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In the metal fabrication industry, the bending process is a key component in shaping sheet metal. As technology continues to advance, the NC Press Brake and CNC press brake have emerged. With their excellent performance and advanced technology, they have greatly improved the efficiency and precision of bending processing, and have become the right hand of many companies in sheet metal processing.
NC Press Brake is an important bridge connecting manual bending operations with fully automated computerized NC Press Brake technology. It performs bending operations with the help of a CNC system, which is a more cost-effective solution for less complex tasks. Although it does not have the full automation and high precision of a computerized CNC press brake, the NC press brake is still a significant upgrade over manual operations, significantly improving productivity and consistency of operation without the need for complex programming or real-time feedback.
NC Controller: Compared to the controller of a computerized NC press brake, it is simpler and allows for basic programming of the bending operation.
Backgauge: used for mechanical positioning of the workpiece, although the accuracy is not as good as the backgauge of the computer numerical control press brake, but can meet the basic positioning requirements.
Ram: Executes the bending action by moving the punch towards the mold.
Punch and Die: This is the key tool for bending sheet metal, and the two work in tandem to shape the sheet metal.
Programming: The operator inputs the bending parameters into the NC controller, which include data such as bending angle, sequence and backstop position.
Setting: According to the input data, the operator manually sets up the machine, adjusts the backstop and installs the proper punch and die combination.
Bending operation: The operator initiates the bending process, the ram moves the punch and presses the workpiece into the mold to form the bend. The backstop positions the workpiece for each bending.
Manual Adjustment: Unlike computerized NC press brakes, NC press brakes may require the operator to make manual adjustments between bends to ensure accuracy.
NC press brakes remain a viable option for many manufacturing tasks due to their ease of operation and lower cost. This is especially true for projects that do not require the high level of automation and flexibility of a computerized NC press brake. By combining NC control with mechanical precision, NC press brakes provide a balanced solution for consistent, accurate bending in a variety of metalworking applications.
The CNC Press Brake is the pinnacle of modern metal fabrication technology, integrating advanced computer numerical control technology to dramatically improve accuracy, speed and flexibility when bending sheet metal. The machine utilizes precise programming and real-time feedback systems to automate the bending process, significantly improving productivity and accuracy.
CNC Controller: As the central unit, it interprets and executes the programming instructions and controls the entire operation process.
Backgauge: This is a precision positioning system that accurately places the sheet metal in preparation for bending.
Ram: It is responsible for moving the punch downward to complete the bending action.
Punch and Die: Customizable tools that come into direct contact with the metal to create the desired bending shape.
Safety Systems: Integrated safety features such as light curtains and laser systems ensure the safety of the operator during operation.
Programming: Detailed instructions, including bending angle and sequence, are programmed into the computer numerical control controller.
Setting: Based on the input information, the machine automatically adjusts the backstop and selects the appropriate tooling.
Bending Process: A controlled force is applied by the slide to press the sheet metal into the mold, guided by real-time feedback to achieve high precision bending.
Quality Assurance: Continuous monitoring ensures that each bend meets the programmed specifications, making adjustments in real time as necessary.
The synchronization control of NC press brake (torsion bar synchronization) relies heavily on the mechanical transmission system, and its accuracy is affected by the torsion bar and connecting rod and other components. The elastic deformation of the torsion bar and the adjustment of the adjusting lever may lead to unsynchronized movement of the slider, affecting the accuracy of the bending angle and flatness, which is usually within the range of 0.1 mm. It is suitable for general bending operations, especially for small workpieces and applications with low to medium accuracy requirements. However, our NC press brakes are capable of achieving ±0.01 accuracy, exceeding industry standards and providing a cost-effective, high-performance solution.
Computerized CNC press brakes (electro-hydraulic) use a closed-loop control system to achieve high-precision, synchronized bending operations. The system uses electro-hydraulic valves to regulate the movement of the hydraulic cylinders to ensure precise synchronized movement of the tooling. In contrast, CNC press brakes offer higher bending accuracy, often with tolerances as small as 0.01 mm or even less, and maintain better stability even after long periods of use. As a result, it is ideally suited to applications where high precision is required, especially in the production of complex workpieces.
Speed and efficiency
NC press brake (torsion bar synchronization) is relatively slow in speed and response due to the limitations of the mechanical torsion bar system. It usually descends faster but rises and returns relatively slower because the torsion bar system takes some time to ensure synchronization between the upper and lower modules. Changing bending speeds or performing complex multi-stage bending may require more time and adjustment, and speeds are usually fixed at a relatively constant rate.
Computerized CNC press brakes (electro-hydraulic) offer higher bending speeds and productivity with advanced electric servo systems and hydraulic control technology. Through the electro-hydraulic servo system, it can quickly adjust the movement speed and force of the hydraulic cylinder to achieve higher bending speed and shorter working cycle, and ultimately improve productivity.
NC press brake (torsion bar synchronization) adopts a simple mechanical synchronization system with low maintenance cost. Its simple structure eliminates the need for complex control systems, and usually only requires regular inspection and lubrication of key components, such as the torsion bar, and the cost of replacing components is relatively low.
