Professional Documents
Culture Documents
INTRODUCTION
Press brakes are one of the most difficult machine tools to safeguard because of their general purpose-type use in industry. General purpose means a press brake can be used to bend from very small parts to very large parts. Production runs on these machines can be one part to thousands of parts. With this type of operation, press brakes must be versatile. Today, with advanced technology, it is now possible for industry to safeguard press brakes and maintain the same levels of productivity when the employer (user) considers all components in the press brake system. A complete safeguarded system includes, but is not limited to, the type of press brake, the safeguard itself, tooling to be used, size, shape or configuration of workpiece, material handling, production, maintenance, and any anticipated future needs.
OSHA STANDARDS
Under OSHA, press brakes are cited for noncompliance in accordance with 29 CFR 1910.212 Machine Guarding, which specifically requires point-of-operation safeguarding. All machines fall under this same regulation where it states: the safeguarding shall be in conformity with any appropriate standard. Some states may have their own rules and regulations for press brakes.
ANSI STANDARDS
There are several references available on press brake safety; however, most industries use the ANSI (American National Standards Institute) B11.3 standard. This standard can be purchased by contacting: ANSI
American National Standards Institute, Inc. 25 West 43rd Street, 4th Floor New York, New York 10036 Phone: (212) 642-4900 Fax: (212) 398-0023 www.ansi.org
POINT-OF-OPERATION HAZARD
Fortunately, most press brake operations do not require the operators to place their hands or any part of their body into the point-of-operation hazard; however, exposure to point-of-operation injuries still exists. Because of this exposure, the operator(s) must be safeguarded from point-ofoperation hazards. Best safety practice is when operators are never required to put their hands or any part of their body in the point of operation at any time. Sometimes as the workpiece bends up, a hazard may be created between the part and the front face of the slide. When this happens, be sure the operators do not place their fingers on the top or sides of the material, but support the material from underneath.
OR AMT
The Association for Manufacturing Technology 7901 Westpark Drive McLean, VA 22102 Phone: (703) 893-2900 Fax: (703) 893-1151 www.amtonline.org
OR GLOBAL ENGINEERING
15 Inverness Way East Englewood, CO 80112 Toll-Free: 1-800-624-3974 http://global.ihs.com
HELPERS
Many times two or more operators are feeding and retrieving workpieces from press brake dies. The employer may describe one person as an operator and one person as a helper; however, a helper is
(Continued on next page.)
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FAB 145
SAFEGUARDING
Press brake safeguarding can be accomplished by using one of the following safeguarding devices: 1. Presence-sensing device (pp. 45-73) 2. Two-hand control device (p. 74) 3. Pullback device (p. 77) 4. Restraint device (pp. 78-79) 5. Hostage control device (pp. 148-149) PRESENCE-SENSING DEVICES Of all the recognized point-of-operation safeguarding devices for press brakes, the light curtain is the most versatile for short- to long-run operations and for small to large workpieces. Proper use of this device provides protection for all operators and passersby in production modes of operation. It also minimizes operator resistance to using safety devices. A muting feature, most commonly used with press brakes, allows the light curtain to be bypassed during the nonhazardous portion of a press brake stroke. This is generally from 14" or less above the workpiece to the bottom of the stroke and back to the top of the stroke. Blanking of beams or the use of float blanking are also popular options for press brake applications; however, these options must be closely supervised and discouraged whenever possible. When applying light curtains, they must be mounted at a safe distance according to the formulas found on page 46.
Light Curtain
so the operator(s) must hold the palm buttons depressed until the slide reaches a point 14" or less above the workpiece. If either palm button is released, the slide stops. Both palm buttons must then be released and reactuated to finish the stroke. Two-hand control is usually arranged to provide this protection in the twohand single stroke, sequence, or high/low mode of operation. See information below and on the next page for additional details on how two-hand control and sequence mode of operation work. How Two-Hand Control Works:
STEP 1 By depressing the two run buttons, the operator(s) initiate the press brake cycle. STEP 2 The operator(s) must hold the two run buttons until the slide completes its downward travel to the workpiece or until the slide stops 14" or less above the workpiece. If the operator(s) remove one hand from the run buttons, the slide will stop. In the singlestroke or high/low mode, the slide will make one complete cycle. STEP 3 In the sequence mode, the slide will automatically stop at a preset position 14" or less above the workpiece. This preset position is adjustable for different feed-line heights or material thicknesses. STEP 4 If the workpiece is not already placed in the die, it may be inserted at this time. STEP 5 The palm buttons or the foot switch is now reactuated, causing the slide to continue through the bottom of the cycle and automatically return at high speed to the beginning of the cycle.
Note: The controls illustrated provide the ability to inch the slide down with the palm buttons or foot switch in the single, sequence, or high/low mode of operation. By inching the slide down in these modes, the operator makes sure the upper die is going to bend the workpiece in the correct position. This also avoids hazardous whip-up action of the workpiece when inching through the workpiece bend.
TWO-HAND CONTROL (TWO BUTTONS)
This illustration is of a down-acting press brake bending a workpiece with a light curtain used as the safeguard.
SLIDE DIE
TWO-HAND CONTROL DEVICES Two-hand control, as a point-of-operation safeguarding device for press brakes, is ideal for shortrun job-shop operations. Workpieces can be from very small to very large. Each operator station is arranged with two guarded run palm button assemblies. These buttons are usually mounted to the slide of the press brake; however, they can also be installed on a floor stand (see page 123) for more flexibility. Two-hand control provides protection against point-of-operation injury during the die-closing portion of the cycle. Two-hand control is arranged Rockford Systems, Inc.
