Should I buy a Hydraulic, Electric, or Hybrid Press Brake?

Found yourself in the market for a new press brake? The best (and easiest) first step is to contact your Sales Engineer. Set up a virtual or in-person appointment to review machine options and how they would fit into your production flow. Your Sales Engineer can walk you through options for controls, backgauges, material support, and automation; as well as brainstorm machine capabilities which would assist in growth and increased productivity.

In addition to reviewing options your Sales Engineer can help you decide what tonnage and bed length would suit your needs. They spend their days solving problems for metal fabricators and can offer helpful recommendations from past experiences.

Key factors when asking yourself – “should I buy a Hydraulic, Hybrid, or Electric Press Brake?”

Advantages of a Hydraulic Press Brake

When considering a new hydraulic brake look for a machine with a solid foundation, energy-saving technology, and options that automate the bending process. A well-built hydraulic press brake will have:

  • Widest variety of options and configurations
  • Configurations from a simple machine to a highly sophisticated machine, with a wide variety in between
  • Wide range of budget options
  • Potential for significantly higher tonnages and lengths
  • Wider variety of tooling options from planer tooling to precision

            Heavy-Duty Options

Keep in mind, if you are bending BIG and need 650 to 3000+ ton capability to do it, the High-Tonnage Hydraulic Press Brakes are your answer. These machines are built with oversized components, powerful gauging devices, and increased open heights/stroke lengths. When considering high tonnage, you want a press brake that is tough, durable and will stand up to any forming challenge.  

Advantages of an Electric Press Brake

These brakes run on electric motors that turn on during the bending sequence and shut off automatically when not in use. The ram descends quickly, stops at a preset position, creeps downward to make the bend, then moves quickly upward to start the process again. The short list of perks for electric brakes includes:

  • High speed and productivity
  • Designs (check out the SafanDarley models) require minimal crowning
  • Impressively high forming tolerances
  • Extremely quiet and clean – make for a nice working environment
  • Saving in electricity

Advantages of a Hybrid Press Brake

A hybrid press brake uses both hydraulic cylinder technology and a servo-drive motor – combining the best of both the hydraulic brake and electric brake. They are built with hydraulics to assist the bending process, but without gear pumps. Like an electric press brake, the hybrids shut off to conserve energy when not performing bending functions. A hybrid brake can be 20-30% more energy efficient than a hydraulic press brake.

  • Close to the productivity of electric with more size options
  • Less drive system maintenance then a hydraulic brake
  • Same high tolerances as an electric brake

Which Press Brake Machine Is Best?

Purchasing a new press brake should be like ordering at a restaurant: choosing options based on your preferences and needs, with the goal of ordering a machine built to help achieve your production goals.

Take advantage of your Sales Engineer’s expertise – call to discuss the best choice for your shop!

HOW TO COMPENSATE FOR PRESS BRAKE DEFLECTION

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If you own a press brake that is eight feet or longer, chances are you’ve experienced press brake deflection. Press brake deflection is when the ram and bed flex under load. Most modern press brakes are powered by two hydraulic cylinders on either end and are supported by side frames, meaning that both the power and support are isolated to either end of the machine. This results in the machine being the strongest and most rigid at the two ends. As a result of this design, ram and bed deflection is a normal part of press brake operation. Ram and bed deflection occurs most dramatically in locations farthest away from the hydraulic cylinders; in other words, it is most noticeable in the middle of the press brake.

DEFLECTION: the ram and bed deflect in the shape of an arc,
as a result the angle produced will be more obtuse in the center of the work piece

While press brake deflection is a natural occurrence in modern press brake operations, it can pose challenges to getting consistent bend angles, particularly across the entire length of long parts. Because the ram and bed deflect in the shape of an arc, the angle produced will be more obtuse in the center of the work piece, or at the peak of the arc. For instance, imagine you are bending a 90° angle across the length of a 10 foot part. While the ends of the finished part may be an accurate 90°, you could end up with as much as a 98° bend angle in the center. This phenomenon is known as the “canoe effect.”

There are a variety of methods used to compensate for press brake deflection, some of which are more effective than others.

