The first electronic press brake for heavy-duty work
A
A head start with the Safan e-standards Safan has set new standards in terms of efficiency, economy, ergonomics and ecology with the SAFAN E-Brake
machine
concept.
These
E-standards will give you, as a sheetmetal working manufacturer, a head start over your competitors, now also with sheet bending using pressure forces up to 300 T. What are the most important advantages for you in comparison with (traditional) hydraulic press brakes?
The e - volution in sheet-metal working reaches a new milestone
2
The
e-standard
in Efficiency
* Up to 30% shorter cycle times * Bending without crowning * Back stop can be used across the entire
Since the very first CNCK servo-hydraulic press brake in 1980,
I-Brake won the Techni-Show Innovation Award (among others).
Safan has been world leader in the development of innovations for
And the
sheet-metal working. Safan introduced the patented servo-elec-
After all, top performances in terms of efficiency, economy, ergo-
tronic brake press (SMK) in 1995, the hybrid guillotine cutter in
nomics and ecology are needed now more now than they ever were
The
1999 and the first full electronic press brake in 2004, the SAFAN
in order to stay ahead of the competition in the world of sheet-
* Up to 50% energy savings
E-Brake. With this pioneering machine concept Safan began the
metal working manufacturers. With the SAFAN E-Brake ‘Dual
* Minimum maintenance costs
'e-volution in sheet-metal working', a development in which the
Drive’ 300T, Safan has now ensured that the unique advantages
application of innovative electronic technology has a central role.
of the E-Brake technology are available for the heavy-duty segment
The
Safan has taken a leading role in that development as inventor of
with pressing forces up to 300 T. This breakthrough was only pos-
* SAFAN E-Control touch screen controls
the electronic press brake with pulley drive. After the first genera-
sible thanks to a new Safan invention; the 'Dual Drive' with double
* Significant bending leeway due to slender
tion 'Original E-Brake' with pressure forces up to 100T, the
pulley system. Together with the newly developed lower beam and
middle-weight E-Brake 150T and E-Brake 200T followed in 2006.
the new E-Control touch screen controls, this results in an unprec-
Safan surprised the sheet-metal working world a short while later
edented increase in performance in heavy-duty work. The SAFAN
with the SAFAN I-Brake, the intelligent press brake with two inte-
E-Brake Dual Drive 300T: a new milestone for SAFAN, a potential
grated robots. Both the SAFAN E-Brake 200T and the SAFAN
head start for you.
e-volution
In sheet-metal working continues undiminished.
working length * Optimum programmability
e-standard
e-standard
in Economy
in Ergonomics
lower beam * Optimum safety The
e-standard
in Ecology
* No environmentally harmful oil * Low-noise operation 3
T
P
The SAFAN Dual Drive, a unique innovation
Perfectly compensating lower beam, just as unique
As a manufacturer of the most advanced press brakes, Safan is aware of the requirements that are set in the heavy-duty market. This know-how is combined
The lower beam of the SAFAN E-Brake Dual Drive 300T is a
with the latest technology in the field of electronic bending in the SAFAN E-Brake
completely new development, as a second important innovation
Dual Drive 300T.
within the E-Brake concept for the heavy-duty market.
In order to facilitate the step towards tonnages of 300 T
of forces across the entire press beam. The poly-
The lower beam perfectly compensates the minimum
Reinforced O-frame for optimum
(and more in the future), the Safan R&D department were
urethane belts are 100 mm wide and reinforced with
deflection, eliminating the need for a crowning table,
stability
faced with an amazing challenge: developing a new con-
steel wires, a very reliable and abrasion resistant
even at maximum pressing force. The machine does not
The machine has a very stable O-frame construc-
cept drive based on the tried and tested E-Brake pulley
technology that is also used in the elevator industry.
have to be fitted with a sword. The lower beam is only
tion with a reinforced bridge and side frames. The
technique. The solution was found in a double pulley sys-
This is why Safan gives a 5 year guarantee on this part
180 mm wide, a beam as slim as this is unprecedented
bending tools remain in a straight line even under
tem, the patented SAFAN Dual Drive.
of the drive (in combination with an annual service con-
in this heavy-duty machine class. The machine also has
maximum bending loads. In addition to optimal
tract).
an exceptionally large 400 mm stroke. This means that
stability, there is another advantage to this con-
300 T of evenly distributed pressing force
Thanks to the balanced distribution of force, the deflec-
the SAFAN E-Brake Dual Drive 300T provides an e-nor-
struction: the back gauge can be used across the
The press beam is driven by eight servo-motors on
tion is still minimal, even at 300 T pressing force. And
mous freedom to bend for your operators.