This illustration is of a downacting press brake bending a workpiece with two-hand control used as the safeguard.
SLIDE DIE TOP OF STROKE BOTTOM OF STROKE 1/4" SEQUENCE STOP OR LOWSPEED POINT BED BACKGAUGE
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FAB 147
When using two-hand control, the operator cannot hold onto the workpiece during the die-closing portion of the stroke. Material tables (page 65), rails, magnets on backgauges, etc., can be used to support the workpiece. If the dies are not the exact length of the material, auxiliary safeguarding is required. PULLBACK DEVICE The overhead-pullback device is usually applied on press brakes that perform long-run jobs and when small- to medium-size parts are being produced. The pullback is a mechanical device operated from the linear motion of the slide or upper die. When adjusted properly, it pulls the operators hands back should they inadvertently be put into the point-of-operation hazard. The overhead design allows the operator freedom of movement for loading and unloading workpieces without interference. Pullbacks are designed for a fixed-length-stroke mechanical press brake; therefore, when applying them to a hydraulic press brake that may have an adjustable stroke, the stroke length will need to remain the same at all times.
RESTRAINT DEVICE Similar to the overhead pullback, restraints are usually applied on press brakes that perform long-run jobs. The parts being produced are usually medium size with the operator holding onto the workpiece. If small parts are being fed into the die, a hand-feeding tool must be used. Restraints are adjusted so that an operator cannot reach into the hazardous area at any time. Both pullbacks and restraints must be properly worn, adjusted, and maintained at all times.
Restraints With Two Operators HOSTAGE DEVICE Hostage control devices are used on machines that perform short-run jobs with very large workpieces. The actuating means (hand or foot) must be protected against unintended operation and arranged so the operator(s) can never reach the point-of(Continued on next page.)
COVERS
Mechanical power-transmission apparatuses of the press brake such as rotating flywheels, gears, sprockets, chains, and shafts must be covered in accordance with OSHA 1910.219, Mechanical Power-Transmission Apparatus and ANSI B15.1. All apparatuses that create a hazard up to 7' above the floor or platform must be guarded (covered). This is usually done by the user, either by modifying existing guards or by contacting a local sheet-metal fabricator. See pages 272-275.
AUXILIARY SAFEGUARDING
Auxiliary safeguarding is used for additional protection from injuries for all personnel in the machine area. It is used in conjunction with primary safeguarding devices. Auxiliary safeguarding also involves the guarding of other components or hazardous openings on machines. Auxiliary safeguards include such items as point-ofoperation side barriers when light curtains are used, pressure-sensitive floor mats, workpiece tables, or horizontal light curtains. An additional set of light curtains can be used horizontally to prevent an operator or other persons from standing between the vertical plane of light and the point-of-operation hazard. To prevent unauthorized entry on the back side of the press brake, an interlocked cable and danger sign can be used (see page 213). Danger signs, used for warning, can be mounted on the press brake slide in a position that is readily visible to the operator, setup person, or other personnel. Hand tools are another auxiliary safeguard often used when feeding and retrieving small workpieces. Hand tools by themselves are not a point-of-operation safeguarding device.
CONTROLS
Press brake controls are furnished according to the type of press brake: mechanical friction, air clutch, hydraulic, hydra-mechanical, or electric. The controls and system of the safety-related functions must be control reliable. Please see page 259 for further explanation.
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FAB 149
TYPE
Air
One Clutch Two Clutches Down-Acting Up-Acting Hostage Low Production. Very Large Parts
Mechanical Friction
AFM
150 FAB
ACCURPRESS
ADIRA
ALLSTEEL
AMADA
ATLANTIC
AUTOMATED
BARER
BASIC
BECKWOOD
BETENBENDER
CHICAGO D&K
CINCINNATI
CYRIL BATH
DARLEY
DI-ACRO
FALCON
FISCHER
GUIFIL
HMC
HTC
HACO
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HEIM
TYPE
Air Clutch
One Clutch Two Clutches Down-Acting Up-Acting
Mechanical Friction
HELLERS
HURCO
HYDRAPOWER
KOMATSU
LVD
MEGFAB
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MERCURY
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MILWAUKEE
MITSUBISHI
NIAGARA
PACIFIC
PIRANHA
PROMECAM
PULLMAX
ROTO-DIE
STANDARD
STEELWELD
TOYOKOKI
TRUMPF
VERSON
WISCONSIN
WYSONG
FAB 151
152 FAB
1 2 3 4
The guide on the previous pages can be used for reference only. It lists the major press brake manufacturers and the types of press brakes each one manufactures. The numbers in the columns reference the press brake descriptions listed below. The second part of the guide references the pages where the safeguards for that particular press brake type can be found in this catalog. The page reference for clutch/brake and hydraulic control information is below.
1. MECHANICAL-FRICTION CLUTCH
When a press brake has a mechanical-friction clutch and it has not been updated with any electrical or pneumatic system, the actuating means is usually a mechanical foot pedal/treadle. If a light curtain, twohand control, or hostage control will be used as a safeguard, an electrical and pneumatic control system is usually installed on the machine. This furnished control system must have control reliability to comply with ANSI B11.3. See pages 154-160 for control choices.
2. AIR CLUTCH
To properly interface a light curtain or two-hand control to press brakes with one or two air clutches, the electrical schematics are required. On older air-clutch press brakes, the electrical and pneumatic systems may need to be replaced to provide control reliability according to ANSI B11.3. See pages 161-175 for control choices.
3. HYDRAULIC
To provide the proper new control or interface for light curtains or two-hand control on press brakes using a hydraulic system as the energy source, the electrical and hydraulic schematics are required. On older hydraulic press brakes, the electrical and hydraulic system may need to be replaced to provide control reliability according to ANSI B11.3. See pages 176-181 for control choices.