Shimming

Shimming is the most basic method of compensating for press brake deflection and is achieved at the operator level. perators incrementally insert thin pieces of metal, paper, or cardboard underneath the dies. This process adds height to the dies in areas where your bend angle is greatest, closing up the produced angle. Shimming is an extremely time consuming and inconsistent process. It should be avoided at all costs, serving only as a last resort when all other methods have been exhausted. Shimming is an art form that requires a skilled and experienced operator. However, even when performed by the most skilled operators, it typically requires multiple test bends, which result in excess scrap material and can eat up valuable production time. It is also worth noting that shimming can lead to premature wear on tooling and other components. Find out how much shimming is costing you.

Servo-Electronic Pulley Press Brakes

Some modern press brakes utilize a servo-electronic pulley system that can often eliminate press brake ram and bed deflection. Because the design distributes force more evenly across the full working length of the machine, deflection is virtually nonexistent when used properly. What does “proper use” entail? Most machines require the use of dies with V-openings that are equal to eight times the material thickness. When using V-openings of less than eight times the material thickness, deflection may still occur. Check with the manufacturer for the recommended use for maximum accuracy.

SafanDarley servo-electric brake – talk to your FMA Sales Engineer about these effective machines.

Hydraulic Crowning

Some press brakes come from the factory with hydraulic crowning already built in. Hydraulic crowning uses hydraulic cylinders located in the bed of the machine. As the cylinders are filled with hydraulic pressure, they exert an upward force on the bed of the machine to compensate for deflection. Modern hydraulic crowning systems often feature what is known as dynamic crowning. Dynamic crowning provides a unique benefit of monitoring inconsistencies and resistance during the bending process, allowing for it to make real time adjustments to correct not only inconsistencies in the press brake but inconsistencies in the material as well.

WILA Hydraulic Crowning Unit

Mechanical Crowning

By far the most common solution to compensating for deflection is mechanical crowning systems. Mechanical crowning systems are installed in place of a bottom tool holder, as they also serve this function. They typically feature either mechanical or hydraulic clamping as options. They also typically feature different drive designs, from analog to digital readouts and from hand crank assemblies to CNC motors. Mechanical crowning systems can typically be outfitted to the press brake at the time of purchase, as well as after the purchase in the form of a retrofit. Mechanical crowning systems vary in design, accuracy, and ease of use from product to product. Unless your press brake has a hydraulic crowning system, a mechanical crowning system will probably be the solution you need to compensate for deflection. Don’t make the mistake of assuming all mechanical crowning systems are made equal and buying just any system.

WILA Mechanical Crowning Unit

Consider your applications, your challenges, and determine the set of features you need to increase your productivity and efficiency before making the investment. Questions or need to brainstorm? Your FMA Sales Engineer is here to HELP.

What unique forming challenges do you need to overcome?

The Accurpress Accell is designed to be the answer to unique forming challenges. Check out the video below featuring two unique custom features – a cut out in the ram and a CNC sheet follower built behind the machine. Both features were designed to achieve a specific manufacturing goal.

Simply put – Accurpress will do things other machine builders will not.

Plan to brainstorm with your Sales Engineer – the sky is the limit when customizing the Accurpress Accell Press Brake.

Explore the ACCURPRESS ACCELL line up

Anniversary Edition SafanDarley E-Brake

Celebrating 25 years of sustainable success.

Sustainable production delivers pure profit, both for the planet and for your business. With that in mind, we developed and introduced the E-Brake. As the inventor of the electronic press brake, we have extended our lead with continuous innovations. The SafanDarley E-Brake offers the fastest bending cycle and the greatest energy and CO2 savings. Fully electric, without environmentally harmful oil.

Celebrate 25 years of sustainable success with us and take advantage of our E-Brake anniversary promotion!

Check out the Anniversary Edition SafanDarley E-Brake (35T-1250)

SafanDarley {hearts} robots!

A new video was released by SafanDarley – featuring their 130 ton electric R-Brake. This 3-minute video clearly illustrates an integrated press brake-robot system. Check out the robot as moves horizontally along a gantry on the top-side of the press brake, using the auto gripper to pull tools. If you weren’t visualizing how this set up operates, here is your chance…


 

4 Things You Need To Know About Electric Press Brakes

 

https://foxmachinery.tumblr.com/post/186398482419/4-things-you-need-to-know-about-electric-brake

Want to know more? Keep reading about SafanDarley & browse machine options.  

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