Detailed

Design & Process

Frame design: 

The GHT series represents the top of the range of press brakes produced by G-Press as they are characterized by advanced technological solutions deriving from previous experiences with an historic Italian partner.  It has a complete configuration that guarantees high speed and accuracy which can meet the bending requirements of the most demanding customers.  

In order to ensure that the machine can still maintain good rigidity and accuracy after long time use, the structure has been designed considering 2.5 times the theoretical frame deformation inertia, and has passed the stress 

analysis and fatigue resistance test.

Process:

The frame is a bolt connection structure in Q345 type material and have following specifications:

 

? Bolts which connects square tube and side plates;

? Pins, to ensure rigidity and stability as square tube and the side plate are not subject to displacement in the long term.

6Mt machining center    

 12Mt machining center

 Automatic hydraulic crowing system The"G-CS"system is equipped with high-precision pressures gauges which are installed in the upper and lower beam of the machine to detect the deformation of the relevant beam during the bending process. KEYENCE PLC receives and processes the data fed back and then controls the action of the pressure proportional valve and independent oil pump to ensure the compensation during the entire bending process thus perfectly achieving "the consistency of the bending angle within the full length of the work piece".

G-REFLEX – Frame deflection compensation system

With REFLEX System, the natural "Yawning" effect of "C" frames is eliminated.

The actual position of the upper beam is measured by two linear encoders installed on the auto-balanced lever and "C" shaped sub-frames that are independent from the main frame; as such the system corrects the deformation during bending.

Thanks to this system it is possible to achieve up to 1-micron accuracy in ram positioning as well as ensure a great repeatability and consequently guarantee angle consistency.

Bending Accuracy Testing

The consistency and accuracy of the bending angle over the entire length of the machine is one of the important factors in bending. Thanks to the hydraulic crowning unit, the G-Reflex system and the special beam assembly, the G-Press press brake can ensure that the bent part maintains a tolerance of ± 15' along the entire length.

Back gauge system and rear finger  

The back gauge system is another important part of the press brake as a guarantee of dimensional accuracy of the bending product. The 4 axes (X-R-Z1-Z2) back gauge of the standard GHT series ensures the most flexible, precise and high-speed positioning of almost all complex bending work pieces, thanks to the guide design which foresees the use of double sliders to ensure the accuracy.

The X-R axes motion is controlled by a double gear reducer system which is considered a “smart” design and has allowed to make a more compact version.

The anti-collision rear fingers 

have two major design features:

 The fingertip can be replaced in case of wear out; this is a solution economically convenient for customers who do not need to replace the entire finger.

 If the finger is subject to large impact force, it will automatically pop out, thus avoiding damage to the overall mechanism and affecting the positioning.

Components features 

Servo motor

 The motor offer excellent acceleration and are ideally suited for high speed and precision press brakes:

• high feed smoothness
•  Large torque range
•  High maximum speed
•  High-resolution encoder

Benefits:

•  High travel speed in the downward and backward movement
•  High energy savings
•  Longer service life for pump, oil, filter and all related components
• Path-time diagram of the upper cylinder of a press brake.

  CNC control DELEM DA 66T

 

The Netherlands DELEM CNC control features the following characteristics:

•  2D graphical touch screen programming;
•  3D visualisation in simulation and production
•  17” high resolution color TFT; 
•  Full windows application suite
• Bend sequence calculation;
• USB, peripheral interfacing
•  Sensor bending & correction interface

HAWE Hydraulic System

HAWE hydraulic system: the hydraulic control system of the bending machine is composed of a SAKB pressure control block and two independent filling valves to ensure accurate and efficient operation of the CNC bending machine. All valves (except the filling valve) are integrated into one control unit. The bending force flow is controlled by proportional technology. In this way, the operating speed (approaching, working and returning) and the required pressure can be controlled.

•   Applicable to models with bending force up to 2000kN
•  PIH and PSH valves provide very fast and accurate control by simultaneously energizing the solenoid coils at both ends of the solenoid valve.
• Other options (such as hydraulic clamping module or proportional hydraulic deflection compensation) can be connected to the hydraulic system module interface.
• The system complies with effective accident prevention regulations and has been certified by the Type Inspection Certificate No. 13028.

 LED Bar to indicate back gauge position

•  Real-time tracking of the current position of the back gauge finger when bending.
•  The LED light strip on the top beam indicates the actual position of the "back gauge finger" allowing the operator to quickly align the workpiece during the bending process, thus improving bending efficiency
•  The LED light strip provides warning and protection signs by changing color according to the three press brake working conditions: approaching speed (yellow LED light), working mode (red LED light) and return (green LED light).

Manual front support arms (SP) 

Manual sliding front support arms.

SP type (available for GHT and GHL series).

Foot Pedal    

G-Press foot pedal is in accordance  to CE safety requirements; its  features are as follows:

• Double safety switch which allows machine descent only if foot is totally insidethe pedal;
• 3-position safety design
• With shielded snake skin hose cable
•  Can be upgraded to wireless foot switch

Safety device DSP AP+MCS

Main Technical Features:

• Laser protection, Multi beam Receiver
• Protective areas: Front, middle and rear
• The safety level is CAT.4 and SIL3
•  Detection Case protection degree: IP 65
•  Laser classification: class 1 M
•  Response time: 5 ms
•  Operating temperature 0°C~50°C
•  Mounted on the upper beam
•  Change Speed Point: 5mm + Stopping Space
• The maximum protective distance: 15M
•  LED indicators show various states

Rear safety protection

Consists of light guards mounted to the side frame which stops the machine if a human steps inside.

 Electrical cabinet

G-PLC is a safety module developed by our company. Downstream and upstream dual channel mode is used to ensure machine safety; it also integrates the upper and lower fixtures, ordinary light barriers, dual pedal interface and it can expanded for more functions.

The indicators on the module provide great convenience for maintenance. It is equipped with an interface that allows direct communication with the software to locate the fault quickly and intuitively reduce downtime.

 Heat exchanging system

 The G-Press hydraulic system is equipped with a fin heat exchanger (see photo) which improves the effect by at least 10-20 times, compared to the traditional brass tube or other heat exchanger.

Air conditioner

Top tool clamping mod. GS-T.M

Standard intermediate clamp with quick release lever for fast tool change. Suitable for vertical loading/unloading of tools. No need to slide the tools laterally. 

Lower tool clamping mod. GS-B.P

 Intermediate pneumatic and self aligning clamps.For quick tooling set up and release on machine.

No risk of any oil leakage.