4. HYDRA-MECHANICAL
These press brakes are a combination of hydraulic and mechanical operation. They usually have a reliable control system to which safeguarding can be conveniently interfaced. These press brakes are usually updated or retrofitted with a light curtain package to protect the point of operation. If these types of press brake controls do not have control reliability, the electrical and hydraulic schematics are required for evaluation.
5. ELECTRICAL
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The electric and electric-hydraulic press brakes are usually newer machines. In most cases, they have control systems that have control reliability. To apply a light curtain or two-hand control for safeguarding, the electrical and hydraulic schematics (when furnished) are required for engineering evaluation.
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FAB 153
UNGUARDED
Part
No.
KSC-000
INTRODUCTION
The most common older press brakes, in metal fabricating, use a part-revolution mechanical-friction clutch, usually operated by a mechanical foot pedal or treadle. Manufacturers of these types of press brakes are listed on pages 150 and 151. These mechanical-friction clutches are widely used because they give the operator control of the machine stroke by mechanically inching and slipping the clutch. This allows the operator to descend the slide to the workpiece and stop, adjust or align the workpiece, then complete the stroke to bend the part. The mechanical-friction clutch also allows the operator to slip the clutch or inch through the bottom of the stroke to avoid a quick whip-up action of the material. To update these press brakes or to apply certain point-of-operation safeguarding devices, an air cylinder and clutch control package are installed to engage and disengage the clutch and brake. Always remember, when applying an air cylinder to the existing operating linkage, it must be a single-action type.
STANDARD BIG FOOT CONTROL BOX The Big Foot control is a microprocessor-based clutch/brake light curtain interface/control with top-stop brake monitoring. The modes of operation are foot pedal single stroke, and foot pedal sequence (foot pedal down to 14" and foot pedal through to complete the cycle). In either of these modes of operation, the operator can inch the slide down to within 14" of the workpiece. The operator has complete control of the stroke of the slide at all times. In the single-stroke mode, the slide automatically top-stops at the end of the cycle. In the sequence mode, the slide will automatically stop 14" above the workpiece and then top-stops at the end of the cycle. This happens even if the foot pedal is held operated throughout the cycle or on the downstroke. The operator does not have to guess when to release the food pedal. The standard control box is a 16" x 16" x 8" NEMA 12 enclosure. The operator controls are normally located on the front of the enclosure. For operator convenience, a remote operator station can be furnished for use with a plain-door control box. Please indicate your preference when ordering this equipment, or consult the factory if another location is required for the operator controls. To obtain the correct Big Foot control part number, see the chart on page 157 and follow directions 1-6.
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FAB 155
FEATURES Mode of Operation Selector Switch Light Curtain Off/On Selector Switch Main Motor Start and Stop Push Buttons Main Motor Forward/Reverse Selector Switch Ram-Adjust Off/On Selector Switch Ram Raise Push Button Ram Lower Push Button
X X X
X X X
SAMPLE
BFC - 2
63 -F A
The sample shown, BFC-263-FA, indicates that the custom Big Foot control box will contain a PSD-400 light curtain interface, an IEC 60-A disconnect, an IEC 23-A reversing main motor starter, and an IEC 12-A reversing ram-adjust motor starter. All operators will be on the door of the enclosure.
BIG FOOT PRESS BRAKE CONTROL BOX PART NUMBERING SYSTEM CHART B F C- X X X - X X X
SYSTEM TYPE PRODUCT CATEGORY
BFC Big Foot Press Brake Control -5 6 7
MODIFIER
Blank, No Modifier Main Motor Operators Remote* Ram-Adjust Operators Remote* Main Motor and Ram-Adjust Operators Remote*
0 No Starter 1 2 3 4 5 6 7 8 9 A B C
MAIN MOTOR STARTER SIZE (Allen-BradleyIEC C Series) Motor Horsepower Chart 1-Phase 3-Phase IEC 115 V 230 V 208 V 230 V 460 V 575 V
1 3 12 A 1 2 16 A 1 23 A 2 30 A 37 A 3 43 A 5 60 A 72 A 7.5 85 A 110 A (B Series) 180 A (B Series) 250 A (B Series)
1 2 3 5 7.5 10 15
3 5 7.5 10 15 20 30 50 75
3 5 7.5 10 15 20 25 30 60 75
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FAB 157
MONITORED DUAL-SOLENOID AIR VALVE Part No. RCL-551*12" Port This three-way cross flow, series/parallel air valve supplies air to the air cylinder that is used in the clutch linkage. This valve consists of two main parts: the piloted monitor assembly and the valve body assembly. The two main valve elements move simultaneously during normal operation. If these elements should fail to move simultaneously, the internal spool Average Cv (Flow Rate) shifts; inhibiting further machine operation. A Ports Ports reset button on the side of the valve can be Part No. 1 to 2 2 to 3 used to reset the valve if an accidental valve RCL-551 3.0 8.0 fault is detected. Monitored DualSolenoid Air Valve FRL (FILTER-REGULATOR-LUBRICATOR) Part No. RCL-044*12" Port This assembly is required to meet the OSHA and ANSI standards. This FRL assembly filters, regulates, and lubricates the air going through it. This filtered and lubricated air then goes to the dual-solenoid air valve assembly and air cylinder. The regulator should be adjusted to meet the original equipment manufacturers requirements. The assembly includes a gauge, coupling, and a steel mounting bracket. *Included in a component package on page 160. Rockford Systems, Inc.
