Light Barrier Safety Distance Adjustment for Press Brakes
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Solution Overview
Problem
Existing methods for setting the safety distance in machine protective devices, such as press brakes, require extensive technical measures and time due to the need for multiple movements and adjustments with different interchangeable tools of varying dimensions.
Innovation Solution
A method that allows for the quick and easy setting of the safety distance by moving the first machine part in the closing direction until the light barrier is interrupted, using electronic comparison to determine the deviation, and adjusting the light barrier arrangement accordingly, without additional hardware, through motorized, manual, or optical means, and fixing it in the correct position.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the light barrier is moved towards the first tool until the light barrier arrangement or at least one light beam is interrupted, then the safety distance can be set, but extensive technical measures and not inconsiderable expenditure of time are required due to the need for two movements and resetting for each tool
Solution Approach 1:
The control device pre-calculates the distance position of the first machine part relative to the second machine part based on tool data and workpiece data entered before operation. This preliminary calculation eliminates the need for time-consuming manual measurement and adjustment during tool changes, as the correct safety distance is already determined before the actual machining operation begins
Solution Approach 2:
The patent replaces the manual mechanical measurement and adjustment process with an electronic control system that automatically calculates and positions the light barrier arrangement. The electronic comparison means compare the actual position with the pre-calculated distance position, and the control device automatically adjusts the light barrier to the correct safety distance, eliminating the need for operators to manually measure and reset safety distances for each tool
2Reliability
If the light barrier is moved towards the first tool until the light barrier arrangement or at least one light beam is interrupted, then the safety distance can be set, but extensive technical measures are required
Solution Approach 1:
The control device performs multiple functions: it stores tool data and workpiece data, calculates the distance position, controls the movement of the first machine part, compares actual position with target position, and adjusts the light barrier arrangement. This multi-functional integration eliminates the need for separate measurement devices, calculation tools, and adjustment mechanisms, reducing device complexity while maintaining safety distance setting reliability
Solution Approach 2:
The system automatically determines the correct safety distance by comparing pre-entered tool and workpiece data, calculates the required distance position, and self-adjusts the light barrier arrangement without requiring external measurement tools or manual intervention. The electronic comparison means and control device work together to self-correct any positioning errors, making the system self-sufficient
3Adaptability or versatility
If different interchangeable tools with different dimensions are used, then the machine can handle various workpieces, but the safety distance has to be reset in each case
Solution Approach 1:
When a tool is mounted in the tool holder, the corresponding tool data is pre-entered into the control device. The control device then pre-calculates the distance position based on this tool data and the workpiece data, so that when the tool is ready for operation, the light barrier arrangement is already positioned at the correct safety distance, eliminating the need for time-consuming resetting during tool changes
Solution Approach 2:
The electronic comparison means continuously monitor the position of the first machine part relative to the light barrier arrangement and compare it with the pre-calculated distance position. This feedback mechanism ensures that the light barrier is automatically adjusted to the correct safety distance for each tool configuration, maintaining accuracy regardless of tool interchangeability
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 method reduces the complexity and time required to set the safety distance, allowing for efficient adjustment of the light barrier arrangement to the correct safety position with a single directional movement, enhancing operational efficiency and safety.
Implementation Method 1
a light barrier arrangement (20) arranged relative to the first machine part (8), in particular on the stationary machine part (9)
Data Source
AI summary
The protection device has an input device (24) to input tool data and workpiece data into the electronic control device (26) which can calculate the clearance position of the first machine part (8), in which the first tool (10) is at the safety clearance from the second tool (11) or the workpiece (14). The first machine part can be moved by a motor.