entire working length of the machine.
four axles using the double pulley system. In a perfect
another Safan innovation is used to eliminate the very
balancing act with fixed and flexible rolls, flexible belts
same minimum deflection!
are used to create the most perfectly even distribution
Detail drawing Dual Drive double pulley technique
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Dual Drive double pulley technique
SAFAN E-Brake 300T ’Dual Drive’
Force distribution with Dual-Drive drive
E-Brake
Conventional
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S
H
Heavy duty backgauge with a large range
Switch to 300 T of competitive power
The SAFAN E-Brake 150-3100 and the E-Brake 200-4100 are both
You will have a much stronger position in the market with the new
equipped with a heavy-duty CNC controlled backgauge system fitted with
Safan electronic heavy-weight. You can produce the most accurate
recirculating ball screws and precision linear ball-bearing guides. The basic
and constant bending angle across the entire 4100mm range of the
model comes complete with CNC controlled X axis.
machine without the need for crowning. Faster, uses less energy, more ergonomic and durable than any other hydraulic press brake. A step forwards in productivity
to achieving the shortest possible cycle times.
Due to the electronic drive (therefore no valves and
the upper beam is actually moving. This generates
The standard version of the backgauge has two
Optional equipment includes backgauge systems
considerable savings that can amount to 50% in
hinging backgauge fingers that can be manually moved
equipped with CNC controlled R, Z1, Z2 and
other hydraulic delays), the switching times of the
A step forwards in durability
comparison with conventional hydraulic press brakes.
along the bending line (Z axis) as well as adjusted in
X axes, or full 3D movement with X1, X2, Z1, Z2,
SAFAN E-Brake Dual Drive are extremely short. This
The absence of hydraulics means that the problems
This means that an e-normous decrease in your pro-
height (R axis). The stop fingers are provided with
results in a cycle time that is an average of 30% faster
associated with environmentally harmful and risky oil
duction costs goes hand in hand with a much lower
interchangeable pins. In optimum use, they permit a
than a conventional hydraulic press brake.
are a thing of the past. The servo-electronic system
burden on the environment.
maximum backgauge range of 1100 mm.
R1, and R2 axes.
is therefore much more reliable than the hydraulic A step forwards in safety
system due to the absence of oil, tank, pump, seals,
A step forwards in working range
In terms of the safety of your operators, the SAFAN
valves and filters.
The back gauge can be used across the entire work-
E-Brake Dual Drive provides the ultimate solution: a
ing length by using an O-frame machine construction. A step forwards in energy savings
the SAFAN E-Control controls. This also contributes
The SAFAN E-Brake Dual Drive only uses energy when
Kilo Watt
safety screen that is automatically controlled from
Heavy-duty backgauge
Standard backgauge stops
3D backgauge stops
E-Brake Conventional
SAFAN E-Brake energy consumption
Integrated safety light guard
kN
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7
S
SAFAN E-Control, the new
e-standard
O
in ergonomics
Options for 2D simulation and 3D graphic programming
Since the introduction in 1995, the SAFAN TS-controls have been the international standard for ease
The optional E-Control 2 and E-Control 3 controls facilitate 2D and 3D
of operation. The Safan touch screen concept is therefore the most functional and intuitive Man-
graphic display and programming.
Machine interface in the sheet-metal working industry. Safan have once again shifted the standards with the SAFAN E-Control as the latest generation touch screen controls.
Complete Touch Screen convenience
controls, which in turn regulates the various axis via
Web-based communication and support
The SAFAN E-Control is fully touch screen, whereby
a so-called CAN-BUS (Control Area Network). The
The controls are set-up for web-based communication
the only buttons visible on the 17” screen are those
system can be programmed quickly and accurately
such as online diagnoses and loading software updates
that are needed during operation. The controls simply
thanks to a ‘self-teaching’ database with data on
via the web. Machines can also be coupled to each
run on a PC under Microsoft Windows®, the software
materials, tools and previous, already corrected
other in a group and tooling databases can be shared.
was developed based on Microsoft.net Framework.
bending. The SAFAN E-Control can be coupled to the
By monitoring and analysing your operating data online,
The unit is fitted with a 100 MB Ethernet UTP network
majority of off-line programming systems. The stand-
Safan will be in a position to optimise your production
connection as standard. The instructions are transmit-
ard SAFAN E-Control 1 controls work with numerical
process from a distance in the near future
ted to a central processor from the SAFAN E-Control
input and bending parameters display, however the
Summary of SAFAN press brake controls TEC1 - EC2 - EC3
Control type
user receives immediate graphic support in many areas.