Filter-RegulatorLubricator
LIMIT SWITCHPart No. CMC-031* This heavy-duty limit switch has an oil-tight construction and the enclosure meets NEMA 2, 4, and 13 requirements. The switch head rotates a full 360 and can be remounted every 90. Movement of the limit switch lever in either direction will operate the switch. The switch has an adjustable roller lever which operates off the mechanical foot pedal/treadle linkage. It is used to indicate the position of the foot pedal/treadle. This switch must be installed so it releases as soon as the operator steps on the treadle. Generous overtravel gives extra installation freedom. The contact arrangement is 2 NO and 2 NC. It is wired using the two normally open contacts; therefore, it must be held closed before the machine circuit can be actuated. As soon as the limit switch is held closed and the machine circuit is actuated, the light curtain turns on. Limit Switch SELF-LATCHING EMERGENCY-STOP STATIONPart No. LLD-800* To meet ANSI B11.3 and NFPA 79 safety standards, a self-latching emergency-stop station is available. This station is a maintained red emergency-stop palm button with a yellow background. It is furnished in a 412" x 312" x 3" NEMA 12 enclosure. To reset this button, turn it to the right.
EmergencyStop Station
LIGHT CURTAIN MUTING LIMIT SWITCHPart No. CMT-008* The CMT-008 limit switch is needed to provide a separate light curtain muting signal.
HOSTAGE (SLAVE) FOOT SWITCHPart No. CTD-011* This foot switch is required when a second operator works on the press brake. For this application, it is designed as a hostage (slave) to the foot pedal/treadle. This means the foot switch must be depressed and held down before the foot pedal can engage the clutch to start a cycle. If either operator lets up on the pedal or foot switch, the press brake will stop.
SECOND OPERATOR SUPERVISORY STATIONPart No. LLD-411* When A second operator is required on the press brake, this supervisory control station must be supplied also. It is furnished separately and has its own enclosure. It includes an off/on key-operated selector switch and green indicator light. This NEMA 12 enclosure size is 3" x 6" x 3". The additional operator also requires the hostage foot switch described above. Supervisory Station *Included in a component package on page 160. Rockford Systems, Inc.
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FAB 159
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FAB 161
SSC-1500 Custom Control Box (Operators Located on Door Front) CUSTOM SSC-1500 PRESS BRAKE CONTROL BOX Custom SSC-1500 press brake control boxes are also available to fit your particular requirements. These boxes are furnished with an IEC throughthe-door main power fused disconnect switch and an IEC magnetic motor starter (with push buttons). A reversing slide-adjust motor starter may also be included. They are prewired and built into a NEMA 12 enclosure. Operator controls can be furnished on the front (F) door of the control box or on a plain (P) door with no operators except a disconnect switch. The SSC-1500 custom control box can be furnished in many different ways. Please refer to page 167 for the part numbering system. If a plain door custom control or a subpanel custom control is required, a remote operator station is needed. See ordering information on page 166. NEMA-style disconnect switches and motor starters, and brand name components specified by our customers are also available. To ensure the starter(s) and disconnect are sized properly, please check horsepower for the main drive motor and slide adjust motor (if furnished) on the press brake, as well as full-load amps, and primary voltage to the press brake. After obtaining this information, please go to the chart on page 167 to determine the proper custom control box part number. Follow directions 1-6 to obtain the correct part number of the control box. Example of the part numbering system: The press brake requires a PSD-400 light curtain interface, a 60-A disconnect switch, a reversing 23-A reversing main motor starter, and a 12-A reversing ram adjust motor starter. All operators will be located on the door of the enclosure except the ram adjust motor control which will be located remote. The part number to order would be PRS-263-FA6.
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FAB 163
Terminals
Style X Includes: Keypad/display Program/run/off selector switch Mode selector switch Actuating means selector switch Light curtain off/on selector switch Internal clutch/brake control module, master control relay, and terminals
Style Y Includes: Keypad/display Program/run/off selector switch Mode selector switch Actuating means selector switch Light curtain off/on selector switch Internal clutch/brake control module, master control relay, and terminals Self-latching emergency-stop button
Style Z Includes: Keypad/display Program off/on selector switch Mode selector switch Actuating means selector switch Light curtain off/on selector switch Internal clutch/brake control module, master control relay, and terminals Self-latching emergency-stop button Two guarded run/inch buttons located on the sides of the enclosure
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FAB 165
FEATURES Keypad/Display Program Off/On Selector Switch Light Curtain Off/On Selector Switch Off/Inch/Single/Sequence Stop Selector Switch Hand, Hand/Foot, Foot Selector Switch High, High/Low, Low Selector Switch Main Motor Start and Stop Push Buttons Main Motor Forward/Reverse Selector Switch Ram-Adjust Off/On Selector Switch Ram Raise Push Button Ram Lower Push Button
Remote Operator Stations for PRS Controls Remote Operator Stations for PRT Controls LLD-1514 LLD-1515 LLD-1516 LLD-1517 LLD-1518 LLD-1534 LLD-1535 LLD-1536 LLD-1537 LLD-1538 X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X
If any of the above remote operator stations are required without the enclosure, please consult the factory. Rockford Systems, Inc.
SAMPLE
6 6
P R S - 2
63 - F A
The sample shown, PRS-263-FA, indicates that the custom part-revolution control box with sequence stop mode of operation will contain a PSD-400 light curtain interface, an IEC 60-A disconnect switch, an IEC 23-A reversing main drive motor starter, and an IEC 12-A reversing ram-adjust motor starter. The keypad/display and all operators will be located on the door of the enclosure, except for the ram-adjust motor controls which will be located remote.
