Laser Safety Device for Press Brake Tool Holder
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Solution Overview
Problem
Existing safety devices for production machines, such as press brakes, often require multiple beams to monitor the working area, leading to increased complexity and control effort, and may not effectively detect obstructions, especially when lightweight bending tools are used, which can result in safety hazards.
Innovation Solution
A safety device with a single laser beam transmitter and receiver integrated into the tool holder, allowing for a greater distance between the components and enabling precise adjustment to avoid obstructions, while ensuring the beam channel remains unimpeded during bending operations, and includes independent clamping mechanisms to manage tool lamellae securely and efficiently.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple beams are used to monitor the working area, then safety coverage is improved, but device complexity and control effort increase
Solution Approach 1:
The single beam is segmented into multiple virtual detection zones along its path. The beam channel extends through the tool holder, creating multiple monitoring points without requiring multiple physical beam sources. This segmentation allows comprehensive safety coverage while maintaining a simple single-beam physical structure.
Solution Approach 2:
The single laser beam serves multiple functions: it monitors the entire working area, detects obstructions at various positions, and provides safety coverage for the adjustable press beam range. This multi-functionality eliminates the need for multiple separate beam systems while maintaining comprehensive safety monitoring.
2Device complexity
If a single laser beam is used, then device complexity is reduced, but the distance between transmitter and receiver must be sufficient to cover the working area
Solution Approach 1:
The beam channel is integrated into the tool holder structure, utilizing the vertical and lateral dimensions of the tool holder rather than requiring a long horizontal distance. This dimensional repositioning allows the beam to traverse the necessary monitoring area through the tool holder's structure, reducing the overall transmitter-receiver distance while maintaining effective coverage.
3Reliability
If the beam channel is integrated into the tool holder, then safety monitoring is improved, but the tool holder structure becomes more complex
Solution Approach 1:
The beam channel is merged with the tool holder structure, combining the safety monitoring function with the existing tool holding structure. This integration allows the laser beam to pass through the tool holder along a defined path, enabling safety monitoring without adding separate complex structures. The beam channel utilizes the tool holder's existing geometry and mounting points.
4Object-affected harmful factors
If lightweight tool lamellae are used, then safety risk from tool mass is reduced, but detection of obstructions becomes more difficult
Solution Approach 1:
The mechanical detection method (relying on tool mass and force) is replaced with an optical detection system. The laser beam provides a non-contact sensing mechanism that detects obstructions through light interruption rather than mechanical force, enabling effective monitoring even with lightweight tool lamellae that pose reduced safety risks.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution allows for immediate detection of tool position and obstruction, reducing control effort, ensuring safety without impairing the bending process, and effectively prevents injuries by maintaining an uninterrupted beam channel and minimizing the risk of beam interference.
Implementation Method 1
a laser beam transmitter (25) arranged in the receiving groove (15) of the tool holder (7)
Data Source
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AI summary
The curved work-tool consists of a tool lamella (33) with a tension device (44) applying tension to a tool receiver (7) and a curved edge (67) for a stamp (75). The stamp is formed via the work-tool shoulders (47) and the curved edge?s mounted grooves (76, 77). There is a pulley rod (78) perpendicular to the rest surface (46) of the work-tool shoulder and having a push rod (79) running parallel to it. The thickness of the work-tool lamella is between 2 and 20 mm.