SAFAN EC2 control
Off-line connections to
EC1 Numerical product data entry - 2D programming of products by means of Touch Screen and bend simulation with - numerical bending parameter Safan Easy 2D representation - usage of the actual database
- SAFAN EC or Easy 2D software - Delem Profile on Windows - Delem V-Bend - Autopol - SomaBend (Radan)
EC2 As EC1, but with graphical - 2D programming of products 2D and 3D representation and bend simulation with of the bending sequence Safan Easy 2D
- SAFAN EC or Easy 2D software - Delem Profile on Windows - Delem V-Bend - Autopol - SomaBend (Radan)
EC3 As EC2, but with graphical (no Safan Easy 2D) 2D and 3D programming and representation of the bending sequence
- SAFAN EC software - Delem Profile on Windows - Delem V-Bend - Autopol - SomaBend (Radan)
SAFAN Easy 2D
SAFAN EC3 control
Possibilities
SAFAN Easy 2D
Off-line programeren met Delem V-Bend
SAFAN TS control with keyboard
SAFAN EC1 running mode
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9
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Options for optimum ease of operation Fast, simple and reliable angle measurement can be essential for your bending process. SAFAN has made
e-volution
advancements in this area too. Two SAFAN E-Bend systems, electronically
linked to the SAFAN Touch Screen controls, increase your efficiency through exact sheet thickness or angle measurement.
With the Electrically or Hydraulically driven bending aids from SAFAN, you prevent angle deviation when bending thin sheets with large dimensions. The bending aid provides the operator with a simple and ergonomic means to remain within set angle tolerances.
SAFAN E-Bend S
SAFAN E-Bend M
It is often not easy for an operator to position large
bending aid. In most cases, it can be used by a single
The SAFAN E-Bend S sheet thickness measurement
This system consists of two pneumatic sensors on
sheets. Especially during the return movement of the
operator to position larger products. In brief, along
system is mounted next to the backgauge finger. The
a rail, which can be programmed at every desirable
top beam, it is difficult work to keep everything in hand.
with accuracy, productivity is increased by the SAFAN
system measures the sheet thickness to an accuracy
position. Both sensors are in contact with the sheet
Instead of having a second operator provide assistance,
Bending Aid, the best partner for your operator.
of ± 0.01 mm. It can be precisely programmed when
during the bending cycle. Before the definitive angle
it is frequently more efficient to install a SAFAN
measurement should take place. Measurement takes
is bent, the spring-back of the sheet is measured.
just tenths of a second and the data in the control
Based on this, a correction is entered after which
Machine type
system is immediately adjusted. The control system
the definitive angle is bent. The values measured can
• E-Mate plus bending aid
150 kg.
database maintains all records of measurement and is
be used for other bends in which angle measurement
• Hydraulic bending aid
500 kg.
set out graphically.
is not possible due to the product’s geometry.
1 SAFAN E-Bend S
10
S
SAFAN bending aids
2
1 SAFAN E-Bend M
2
1 SAFAN E-Mate plus bending aid
Max. sheet weight
2 SAFAN hydraulic bending aid
11
M
Moveable 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.
In 1988, SAFAN had already installed the first robotic press brake in Europe. Safan is now an experienced specialist in the field of automated bending cells including the standard SAFAN R-Brake. The SAFAN integral solutions for your production process go much further than stand-alone solutions. The integral automation is not restricted to the bending cell alone, this also applies to other parts of the process such as punching and spot-welding, and the entire routing of sheet material around the bending cell. Flexible solutions and off-line software
cells. You have a choice between off-line or parametric
From advice & consultancy to manufacturing
and realises turnkey solutions for bending and cutting
the machine and pneumatically adjustable in height
You retain your flexibility with Safan in terms of new
programming. Naturally, you can contract out all pro-
Safan makes automation of sheet-metal working easier
systems with guaranteed cycle times. This fixes the
(programmable on the control)
products or changes in your production process. You
gramming to Safan.
than you think. This starts with the convenience of a
costs per product. The return time of your invest-
All support arms can be used in combination with the
• Support arms movable across the front side of
light guard.The support arms are as standard equipped with brushes. You can choose from the following possibilities: • Support arms fixed to the machine
T
Turn-key delivery of automated bending solutions
are also flexible in relation to coupling with external
The Safan Robowave off-line programming is a guar-
single contact person for the entire project. Our con-
ment can be properly determined based on those set
Optionally all support arms can be
systems and choosing your robot. The SAFAN E-Brake
antee for maximum efficiency of your bending cell All
sultants clearly present you with the entire range of
costs. With the help of a simulation model, you will
equipped with adjustable front stops
is perfectly suited to operate as a mid-point for every
movements can be programmed and simulated in
options, enabling you to make the best possible
get a reliable indication beforehand of your expected
automated bending cell. The SAFAN controls run under
advance.
choice for your production process. SAFAN develops
Return On Investment.