MODIFIER
-5 6 7 Blank, No Modifier Main Motor Operators Remote* Ram-Adjust Operators Remote* Main Motor and Ram-Adjust Operators Remote*
IEC
1 2 3 4 5 6 7 8 9 A B C 12 A 16 A 23 A 30 A 37 A 43 A 60 A 72 A 85 A 110 A (B Series) 180 A (B Series) 250 A (B Series)
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FAB 167
Resolver/Pulser Assembly
Cable
Sprocket Set
Roller Chain
2" FILTER-REGULATOR-LUBRICATOR ASSEMBLY (FRL) Part No. RCL-044* for Mechanical-Friction Clutch This assembly is required to meet OSHA and ANSI standards. This FRL assembly filters, regulates, and lubricates the air going through it. This filtered and lubricated air then goes to the dual-solenoid air valve assembly and clutch/brake. The regulator should be adjusted to meet the original equipment manufacturers requirements. The assembly include a gauge, coupling, and a steel mounting bracket.
1
Filter-RegulatorLubricator Assembly AIR PRESSURE SWITCHPart No. CTD-062* This air pressure switch monitors low pressure to either the clutch/brake-actuating air cylinder and valve or slide counterbalance systems. Each system requires an air pressure switch. The pressure switch must be set so if the air pressure operating the component is not adequate, or if the air pressure suddenly drops, the press brake becomes inoperable. This switch is used on applications where the air pressure should not go below a predetermined amount. Each air pressure switchs low level setting is based on each application. Note: When press brakes have an air counterbalance system, an air pressure switch and check valve are required. See page 116 for a check valve. Air Pressure Switch
PALM BUTTON ASSEMBLY To meet OSHA and ANSI safety requirements, the two run/inch buttons must be protected against accidental operation (ring guards) and separated to require the use of both hands to operate them. They must also be mounted at the proper safety distance, if they will be used as a safeguard. The contact arrangement of these buttons is 1 NO and 1 NC. Part No. CTL-507* This palm button assembly consists of two black run/inch buttons (with ring guards) and a red emergency-stop button. Mounting boxes are furnished with each button. The red palm button has 1 NO and 1 NC arrangement plus a mechanical latch. See pages 187 and 188 for other palm button assembly options. See page 124 for control bars. *Included in a component package on page 171. Rockford Systems, Inc.
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FAB 169
Foot Switch
MULTIPLE-OPERATOR JUNCTION BOXPart No. USC-000* When multiple operator stations are required, this junction box is furnished separately for wiring up to four (4) operator stations. This junction box interfaces palm button assemblies/control bars and foot switches, and will not allow the press brake to run if palm buttons or a foot switch is actuated without its supervisory control station on. A lighted push button with nameplate indicates a fault condition of an operator station. The button is pushed to reset. The enclosure size is 16" x 14" x 6". Multiple-Operator Junction Box
CRANKSHAFT ANGLE DISPLAY Part No. FTL-055 The optional crankshaft angle display is a unit that shows the angular position of the crankshaft for mechanical power presses and press brakes. The crankshaft position is shown both graphically (with red LEDs in a circle) and numerically (with a large, red, three-digit LED). The large display can be easily seen which helps with setup, removal of stuck workpieces, or for assistance during emergency extractions procedures. FEATURES Large LED numerical display and circular LED graphic display can be easily seen Mounts easily Supplied with 25' of cable for connection to the control Helps satisfy the requirements of Canadian Standard CSA Z142-02, Code for Power Press Operation: Health, Safety, and Guarding Requirements, for indication of crank angle position Crankshaft Angle Display *Included in a component package on page 171. Rockford Systems, Inc.
Modes of operation and actuating means required. B Number of operator stations required. C Type of sprockets required.
A
PRS or PRT Control Box
B C
B C
SPECIAL SPROCKETS
A
Two-Hand Inch Two-Hand Single Stroke Foot Single Stroke Sequence Stop
SPECIAL SPROCKETS
MNK-000-SSP Standard Component Package CMS-115 CML-000 CMS-515 RCL-552 RCL-044 CTD-062 CTL-507 CTD-011 Resolver/Pulser Timing Device With 40' Cable and Plug Sprocket Assembly 10' ANSI No. 35 Roller Chain 1 2" Dual-Solenoid Air Valve 1 2" Filter-Regulator-Lubricator Assembly Air Pressure Switch Palm Button Assembly Foot Switch
COMPONENTS REQUIRED IN ADDITION TO THOSE LISTED IN STANDARD PACKAGE AT LEFT CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly CTD-011 Foot Switch LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly CTD-011 Foot Switch LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box
A B
MODES OF OPERATION TO BE USED PRS or PRT Control Box Two-Hand Inch Two-Hand Single Stroke
B C
SPECIAL SPROCKETS
SPECIAL SPROCKETS
MNF-000-SSP Standard Component Package CMS-115 CML-000 CMS-515 RCL-552 RCL-044 CTD-062 CTL-507 Resolver/Pulser Timing Device With 40' Cable and Plug Sprocket Assembly 10' ANSI No. 35 Roller Chain 1 2" Dual-Solenoid Air Valve 1 2" Filter-Regulator-Lubricator Assembly Air Pressure Switch Palm Button Assembly
COMPONENTS REQUIRED IN ADDITION TO THOSE LISTED IN STANDARD PACKAGE AT LEFT CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box
Note: If the press brake has an air counterbalance, an additional CTD-062 air pressure switch is required. Please select an air cylinder from page 172 or 173 to complete this package. For light curtains, mounting brackets and barriers for sides of point of operation, see pages 45-73. Rockford Systems, Inc.
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FAB 171
MECHANICAL FOOT PACKAGEBIG FOOT 1. The air cylinder is added in the linkage to the master cylinder for the Big Foot control package as illustrated. (See PEDAL pages 155-160 for package items.)
