Ultimate Guide on How to Select Press Brake Controller Easily

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Ultimate Guide on How to Select Press Brake Controller Easily

一,Introduction

The controller of the bending machine plays a crucial role in the efficiency and accuracy of the bending process. In manufacturing, bending machines are often used to shape metal parts into the desired shape. The controller of the bending machine is responsible for controlling various parameters, such as bending Angle, bending speed, and the amount of force applied during bending. By effectively setting and adjusting these parameters, the controller ensures that the final product meets the required specifications and quality standards.

In recent years, advances in technology have led to the development of complex controllers for bending machines. These controllers are equipped with advanced features such as programmable logic controllers (PLCS) and computer numerical control (CNC) systems for precise and automated control of the bending process. These advanced controllers not only improve the accuracy and repeatability of the bending process, but also increase the overall productivity of manufacturing operations. With integrated sensors and feedback mechanisms, the controller continuously monitors and adjusts bending parameters in real time, ensuring optimal performance and efficiency.

But do you know which press brake controller is the best choice? This comprehensive guide will explain how to select a press brake controller in metalworking.

二,Different Types of Press Brake Controllers

In the metalworking industry, the control system of press brakes is divided into manual, NC and CNC controllers, each with its own unique features and advantages.

1.Manual Controllers

Manual controller is the most basic bending machine controller, the operation is simple, usually through the handle or button to control the movement and operation of the machine tool. This controller is suitable for simple bending processes and requires the operator to have certain operating skills and experience. However, due to its reliance on manual operation, its accuracy and production efficiency are usually lower.

advantage

Cost effective: Manual controllers are generally less expensive than automated systems, making them a good choice for small stores or operations on a budget.

Simplicity: These controllers are easy to use and require minimal training, making them ideal for simple, small-batch bending tasks.

shortcoming

Time consuming: Manual adjustment is slow and labor-intensive, reducing productivity.

Inaccuracy: Manual Settings are prone to human error, resulting in inconsistencies and reduced accuracy during bending.

2.NC (Numerical Control) Controllers

NC controller is the upgrade version of manual controller, it adds some automatic functions on the basis of manual control, such as preset program, storage function and so on. The operator only needs to set the parameters and procedures, and the machine can be bent according to the preset path, which improves the production efficiency and bending accuracy. However, NC controllers are still limited by the skill level of the operator, and the requirements for the operator are still high.

Features

Digital reading of ram and rear pressure gauge position.

Ability to store and recall bending programs.

Basically automated bending sequence.

It is usually a single - or two-axis control (ram and rear gauge).

Advantages: Improved accuracy and repeatability, reduced setup time and increased productivity compared to manual controllers.

Disadvantages: Limited programming capabilities, not as flexible as CNC controllers, may not be suitable for complex parts.

3.CNC Controllers

The automatic controller is the highest level of the bending machine controller at present, which realizes the full automation of the bending process through the computer control system without manual intervention. The fully automatic controller enables complex bending processes with the advantages of high precision and high production efficiency. However, fully automatic controllers are more expensive and require more skill from the operator.

Key Features

Advanced programming: Detailed bending parameters with high accuracy and repeatability.

Multi-axis control: Manage 3 to 12 axes, including back gauge and stamping, complex operations.

Automatic functions: including tool compensation, collision detection and data logging for accuracy and security.

advantage

High accuracy: Ensures consistent and precise bending to strict tolerances.

Increased productivity: Automation reduces setup time and increases throughput.

Flexibility: Store multiple programs for fast task switching.

shortcoming

Cost: Higher initial and maintenance costs than manual controllers.

Training requirements: Training is required, including a learning curve.

三,NC VS CNC Control System

1.Commonness

The advent of NC and CNC control systems has revolutionized manufacturing by providing advanced automation capabilities for machine tools. NC, short for Numerical Control, refers to the automation of a machine tool using a series of alphanumeric codes programmed into a computer. CNC, or computer numerical control, on the other hand, takes this automation a step further by utilizing dedicated computers to control the operation of machine tools. Both systems rely on the use of code to determine machine movements and actions, but the CNC system offers greater flexibility and precision due to its advanced computing power.