• Support arms movable across the front side of the
Windows®
machine
the
• Support arms movable across the front side of the
options for links, networks, software packages and
platform, adding a whole range of
machine and height adjustable with a handwheel
resolving downtime of the unmanned production process over the Internet. Safan can supply complete, fully tested programs for both new and existing robotic
Movable support arms
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Movable support arms adjustable in height
Off-line programming
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SAFAN E-Brake Dual Drive 300T 4100
Tool adapters SAFAN E-Brake Dual Drive 300T
• Safety in conformance with CE, maximum speed press beam ≤ 10 mm/sec.
80.0
3000
400 690
* Q - size: optional 750 of 790 mm
Clamping table OB II MC Premium
Accessories (optional) • CNC driven R- axis
300-4100
95.0
90
20
20.400 5380
715 715
C in mm (Q = 690 mm.)
B in mm
30
A in mm
90
Weight in kg
73
Motor Power in kW
• 1 Hold to Run operating console
Adapter NSCL-II MC Premium
Return speed in mm/sec
• 2 support arms (300 mm)
80.0
Bending speed max. in mm/sec
• Standard size (in-built) 690 mm (Q-dimensions)
Clamping table OB/S-3-W
Closing speed in mm/sec
• Upper and lower beam prepared for securing various optional tool inclusion systems
Q size* in mm
• Manual variable adjustment of back gauge fingers width across a linear parallel guide
95.0
Maximum stroke in mm
Q=690mm Stroke =400mm
• Back gauge beam fitted with 2 foldable back gauge fingers
Dual Drive 300T
Q=750mm Stroke =400mm
• CNC driven back gauge (X-axis) with a range of 800 mm • Manually operated R-axis
90
Q=790mm Stroke =400mm
• CNC driven Y1-Y2 axis (top beam adjustable inclined +/- 2.5 mm)
Pressure force in kN
• SAFAN EC1 Touch Screen CNC press brake controls
C in mm (Q = 750 or 790 mm.)
Technical specifications SAFAN E-Brake Dual Drive 300T 4100
Standard version:
4100 3175 3175 (Subject to modifications)
87
• CNC driven Z1-Z2 axis (horizontal repositioning back gauge fingers) • Programmable and integrated safety light screen (incl. floating blanking and 1-2 break setting)
Adapter NSCL-II HC Premium
95.0
OPERATOR SIDE
• CNC driven Delta X-axis (horizontal repositioning of one back gauge finger) • Built-in size increase up to 750 mm or 790 mm (Q-size) • Various upper and lower tool inclusions • Various bending aids with a sheet weight of 150 kg to 500 kg
Clamping table OB II HC Premium 90
• SAFAN E-Bend S sheet thickness measurement system • SAFAN E-Bend M angle measurement system
95.0
• Various support arms, fixed, moveable and adjustable in height where required • Finely adjustable stop ridge for the support arms • Extra Hold To Run operating console (compulsory with 2 machine operators)
690
750
790
Clamping table OB/S-3-C
80.0
• Integrated tool kit
STANDARD 14
OPTION
OPTION
Flattening table DD005 Ty
B A
B A
Q
Q 930
170.0
Segmented European Adapter
930
75.0
C
100.0
- EC2 control, graphic representation in combination with off-line programming - EC3 control, complete 2D and 3D graphic programming
715
70
390
3800
350
C
• SAFAN E-Control press brake control:
290
3800
• Machine lighting
2320 2320 15
E-Brake 35 - 200T E-Brake B 20 - 100T
E-Brake 300T Dual Drive
H-Brake
R-Brake
Safan B.V., Kwinkweerd 11, NL-7241 CW Lochem, P.O. Box 96, NL-7240 AB Lochem Tel.: +31 (0)573 222 222, Fax: +31 (0)573 252 057, E-mail: info@safan.nl, Website: www.safan.nl
B-Shear & M-Shear
E300TDD-062010.INT
E-Brake Ergonomic