Computerized CNC press brakes (electro-hydraulic) involve complex electrical and hydraulic systems and have higher maintenance costs. In addition to regular lubrication and inspection of critical components, the control system requires maintenance and calibration to ensure proper operation. Regular inspection of electrical and hydraulic components is also required, and the cost of replacing parts is relatively high.
NC press brakes (torsion bar synchronization) usually have 3 main axes:
Y-axis: Controls the up and down movement of the bending beam (upper die) to achieve the bending of the workpiece and is responsible for the vertical movement of the lower die during the bending operation.
X-axis: controls the horizontal positioning of the backstop to achieve the alignment of the workpiece and is used to position the workpiece during the bending process.
R-axis (optional): controls the depth adjustment of the backstop to realize the depth bending of the workpiece, and is the rotary axis of the backstop, which can make the backstop move up and down to meet different bending requirements.
Computerized CNC press brakes (electro-hydraulic) usually have more axes to provide greater flexibility and accuracy. A typical computerized CNC press brake may have 4 or more major axes including:
Y1 and Y2 Axes: These are the two independent control axes of the double-acting cylinders used to achieve up and down movement of the bending beam (upper die), ensuring parallel movement of the upper die and uniform bending force distribution.
X-axis: Controls the movement and positioning of the backstop.
R-axis: Controls the depth adjustment of the backstop.
Z1-axis and Z2-axis (optional): these axes control the forward and backward movement of the upper mold to adapt to different bending requirements.
Due to the difference in working principle and price positioning, NC press brakes (torsion bar synchronized) usually do not have a deflection compensation system. The computer numerical control press brake (electro-hydraulic) by virtue of its advanced control system and programmability, price positioning is higher, can be equipped with a deflection compensation system to achieve more accurate bending compensation. The presence of a deflection compensation system improves the quality and accuracy of the workpiece and meets the needs of complex components. Although equipping the system increases the cost, the improved capability and flexibility it provides is worth every penny.
Computerized CNC press brakes (electro-hydraulic) are usually more expensive than NC press brakes due to more complex and advanced structures and control systems. NC press brake (torsion bar synchronized) system structure and working principle is more simple, usually using a basic mechanical or electrical control system, the cost is lower. Computerized CNC press brakes require high-precision components and advanced control systems, which increase manufacturing costs and require more engineering and production expenses. In the short term, the NC series is more economical, but in the long term, the computerized CNC series has a higher investment value.
Computerized CNC press brakes (electro-hydraulic) are suitable for applications requiring high accuracy and efficiency in the bending process and are well suited for mass production and complex workpieces. Despite its higher price, it offers higher process quality and flexibility. NC press brakes (torsion bar synchronized) are suitable for general bending processes and are more suitable for small to medium scale production and simple workpieces.
NC press brake (torsion bar synchronization) is limited scalability, usually not easy to integrate with other equipment for tandem operation or integration with robots. Computerized CNC press brakes (electro-hydraulic), on the other hand, have higher scalability, allow tandem operation with other equipment, and are easier to integrate with robots and other automation equipment. With the integration of automated equipment, productivity will be significantly increased, labor costs will be reduced, and production safety issues will be avoided.
Due to the NC system and operating principles, NC press brake (torsion bar synchronization) is more dependent on the experience of workers, which may require companies to pay higher wages to hire more experienced workers. Computerized CNC press brakes (electro-hydraulic) are relatively simple to operate, require less operator experience, and have a higher degree of automation.
Small batch production: NC press brakes are usually suitable for the production of a relatively small number of parts, such as specific custom orders or small projects.
Lower accuracy requirements: NC press brakes are an affordable option for applications that do not require high accuracy.
Simple parts: Commonly used to manufacture simple metal parts such as flat plates, right angles and basic bending.
Manual Programming: Operators are required to manually enter coordinates and programs, making them suitable for users with some NC programming experience.
Cost-effective: NC press brakes are usually more affordable and suitable for limited budgets.
Mass production: Computerized CNC press brakes are suitable for mass production requirements as it improves productivity and consistency.
High precision requirements: for aerospace, shipbuilding, automotive and electronics industries that require high precision in parts manufacturing, CNC press brakes are the first choice.
Complex Parts: Capable of handling the bending of complex parts, including those with multiple bending angles and curves.
Automation: Usually with a higher level of automation, capable of performing bending tasks automatically with less operator intervention.
High cost: Due to their advanced control systems and features, CNC press brakes are usually more expensive and are suitable for applications with high production demands and high precision requirements.
Of course, any factory in need of a press brake can choose a computerized CNC press brake because it is suitable for all types of sheet metal bending processes in the decorative industry (e.g., cabinets, closets, elevators, doors, windows, curtain walls, etc.), the construction industry (e.g., steel structures, towers, bridges, etc.), machine building (e.g., environmental protection equipment, animal husbandry equipment, solar energy equipment, insulating materials, transformers, etc.), and in the electrical and power industry (e.g. poles, light poles, electrical equipment, electronic equipment, etc.) have a wide range of applications.