MACHINE FRAME
BED
ADDED AIR CYLINDER
MASTER CYLINDER MAY HAVE TO BE MOVED BACK TO ALLOW SPACE FOR AIR CYLINDER FLOOR LINE
FOOT SWITCH PACKAGE 2. For control systems on pages 161-171, the RCL-004 air cylinder can be applied as MECHANICAL PEDAL/TREADLE illustrated.
IS REMOVED AND FOOT SWITCH IS FURNISHED FOR ACTUATING PRESS BRAKE MACHINE FRAME
AIR ER ND CYLI
BED
SPECIAL ADDED BRACKET FABRICATED AT TIME OF INSTALLATION FOOT SWITCH FLOOR LINE
MASTER CYLINDER
Side Feet
Approx. Overall Length 2112" 2312" 2512" 2012" 2212" 2412" 28" 30" 32" 15" 16" 17" 20" 21" 22" 1712" 1812" 1912" 2012"
Return Spring Pressure 60 40 20 120 80 40 270 195 120 60 40 20 120 82 40 270 195 120 120
Amount of Pull or Push Force at 75 PSI 100 100 100 295 295 295 460 460 460 135 135 135 330 330 330 520 520 520 520
TYPE AClevis Mount This air cylinder is usually mounted in the vertical position on the side of the machine.
Clevis
Push Type*
Push Type*
Flange
This air cylinder is usually installed in applications where the cylinder rod must go through the frame of the press brake. Rear-flange mount and rod extensions at both ends are also available.
Amount of Pull or Push Force at 75 PSI
100 100 100 295 295 295 460 460 460 135 135 135 330 330 330 520 520 520
Approx. Overall Length 21" 23" 25" 23" 25" 27" 28" 30" 32" 16" 17" 18" 21" 22" 23" 2214" 2314" 2414"
Return Spring Pressure 60 40 20 120 80 40 270 195 120 60 40 20 120 80 40 270 195 120
Amount of Pull or Push Force at 75 PSI 100 100 100 295 295 295 460 460 460 135 135 135 330 330 330 520 520 520
*The spring is inside the cylinder on push-type air cylinders. Rockford Systems, Inc.
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FAB 173
INTRODUCTION
Air-operated clutches and brakes use a friction arrangement that causes engagement and disengagement. When air pressure enters the clutch and brake, through a monitored dual-solenoid air valve, the clutch engages and the brake is released. To stop the motion of the press brake, the opposite takes place. Some press brakes have one clutch that allows only one speed when cycling the machine. Other press brakes have two clutches for two speeds. See the list of manufacturers of these types of press brakes on pages 150-151. Two-speed air-clutch press brakes allow the slide to approach the workpiece at a fast speed, disengage (air is dumped from one clutch), then allow the second clutch to engage for a slower speed through the bending operation to the bottom of the stroke. This prevents fast whip-up action of the material. The clutches are again switched for rapid travel back to the top of the stroke. If these types of machines are newer, they do not always require a completely new clutch/brake control package for control reliability. To verify this, please send the electrical schematics to our engineering department for review. These schematics are also necessary to review for proper interface when a light curtain will be furnished. If a single- or two-speed air-clutch press brake doesnt have control reliability and when brake monitoring is needed, the SSC-1500 control can be furnished.
4" MONITORED DUAL-SOLENOID AIR VALVEPart No. RCL-554 This three-way cross flow, series/parallel air valve includes an air pressure electrical output monitor and muffler. Air is put into the clutch and brake when the dual solenoid air valve is electrically energized. When it is de-energized, the air is dumped from the clutch and brake and the press brake stops. This valve consists of two main parts: the piloted monitor assembly and the valve body assembly. The two main valve elements move simultaneously during normal operation. If these elements should fail to move simultaneously, the internal spool shifts; inhibiting further machine operation. The pressure switch will provide a signal to the control system to indicate a fault condition. A reset button on the side of the valve can be used to reset the valve if an accidental valve fault is detected. Note: Other valves are also available. Please see page 115. 4" FILTER-REGULATOR-LUBRICATOR ASSEMBLY (FRL)Part No. RCL-045 This assembly is required to meet the OSHA and ANSI requirements. This FRL assembly filters, regulates, and lubricates the air going through it. This filtered and lubricated air then goes to the dual-solenoid air valve assembly and clutch/brake. The regulator should be adjusted to meet the original equipment manufacturers requirements. The assembly includes a gauge, coupling, and a steel mounting bracket.
Modes of operation and initiating means required. Number of operator stations required. Type of sprockets required.
B C
SPECIAL SPROCKETS
SPECIAL SPROCKETS
TNK-000-SSP Standard Component Package CMS-115 CML-000 CMS-515 RCL-554 RCL-045 CTD-062 CTL-507 CTD-011 Resolver/Pulser Timing Device With 40' Cable and Plug Sprocket Assembly 10' ANSI No. 35 Roller Chain 3 4" Dual-Solenoid Air Valve 3 4" Filter-Regulator-Lubricator Assembly Air Pressure Switch (For Clutch/Brake) Palm Button Assembly Foot Switch
COMPONENTS REQUIRED IN ADDITION TO THOSE LISTED IN STANDARD PACKAGE AT LEFT CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly CTD-011 Foot Switch LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly CTD-011 Foot Switch LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box
A B
MODES OF OPERATION TO BE USED PRS or PRT Control Box Two-Hand Inch Two-Hand Single Stroke
B C
SPECIAL SPROCKETS
SPECIAL SPROCKETS
TNF-000-SSP Standard Component Package CMS-115 CML-000 CMS-515 RCL-554 RCL-045 CTD-062 CTL-507 Resolver/Pulser Timing Device With 40' Cable and Plug Sprocket Assembly 10' ANSI No. 35 Roller Chain 3 4" Dual-Solenoid Air Valve 3 4" Filter-Regulator-Lubricator Assembly Air Pressure Switch (For Clutch/Brake) Palm Button Assembly
COMPONENTS REQUIRED IN ADDITION TO THOSE LISTED IN STANDARD PACKAGE AT LEFT CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box CML-100 Special Sprockets (Replaces CML-000) CTL-507 Palm Button Assembly LLD-283 Supervisory Control Station (2) USC-000 Multiple Operator Junction Box
Note: If the press brake has an air counterbalance, an additional CTD-062 air pressure switch is required. Rockford Systems, Inc.
