BendVision | real-time analysis of the bending process. BendVision takes a unique approach to press brake angle measurement and angle control through advanced image processing technology that delivers greater flexibility and accuracy for machine manufacturers and users. Press brake users have always faced challenges with air bending due to a number of factors including machine beam deflection, variation in material thickness and variations in material grain direction. Even when a bending job is set-up and program corrections have been made for the machine to produce the desired angles, variations in material thickness and grain direction from one part to the next can still cause issues with angle accuracy and consistency.
BendVision high-speed image processing provides real-time analysis of the bending process, enabling accurate angle measurement and real-time bend angle control. 22
So, what are the options for machine operators? The most common method is manually checking and measuring angles using a protractor or preset angle reference tool. Depending on the accuracy required for each part, the operator may need to check each part after it has been formed, or periodically check a sample of parts when processing a volume batch. Of course, while this method requires no additional upfront investment when the machine is purchased, there is a much longer-term cost in respect to lost production time that is consumed with manual measurement and checking of parts and the potential for more material wastage. The second option is to invest in a factory installed angle measurement system when purchasing the press brake. Most press brake manufacturers today offer some form of proprietary angle measurement solution as an optional extra. The two traditional and most commonly available methods have been laser projection sensors and mechanical contact sensors.
The laser projection sensors are generally housed on the front and back sides of the lower machine beam and then project bands of light onto the undersides of the material. These sensors can either be static, where the operator would manually position the sensors to align with the work-piece, or motorised for automatic positioning. Mechanical contact sensors come is various forms that either contact and measure the outside or inside surface of the material. To be effective, both of these types of measurement solutions are integrated into the machine process by the manufacturer and will often include some form of automated angle correction or control. While these are usually accurate and effective solutions, they are generally also expensive options that need to be carefully considered during the purchase of a new machine. The high cost is attributed to the dedicated optical or mechanical sensors, associated electronics and software, as well as complex motorised mounting systems that are often required in the design of these systems. In a perfect world, all press brakes would include an angle measurement device, however in reality, due to the high initial outlay, they are generally only fitted to a small number of the total machines that are manufactured and sold each year.
PRESS BRAKE BUYER’S GUIDE
