Advantages of Hydraulic Bending Machine

In recent years, the mature and cost reduction of high power and large torque servo motor and driving technology have promoted the more and more applications of the related electric servo drive devices. The CNC bending machine widely used in the sheet metal industry has opened the new trend of the main drive of the pure electric servo system instead of the main hydraulic drive, and the tonnage and production of the pure electric servo CNC bending machine are becoming more and more large. This paper expounds the advantages of the pure electric servo bender compared with the hydraulic bending machine from the aspects of energy saving, environmental protection, machining efficiency, bending accuracy and maintenance cost. The pure electric servo bending machine is a developing trend. But now it is immature, we can see the advantages of this bending machine and get the trend of development.

1. Energy Saving

Modern hydraulic bending machines are designed to be energy-efficient, consuming power only when needed.Variable displacement pumps and advanced control systems contribute to lower energy consumption.

One of the advantages of the pure electric servo drive technology is that the input power of the motor is proportional to the load power, and the power consumption is large at the time of bending. When the slider is empty, the power consumption is small. When the slider stops, it does not consume the electricity. But the main motor and hydraulic pump of hydraulic servo bender are running continuously, even if the slider does not work. In addition, the mechanical transmission efficiency of the pure electric servo bending machine is more than 95%, the hydraulic transmission efficiency of the hydraulic servo bending machine is less than 80%, and the efficiency of the hydraulic system components is lower after aging and wear.

Taking the 100t bending machine as an example, the power consumption of the mainframe of the pure electric servo bending machine is about 12kW. H/d according to the working 8h for one day. The power consumption of the hydraulic bending machine is about 60kW. H/d, and the energy saving of the pure electric servo bending machine is about 80%.

2. Environmental Protection Without Pollution

The pure electric servo bending machine does not use hydraulic oil, does not replace the trouble of hydraulic oil and dismantling hydraulic components. It also has no replacement, dismantling process and the daily hydraulic oil leakage of the system, and there is no waste oil treatment and pollution.

3. Slider Is Fast And Production Efficiency Is High

The response speed of the servo motor is faster than that of the hydraulic servo. Taking the 100t pure electric servo bending machine developed by the Kaifeng numerical control company as an example, the backstroke and fast speed of the slide block are up to 200mm/s and the working speed is 0 to 20mm/s; the overwhelming majority of the same tonnage hydraulic bending machine is below 120mm/s and the speed is below 120mm/s, and the working speed is 10mm/s. The hydraulic servo bending machine is affected by the heating of the environment and the hydraulic system. It is necessary to open the machine to preheat or stop the heat. Once the hydraulic system has a fault, it can find the technical requirements of the troubleshooting and the long time. The pure electric servo bending machine has few components and low failure rate. There are no such problems at all.

Therefore, the efficiency of the pure electric servo bending machine is nearly 1 times higher than that of the same tonnage hydraulic bender.

4. High Accuracy of Bending

The bending speed of the pure electric servo bending machine can be adjusted. It can bend to different thickness, different material and different bending length, set more appropriate bending speed, improve bending precision and maintain high productivity. The deflection compensation shaft of the pure electric servo bending machine adopts the VILA structure compensation device, and the bending accuracy is higher.

The bending angle error of the hydraulic bending machine is less than 1 degrees, and the main drive of the servo bending machine is driven by the servo motor drive screw, and the transmission precision is higher. By measuring the bending angle of various specifications plate, the bending angle error can be guaranteed to be within 0.5 degrees.

5. Low Maintenance Cost

The hydraulic oil of the hydraulic bending machine needs to be replaced regularly; the pump, valve and seal are easily broken, easily damaged, the hydraulic system is easy to pollute, and it is difficult to find out the trouble. Once the hydraulic system is polluted, the cleaning system is difficult, and it will cause the environmental pollution. The pure electric servo bending machine has simple drive system, basically no maintenance cost, and only needs regular lubrication.

The design and manufacture of the pure electric servo bending machine is aimed at high bending precision, high efficiency and high reliability. The finite element analysis of the bed and slider has been carried out to optimize the rigidity of the bed and slider.

6. Safety Features

These machines are equipped with advanced safety features, such as light curtains, safety guards, and emergency stop buttons, ensuring operator safety.Easily accessible emergency stop buttons allow operators to immediately halt the machine's operation in case of an emergency.

Light Curtains: Light curtains create an invisible safety barrier around the machine. If an operator's hand or another object interrupts the light beam, the machine will stop operating to prevent injury.

Safety Guards and Fences: Physical barriers such as guards and fences are installed around hazardous areas to prevent accidental contact with moving parts.

Two-Hand Control: Requiring the operator to use both hands to initiate the machine's operation ensures that their hands are away from the danger zone during the bending process.

Foot Pedal with Guard: The foot pedal used to operate the machine is often equipped with a guard to prevent accidental activation.

Automatic Tool Detection: Some machines are equipped with sensors that detect the presence of tools and workpieces, ensuring proper alignment and reducing the risk of malfunctions.

Hydraulic Overload Protection: This feature prevents the machine from applying excessive force that could damage the machine or cause accidents.

Anti-Tie Down and Anti-Repeat Controls: These controls prevent the machine from cycling continuously, reducing the risk of repetitive motion injuries.