Operating a press brake effectively and safely requires thorough understanding and meticulous maintenance. This guide provides detailed instructions on the operation and upkeep of a press brake, ensuring longevity and optimal performance of the machine.
Operating Instructions
1. Powering Up and Starting the Oil Pump
- Power On: Switch on the power to the press brake.
- Start the Oil Pump: Activate the oil pump to initiate hydraulic pressure. You should hear the oil pump running, indicating it is operational.
2. Stroke Adjustment
Adjusting the stroke is crucial to avoid damaging the machine:
- Leave Clearance: Ensure there is a safe distance when the press brake reaches its lowest point to prevent damage.
- Adjustment Methods: Use either electric adjustment for quick changes or manual adjustment for fine-tuning the stroke.
3. Selecting the V-Die
Choosing the correct V-die based on the thickness of the sheet metal is essential for accurate bending:
- Die Selection: Select a V-die with a width that is a multiple of the sheet thickness. For instance, bending a 4mm thick sheet requires a 32mm wide V-die.
4. Back Gauge Adjustment
The back gauge controls the bending depth:
- Adjustment Methods: Adjust the back gauge using electric rapid adjustment or manual fine-tuning.
- Operation: Open the foot switch before bending. Releasing the foot switch stops the bending process, while pressing it again resumes the operation.
Maintenance Guide
Proper maintenance ensures the press brake remains in good working condition and prolongs its life.
Daily Maintenance (Operator Responsibility)
1. Check Protective Devices: Ensure that all protective guards, covers, and doors are functioning correctly.
2. Limit Switches: Verify that all axis limit switches are working properly and are set to the correct positions.
3. Inspect Guides: Look for signs of scratching or excessive wear on the guide rails.
4. Guide Cleaners: Ensure the guide rail cleaners are not damaged.
5. Lubrication: Check that the guide rails are properly lubricated.
Regular Maintenance (Technician Responsibility)
1. Inspect Fans: Ensure that all exhaust fans are operating correctly.
2. Check for Heat and Noise: Inspect the machine cabinet and motors for excessive heat or unusual noises.
3. Pressure Gauge: Ensure the pressure gauge readings are within normal ranges.
4. Check for Leaks: Inspect all pipelines and joints for any signs of leakage.
5. Lubrication: Confirm that all lubrication points are properly serviced.
6. Address Issues Promptly: Immediately address any irregularities to prevent further damage.
Detailed Operating Steps
Adjusting Step Molds
1. Fixed Step Molds: These molds have a constant double bend size.
2. Adjustable Step Molds: Adjust the center of the upper and lower molds to vary the gap.
Back Gauge and Bending Operations
1. Determine Positions: Set the positions of the front and rear back gauges and establish the bending process.
2. Positioning the Workpiece: Place the workpiece in the center of the press brake table.
3. Installing the Upper Mold: Install the upper mold as with standard press brake molds, with the mold core facing the operator.
4. Installing the Lower Mold: The mold core should face the interior of the press brake.
5. Adjusting the Back Gauge: Use electric quick adjustment or manual fine-tuning for precise positioning.
6. Starting the Bending Process: Press the foot switch to begin bending. Release the switch to stop, and press again to continue bending.
Adjusting the Slider Upper Limit and Gap
1. Slider Upper Limit: Adjust the position of the stop block to set the slider at the desired top dead center.
2. Upper and Lower Mold Gap: When the slider is at the top dead center, use the button on the worktable control box to set the initial gap larger than the sheet thickness.
Hydraulic Bending Force Adjustment
1. Calculate Bending Force: Determine the required bending force based on the sheet material.
2. Set Pressure Value: Adjust the overflow valve handwheel to produce a force slightly greater than the required bending force.
Safety Precautions
1. Foot Switch Activation: Always ensure the foot switch is activated during operation.
2. Mold and Slot Matching: Verify that the molds and slots are appropriately matched in size.
3. Tighten Screws: After adjustments, tighten all screws and measure the gap between the upper and lower molds with calipers.
4. Address Abnormalities: Stop operation immediately if any abnormalities are detected and contact maintenance personnel.
Conclusion
By following this comprehensive guide, operators can ensure the safe and effective use of press brakes. Proper preparation, accurate adjustments, and regular maintenance are key to achieving high-quality bending results while maintaining a safe working environment. Understanding the machine’s functions and adhering to safety protocols will help prevent accidents and extend the lifespan of the equipment.