One of the main advantages of NC and CNC control systems is their ability to produce complex and intricate parts with high precision and consistency. Traditional manual machining processes rely on the operator's skill and expertise to manually direct the cutting tools, which is prone to human error and inconsistencies. In contrast, NC and CNC systems follow precise instructions programmed in a computer, ensuring that each part is manufactured to exact specifications every time. This level of precision is critical in industries such as aerospace, automotive, and medical devices, where even the smallest deviations can have significant consequences.

Another significant advantage of NC and CNC control systems is their ability to increase the productivity and efficiency of manufacturing operations. By automating the machining process, these systems can reduce the time and labor required to produce parts, thereby reducing turnaround times and increasing production capacity. In addition, CNC systems can perform complex operations that are difficult or impossible to do manually, such as 3D contours and complex surface treatments. This level of automation not only simplifies the manufacturing process, it also allows manufacturers to confidently take on more challenging projects.

In addition to improved accuracy and productivity, NC and CNC control systems provide greater flexibility and adaptability for manufacturing operations. With the ability to easily reprogram machine tools to produce different parts, manufacturers can quickly respond to changing market demands and production requirements. This flexibility is critical in an industry where customization and rapid prototyping are critical, enabling manufacturers to remain competitive and agile in a fast-paced market environment. In addition, CNC systems can be integrated with CAD/CAM software to further enhance the design and production process, enabling seamless communication between the design and manufacturing stages.

2.Difference

NC (numerical control) and CNC (Computer numerical control) are two commonly used industrial control systems, which play an important role in the field of manufacturing. While their purposes are similar, there are some significant differences between them.

First of all, the NC control system uses a digital controller, which is composed of specially designed circuits and equipment. Such a system requires a control program written in advance and input on the machine via tape or paper tape. In contrast, a CNC control system uses a computer as a controller, which can process the control program in real time with greater precision and flexibility.

Secondly, the NC control system is mainly suitable for dealing with simple geometric shapes and basic motion trajectories, while the CNC control system is more suitable for complex shapes and motion paths. This is because the CNC system has more powerful computing power and more flexible program control functions, which can achieve more complex machining tasks.

In addition, the NC system usually needs to go through a tedious programming and setting process, which has high technical requirements for the operator. The CNC system is more intelligent and easy to operate, and can be controlled through a graphical interface and simple instructions, reducing the technical threshold of the operator.

In addition, the control accuracy and stability of NC system are relatively low, and it is easy to be affected by external factors. The CNC system has higher control accuracy and stability, and can better adapt to the complex processing environment and requirements.

In addition, the CNC system also has online monitoring and automatic adjustment functions, which can realize real-time monitoring and optimization of the machining process. This makes the CNC system more adaptable and flexible, and can better meet different production needs.

Another important difference is that NC systems usually use fixed control procedures and parameters, which are difficult to adjust and change flexibly. The CNC system can be adjusted and optimized at any time according to needs to achieve personalized customization and adaptive processing.

四,Different Brands of CNC Control Systems

1. Delem CNC Control Systems

Delem CNC control systems are advanced technological solutions that have revolutionized the field of industrial automation. These systems are designed to provide precise and accurate control of machine tools and processes, allowing for increased productivity and efficiency in manufacturing operations. The Delem CNC control systems are known for their user-friendly interface and powerful capabilities, making them a popular choice among businesses looking to optimize their production processes.

One of the key features of Delem CNC control systems is their ability to program and execute complex machining operations with ease. These systems use advanced algorithms and software to generate high-quality toolpaths, allowing for precise control of cutting tools and spindle speeds. This level of precision is crucial in industries such as aerospace and automotive manufacturing, where tight tolerances and strict quality standards must be upheld.

In addition to their programming capabilities, Delem CNC control systems also offer a wide range of monitoring and diagnostic tools that help operators identify and address potential issues before they escalate. These systems can generate real-time reports on machine performance, allowing for quick intervention and troubleshooting in case of any malfunctions. This proactive approach to maintenance helps businesses minimize downtime and optimize their production schedules.