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FAB 175
UNGUARDED
INTRODUCTION
Hydraulically operated press brakes are widely used in industry today. Manufacturers of these types of press brakes are listed on pages 150-151. Most hydraulic press brakes have single-stroke and high/low modes for cycling the machines. When the high/low mode is selected, usually the slide or beam will start to close at high speed and then automatically go to a slow speed to finish bending the workpiece. The slide or beam will usually return at a high speed. These press brakes usually have a down-acting slide or an up-acting slide (moving lower slide or beam). The existing electrical controls may have control reliability. For verification of this, a review of the electrical and hydraulic schematics by our engineering department is required. SAFEGUARDING Like any other hydraulically operated press brake, the moving slide creates a point-of-operation hazard as the dies close. To safeguard these machines, a light curtain control package can be installed. These controls also include two-hand control that can be used as a point-of-operation safeguarding device. The palm buttons must be pressed concurrently and maintained during the hazardous portion of the stroke. Release of one or both palm buttons reverses or stops the action of the slide. The palm buttons must also be mounted at the proper safety distance. Please refer to the safeguarding section of this catalog for choices of other safeguards that are available.
Selector Switches
STANDARD SSC-500 HYDRAULIC PRESS BRAKE CONTROL This SSC-500 solid-state control system is The system output to the solenoid valves is prodesigned for use on hydraulic press brakes. It is vided by one safety relay with force-guided contacts designed and built to comply with OSHA 29 CFR and two 115-V AC solid-state relays. These output 1910.212 and ANSI B11.3 and B11.19. This conrelays are independently controlled and crosstrol can update or replace existing relay-based or checked by the microprocessors. This allows conPLC control systems on hydraulic press brakes trol reliable operation of the outputs in the event of that are found in users plants or can be furnished a single control component failure. for new hydraulic press brakes. The standard control box is a 24" x 24" x 8" NEMA The control includes control reliability, light curtain enclosure with the operator controls, ground indiinterface, and diagnostics (one user-programmable cator light, and the keypad/display mounted on input). It also includes batch and stroke counters the door, as illustrated in the left photo above. with presets, and a hard-wired emergency-stop Please go to the chart on page 138 to obtain the master control relay. correct SSC-500 hydraulic control part number The SSC-500 is an economic, full-featured dualand follow directions 1-8. microprocessor-based control system. The system Please see page 139 for the information on the uses redundant inputs from components such as cams and limit switches for cycle timing. palm buttons, foot switches, and light curtain(s).
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FAB 177
PROGRAMMING The SSC-500 can be quickly and easily programmed. There is one 24-V DC current-sinking (NPN) programmable input provided for the user. A fault message, input logic, and stop type can be assigned to the input from the following list. When a fault condition is detected, the machine will top stop or emergency stop, and the assigned message will be displayed. This feature helps when troubleshooting common fault conditions. Fault Message List: Lube Fault High Lube Fault Low Lube Fault Low Lube Level Main Motor Overload Fault Lube Motor Overload Fault Auxiliary Motor Overload Fault Guard Open Fault Rear Guard Fault Left Guard Fault Right Guard Fault Load Monitor Fault Safety Block Fault Stock Buckle End of Stock Die Protection Fault
SPECIAL NOTE
To determine whether the SSC-500 hydraulic control can be used with the existing hydraulic system, please furnish both electrical and hydraulic schematics of the existing equipment to Rockford Systems engineering department for verification when requesting a quote or when ordering.
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FAB 179
Fix label
The above remote operator stations are available without the enclosure. Please consult the factory.
INDIVIDUAL COMPONENTS
Individual components such as cycle timing devices and blocking valves, may be required to complete the SSC-500 hydraulic press brake control system. Other components may include a palm button assembly, foot switch, PSDI station, supervisory control station, etc. Please see pages 139 and 140 for the part numbers and descriptions of these components.
Moving Lower Beam Press Brake With a Light Curtain as the Point-of-Operation Safeguard
part of the stroke. During the mute portion of the stroke, the workpiece can be bent into the plane of light and the machine will finish its cycle. Electrical and hydraulic schematics must be sent to our engineering department to review for control reliability for all up-acting press brakes. After engineering has reviewed these schematics, a proposal detailing the necessary equipment to update or replace your hydraulic control will be sent to you. CONTROL BOX The following control boxes and components can be applied to various up-acting press brakes such as Amada RG series and Hurco. Send electrical and hydraulic schematics to our engineering department in order to verify that this control will provide a light curtain interface to your existing machine. ORDERING INFORMATION Control Box Additional Components Part No. Required
CMC-029Limit Switch LRS-402 CMT-027Linear Cam Assembly RCD-533Hydraulic Valve* LRS-280 (For use with Amada RG series with an NC9EX backgauge only) CMC-029Limit Switch CMT-024Linear Cam Assembly RCD-533Hydraulic Valve*
*If required
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FAB 181
NO.
