Press Brake Optical Safety Layout for Working Gap Protection
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Solution Overview
Problem
Deformation devices in machine tools face challenges in simplifying operation and ensuring operator safety, particularly in preventing accidents during the bending process where the risk of operator interference with moving tools and workpieces is high.
Innovation Solution
The implementation of a dual optical safety device system that monitors three distinct safety spaces around the working gap, using radiation sources and light receivers to detect any intrusion and automatically control the movement of the tools, thereby preventing accidents without the need for manual intervention.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If multiple optical safety devices are used to monitor different safety spaces, then operator safety is improved, but device complexity increases
Solution Approach 1:
The second optical safety device is configured to perform dual functions: monitoring the second safety space in front of the upper tool and monitoring the third safety space extending downward along the movement path. This multi-functionality reduces the total number of safety devices needed while maintaining comprehensive safety coverage.
Solution Approach 2:
The patent combines the monitoring functions for the second safety space and third safety space into a single optical safety device (the second safety device), merging multiple safety monitoring tasks into one integrated system rather than using separate devices for each space.
2Reliability
If automated safety monitoring is implemented, then operator protection is improved, but ease of operation deteriorates due to system complexity
Solution Approach 1:
The safety system operates autonomously by automatically detecting intrusions into safety spaces and triggering tool movement or shutdown without requiring manual intervention from the operator. The system monitors itself and responds automatically, eliminating the need for operators to manually manage safety protocols.
Solution Approach 2:
The optical safety devices continuously monitor the safety spaces and provide real-time feedback to the control system. When an intrusion is detected, the system immediately responds by activating safety measures, creating a closed-loop feedback system that automatically maintains safety without operator involvement.
3Device complexity
If the second optical safety device monitors both the second safety space and third safety space, then device quantity is reduced, but measurement precision may deteriorate
Solution Approach 1:
The second optical safety device divides its monitoring function into distinct segments: one set of radiation sources and light receivers monitors the second safety space, while another set monitors the third safety space. This segmentation allows each sub-system to maintain precise monitoring of its specific zone despite the device's multi-functional role.
Solution Approach 2:
Different regions of the second optical safety device are configured with specialized monitoring capabilities optimized for their specific monitoring zones. The device applies different monitoring parameters and sensitivity levels to different safety spaces, ensuring each area receives appropriate monitoring precision tailored to its specific safety requirements.
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 enhances operational simplicity and safety by automatically controlling tool movement based on sensor inputs from the optical safety devices, reducing the risk of operator injury and ensuring safe operation during the deformation process.
Implementation Method 1
a first radiation source for providing first safety light beams and a first light receiver for receiving the first safety light beams
Data Source
Figure 1
Figure 2
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AI summary
The invention relates to a deformation device (1) with a machine frame (2) on which an upper tool (4) and a lower tool (5) are arranged, forming a variable-size working gap (8), with a first optical safety device (20) for safeguarding a first safety space (28) adjacent to the working gap (8), and with a second optical safety device (30) for safeguarding a second safety space (31) located upstream of a largest surface (18) of the upper tool (4). According to the invention, the second optical safety device (30) is configured for monitoring a third safety space (51), which extends downwards beyond the end face (6) of the upper tool (4) facing the lower tool (5) along the path of movement (14) in the direction of the lower tool (5), such that a projection of the third safety space (51) onto the working gap (8) covers at least a section of the working gap (8).