Delem's press brake control systems include DA-Retrofit solutions, DA-40 series, DA-50 series, and DA-60 series. The DA-66T, 69T, 53T, 58T, 41T, and 42T of Delem CNC control systems are touchscreen versions. While DA-66W and 65R CNC control systems are button versions.

(1) Touch Screen Version

Delem has a variety of touchscreen versions of the CNC controller.

DA-40 series

The controller of this series is specially used for traditional torsion shaft press brakes. The system is able to control the back gauge(X&R), and beam(Y).

The bright LCD screen can be used for programming parameters including angle, tool, and material. The DA-42 also has the functions of crowning control and pressure control.

DA-50 series

DA-58T is suitable for the electro-hydraulic synchronous press brake. DA-58T provides 2D touch graphic programming to calculate the bending process and collision detection automatically. The positions of all axes are calculated automatically.

The bending process is simulated by the real scale machine and toolings. DA-58T also can be used for tandem operation. DA-53T is able to control Y1, Y2, and two auxiliary axes.

DA-60 series

The DA-60 series offers 2D and 3D full touch screen graphics programming. The DA-69T and DA-66T are suitable for bending procedures requiring high accuracy. The DA-66T offers 2D programming that includes automatic bend sequence calculation and collision detection. The system is modular, the program is expanded, and the operation is more flexible.

(2) Button Version

Delem's two common button version controllers are the DA-66W and the DA-65R. These two systems provide 2D graphic programming and 3D graphic display functions. They also offer a multi-machine linkage function, and the touch screen is an optional configuration.

2. ESA CNC Control System

The ESA CNC Control System is a cutting-edge technology that has revolutionized the manufacturing industry. This system uses computer numerical control (CNC) to automate the operation of machines such as lathes, mills, and routers. It allows for precise and accurate machining of parts, resulting in higher quality products and increased productivity. The ESA CNC Control System is known for its user-friendly interface, advanced features, and superior performance.

One of the key benefits of the ESA CNC Control System is its high level of precision. This system uses sophisticated algorithms and sensors to ensure that each machining operation is carried out with incredible accuracy. This precision is essential for industries that require tight tolerances and exact specifications, such as aerospace and medical device manufacturing. With the ESA CNC Control System, manufacturers can produce parts with consistency and reliability, reducing the risk of errors and rework.

Another advantage of the ESA CNC Control System is its versatility. This system can be customized to work with a wide range of machines and applications, making it suitable for a variety of industries and production environments. Whether a company is producing small batches of specialized parts or high-volume production runs, the ESA CNC Control System can be tailored to meet their needs. This flexibility allows manufacturers to adapt to changing market demands and stay competitive in today's fast-paced business world.

In addition to precision and versatility, the ESA CNC Control System is also known for its user-friendly interface. While this technology is highly advanced, it is designed to be intuitive and easy to use. Operators can program the system using simple commands and graphical interfaces, eliminating the need for complex coding or specialized training. This accessibility makes the ESA CNC Control System accessible to a wide range of users, from experienced machinists to new operators.

ESA's products will mainly include the 600 and 800 series. Commonly used are the S660, S640, S630, S830, S840, S850, etc.

S600 Series

The S600 series are all touch screens. They can control a minimum of 3 axes and a maximum of 128 axes. The PLC and HMI can be reprogrammed to meet customized requirements. They can adapt to a variety of bending machines, including hydraulic press brakes, synchronous hydraulic press brakes, electric press brakes, and tandem press brakes, etc.

S800 Series

The S800 series is a new product line launched by the company in 2020. The innovation of the S800 series is mainly reflected in intelligent modularization, complete digitalization, and wireless network connection. The screen is 100% full touch, and graphical tools can develop complex 3D interfaces.

3. Cybelec CNC Control System

Cybelec CNC Control System is a cutting-edge technology that has revolutionized the manufacturing industry. With its advanced features and capabilities, this system allows for precise and efficient control of machine tools, making it an essential tool for modern manufacturing processes.

One of the key features of the Cybelec CNC Control System is its high level of intelligence. This system is equipped with sophisticated algorithms that allow it to optimize cutting paths, speeds, and feeds to ensure maximum efficiency and accuracy. By analyzing real-time data from sensors and actuators, the system can make adjustments on the fly to maintain optimal performance.

