroughly cleaned.
b. If the machine tool has an alarm or other indication of an unclean oil quality, the filter should be replaced.
c. Inspect and clean the air filter on the oil tank every three months, and it is recommended to replace it once a year.
3. Hydraulic components
a. Clean the hydraulic components (base plate, valve, motor, pump, oil pipe, etc.) every month to prevent contamination. Do not use soap or other cleaning agents.
b. After the machine has been in use for one month, inspect the bend of each oil pipe for any deformities. If any are found, replace the pipe. After two months of use, tighten all connections of accessories. Perform this maintenance with the machine turned off and with no pressure in the system.