Adjustable Secondary Light Curtain for Press Brake Crush Zone Detection
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Solution Overview
Problem
Existing safety systems for press brakes do not adequately protect operators from the risk of crushing injuries during secondary bending processes, as they fail to detect intrusions into the crush zone between the ram and the leading edge of a formed flange, and lack adjustable mounting options for the light curtain.
Innovation Solution
A secondary light curtain system with an adjustable mounting bracket is implemented to detect intrusions into the crush zone between the ram and the leading edge of a formed flange, using a light curtain emitting and detecting array that communicates with the press brake's ram to halt operation upon detection of an operator's fingers, and a method to reset the process safely.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a fixed light curtain position is used, then installation is simplified, but adaptability to various workpiece configurations and crush zone locations is reduced
Solution Approach 1:
The second light curtain array is mounted on the ram in a manner that allows its position to be adjusted dynamically. The mounting structure includes adjustment mechanisms that enable the light curtain array to be repositioned along the ram's travel path and at different heights, allowing adaptation to various workpiece configurations, flange lengths, and crush zone locations while maintaining protection effectiveness.
2Reliability
If a secondary light curtain is added to protect the crush zone, then crush zone intrusion detection is improved, but device complexity increases
Solution Approach 1:
The first and second light curtain arrays are integrated into a unified safety system with a common controller that receives signals from both arrays. The controller coordinates the operation of both arrays and the ram, halting the ram's downward movement when either array detects an intrusion. This merging approach consolidates control functions and reduces overall system complexity despite adding the second protection layer.
3Measurement precision
If the light curtain is mounted on the ram, then positioning accuracy for various workpiece configurations is improved, but mounting complexity increases
Solution Approach 1:
The mounting structure for the second light curtain array on the ram is designed as a universal, multi-functional assembly that combines adjustment mechanisms, mounting brackets, and positioning features into a single integrated unit. This universal mounting structure can accommodate different light curtain array sizes and configurations while providing accurate positioning and easy adjustment, reducing the need for multiple specialized mounting components.
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
The secondary light curtain effectively prevents crushing injuries by detecting operator intrusions into the crush zone and halting the press brake's operation, allowing for safe removal of the operator's hand and resumption of the bending process, while the adjustable mounting ensures proper positioning for various workpiece configurations.
Implementation Method 1
a light curtain emitting and detecting array in which a light curtain is emitted
Implementation Method 2
detecting array that are in operative communication with the ram... detect intrusion by all or a portion of an operator's hand
Data Source
AI summary
A secondary light curtain for preventing injury to an operator of a press brake during formation of a second flange on a workpiece and a method for using the same. The secondary light curtain detects intrusion by the operator into a crush zone, i.e. the area, between the ram and the leading edge of a prior formed flange. In order to provide for ready adjustment of the height of the secondary light curtain, a mounting bracket having a longitudinal mounting slot, and a cooperating secondary angle bracket are provided. The mounting bracket of the present invention allows the secondary light curtain light assemblies to be mounted directly on the front or side of the ram.