Furthermore, the Cybelec CNC Control System is capable of comprehending complex machining instructions. It can interpret CAD drawings and CAM files to generate tool paths and control the movement of the machine tool with precision. This level of comprehension allows for the creation of intricate and detailed components with minimal human intervention, saving time and reducing the risk of errors.

In addition to its intelligence and comprehension, the Cybelec CNC Control System offers a user-friendly interface that makes it easy to program and operate. With its intuitive menu system and graphical representation of machining operations, operators can quickly set up jobs and monitor progress in real-time. This reduces the learning curve for new users and increases overall productivity.

五,Controller Features

1.Programming Capabilities

Advanced Programming Options

Modern controllers enable precise and repeatable bends with complex sequences. Visual programming interfaces and simulation tools assist operators in designing and adjusting bending processes easily. Features include:

Graphical Programming Interfaces and 2D/3D Simulation: Provide a visual representation of the bending process, simplifying the design and adjustment of bending sequences.

Offline Programming: Enables the creation and adjustment of bending programs without interrupting ongoing production, optimizing workflow and productivity.

2.User Interface

Touchscreen Controls

A user-friendly interface is critical for efficient operation. Modern controllers typically feature intuitive touchscreens that simplify navigation and parameter input. Key aspects to look for include:

Large, High-Resolution, Multi-Touch Displays: Make navigation and parameter input straightforward and intuitive.

Customizable Layouts: Enable operators to tailor the interface to their preferences, enhancing usability and efficiency.

3.Safety Features

Essential Safety Mechanisms

Safety is paramount in metal fabrication, and press brake controllers come equipped with various safety features to protect operators and machinery. Important safety mechanisms include:

Emergency Stop Buttons: Easily accessible buttons that immediately halt machine operations in emergencies.

Light Curtains: Infrared barriers that stop the machine if an object or person enters the danger zone.

Safety Interlocks: Ensure that all safety gates and doors are securely closed before the machine can operate, preventing accidental starts.

4.Tooling Compatibility

Integration with Tooling Systems

Compatibility with various tooling systems is crucial for efficient production. Controllers should offer features that facilitate seamless integration and management of tools, such as:

Tooling Libraries: Preloaded databases of common tools that simplify setup and ensure the correct tools are used for each task.

Automatic Tool Identification: Recognizes and configures tools automatically, reducing setup time and minimizing errors.

Tool Compensation: Adjusts for wear, ensuring consistent quality.

5.Advanced Features

Enhancements for Precision and Efficiency

Advanced press brake controllers often include additional features that enhance precision, safety, and overall productivity. Notable features include:

Automatic Tool Compensation: Adjusts for tool wear and variations, ensuring consistent bending results.

Collision Detection: Prevents accidents by identifying potential component clashes.

Data Logging: Records machine performance, tool wear, and production metrics, providing valuable insights for maintenance and optimization.

6.Connectivity and Integration

Networking Capabilities

Modern controllers often include connectivity features that allow them to integrate with other systems and devices. Key connectivity options include:

Ethernet and Wireless Connectivity: Enable easy data transfer and remote monitoring, enhancing control and flexibility.

Integration with ERP Systems: Facilitates seamless communication between the press brake and enterprise resource planning systems, streamlining production management.

六,Conclusion

Modern brake machines are equipped with advanced controllers, and different brands and models of brake controllers may have their advantages. Before choosing an advanced press brake controller, it is necessary to thoroughly understand its functions and brand, and then choose the right controller according to the budget.

The most important points when choosing a press brake controller are functionality, stability, ease of use and safety. User-friendly controllers provide you with efficient working hours and exceptional levels of productivity and performance. High quality controller design ensures bending accuracy.

In my article, I discuss three advanced press brake controller brands that can give you the best user experience. ESA quickly upgraded its wide range of products and features. Delem's products are easy to operate, but tend to be more expensive. Cybelec's products are of excellent quality, although the operation can be slightly complicated. Upgrading press brake numerical control can improve performance and reduce cost.

After knowing this, you can visit our website, if you need to learn more about press brake or buy a machine, you can also consult our sales staff, they can recommend you the best press brake or CNC machine for you.

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