____________
INSTALLATION N Y If Y: Standard Stripdown When filling out this form, be sure the information is filled in for satisfying the basic areas of safety. Basic Areas1. Safeguarding 4. Starter 2. Control 5. Cover 3. Disconnect 6. Other Considerations For identification and reference, please fill in this area first. Machine No. Manufacturer Model No. Serial No.
Size (length of slide or bed in feet) Type: Mechanical-Friction Clutch N Y If Y, does it have a band brake? N Y Air Clutch N Y If Y: (circle one), 1 2 Clutches Hydraulic N Y If Y: (circle one), Down-Acting Ram Up-Acting Ram Hydra-Mechanical N Y Air Only N Y Servo Motor (Electrical) N Y Is press brake out of service? N Y Is press brake used as a mechanical or hydraulic power press? N Y If Y, use either mechanical power press part revolution form or hydrualic press form. (If press brake is operated from the rear, an operating station(s) and safeguarding must be furnished.) 1) Safeguarding: Safeguard Provide Type, Series, or Size Light Curtain If press brake has light curtain, is it at the proper safety distance? N Y If we are to provide the light curtain, what is proper the safety distance?________" (See FAB catalog for guidelines.) (Customer to Are Mounting Brackets required? N CTF Furnish) Y If Y: EX-AL Swing-Away N Y If Y, please complete and attach SAB Measurement Form EX-AL Stationary N Y If Y, please complete and attach SLCMB Measurement Form Are Floor Stands required? N Y Is No-Go Indicator required? N Y Is Material Support Table required? N Y: Size Two-Hand Control If press brake has two-hand control, are the palm buttons at the proper safety distance? N Y If we are to provide, what is the proper safety distance?________" (See page 74 in FAB catalog) Pullback Restraint When providing any of the above safeguarding devices, the sides and rear of the point of operation must be safeguarded. If light curtain swingaway brackets are not furnished, are side & rear guards required? N CTF (Customer to Y Furnish) If Y, please complete and attach measurement form. Is switch, cable, and sign for rear of press brake required? N Y Has
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Actual space available______"H x ______"W x _____"D 5. Modes Required: Inch Single High/Low Sequence PSDI Other________________ 6. Options Required: Hour Meter Duplex Outlet None 7. Brake Monitor: N Y F. Cycle Timing Device?: N Y Resolver (1500) N Y Linear Unit N Y Other______________________ G. Timing Device Drive?: N Y Reuse Existing Standard Sprocket Set (For 1:1 drive) N Y Special Sprocket Set (If 1:1 drive is not available) N Y Chain N Y H. Actuating Means: How many operating stations? 1 2 3 4 (circle one) 1. Hand (push buttons) N Y Hand (other) N Y_________ 2. E-Stop Button N Y Top-Stop Button N Y Return Button N Y 3. Foot Switch N Y Reuse Foot Pedal/Treadle N Y Is Special Plug and Receptacle Required? N Y H. Monitored Dual-Solenoid Valve? N Y: (circle one): 12" 34" J. Air Pressure Switch? N Y If Y: Clutch/Brake? N Y Counterbalance? N Y K. Counterbalance Check Valve? N Y: (circle one): 1 3 2" 4" 1" 112" 2" N/A No Tank 3 L. Filter-Regulator-Lubricator? N Y: (circle one): 12" 4" 3 M. Air Lockout Valve? N Y: (circle one): 12" 4" N. Is Air Cylinder to be furnished? N/A N (reusing existing) Y: If yes; provide details; " Stroke Mount Push Pull " Bore Standard Tie Rod O. Does press brake have automatic backgauge? N Y If Y, please provide existing interface or include it in control schematic supplied.
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FAB 183
4. Starter: A. Present Location of Starter: 1. On Press Brake or Off Press Brake 2. With Control Separate from Control With Disconnect Only Not Furnished B. Is transformer for reducing voltage to starter required? N Y C. Is magnetic starter required for main drive? N Reuse Existing Customer to Furnish If N, existing starter must have 115-V coil and a normally open auxiliary contact. Y Estimate Actual D. If Y, provide: ______ Horsepower ______ ______ Full-Load Amps ______ ______ Voltage ______ E. Reversing N Y Nonreversing N Y F. How is starter to be furnished? Separate Box Combination W/Disconnect Box In Custom Box G. Is remote push-button station required? N Y If Y, Main Motor Ram Adjust H. Does press brake have Variable-Speed Drive? N Y If Y: Mechanical Adjust Electronic I. Are other starters required? Ram Adjust: N Reuse Existing Customer to Furnish Y Estimate Actual If Y, provide: ______ Horsepower ______ ______ Full-Load Amps ______ ______ Voltage ______ Lube System N Y (Also see 6A.) Estimate Actual If Y, provide: ______ Horsepower ______ ______ Full-Load Amps ______ ______ Voltage ______
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6. Other Considerations: A. Does press brake have lube system? N Y If Y, what kind of system?: Manual or mechanical pump N Y *Timer N Y *Motorized N Y (Please fill in Section 4I.) *Be sure to furnish lube schematics and/or instructions with this form. If only control schematics are supplied, be sure the lube system is indicated. B. Is safety block to be furnished? N Y If Y: What size is needed? ________" (Height) How many? _______ S M L (circle one) Interlock N Y Holder N Y C. If questionable about any information furnished, please enclose photos of entire front, sides (left and right), and rear of press brake. Include close-up photos of the inside of the existing control box, clutch/brake, and shaft end which would drive the timing device. If hydraulic, enclose photos of valves, system, and existing cycle timing. Sending Enclosed
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FAB 185