Is setting up your HARSLE Genius Press Brake with ESA S860 or S875 a challenge? Learn the steps for precise and efficient operation, ensuring optimal bending results.

This tutorial will guide you through setting up the HARSLE Genius Press Brake with ESA S860 and S875 controllers. Follow these easy-to-understand steps for achieving high precision and better productivity in your bending operations.

Now, let’s break down each step of the setup and explain how to maximize the potential of your press brake.

Part 1 Fill The Oil and Cable Connections

Properly Filling the Oil Tank with Anti-Wear Hydraulic Oil

Filling the oil tank with anti-wear hydraulic oil is a crucial step to ensure the smooth operation and longevity of your press brake. Before filling, make sure the tank is clean and free of contaminants. Use the recommended hydraulic oil type and viscosity to maintain optimal system performance. Slowly pour the oil into the tank through a fine mesh filter to prevent impurities from entering the hydraulic system. Avoid overfilling, as it can lead to excessive pressure and leaks. Once filled, check the oil level gauge and ensure proper sealing of the tank cover before starting the machine.

Maintain Proper Oil Volume for Optimal Press Brake Performance

To ensure the HARSLE Genius Press Brake operates smoothly and efficiently, always maintain the hydraulic oil level at no less than two-thirds of the oil volume indicator. Insufficient oil can cause unstable pressure, reduced bending accuracy, and increased wear on hydraulic components. Low oil levels may also lead to overheating and compromised lubrication, affecting the machine’s lifespan. Regularly check the oil gauge and refill with high-quality hydraulic oil as needed. Keeping the oil at the recommended level helps maintain consistent bending force, precision, and machine reliability, ensuring long-term performance and minimizing downtime. Proper maintenance is key to optimal operation.

Connecting the HARSLE Genius Press Brake to Power

Before operating the HARSLE Genius Press Brake, ensure the machine is correctly connected to a stable power source. First, verify that your facility provides a three-phase power supply compatible with the machine’s voltage requirements. Carefully connect the power cables to the designated terminals, following the provided wiring diagram. Ensure all connections are secure and properly insulated to prevent electrical hazards. After connecting, check the power stability before switching on the machine. A proper power connection is crucial for safe operation, preventing voltage fluctuations that may impact performance. Always follow the user manual and local electrical safety regulations.

Switch on the power source

To begin operating the HARSLE Genius Press Brake with the ESA S860 or S875 controller, the first step is to switch on the power source. Locate the main power switch on the machine’s control panel or electrical cabinet. Turn the switch to the “ON” position, ensuring that the power indicator light is activated. Wait a few seconds for the system to initialize. The ESA controller will begin booting up, displaying the startup screen. If the machine does not power on, check the emergency stop button and reset it if necessary. Always follow safety protocols before proceeding with operation.

Turn On the Machine Power Switch

To begin operating the HARSLE Genius Press Brake with the ESA S860 or S875 controller, the first step is to turn on the machine power switch. Locate the main power switch, usually positioned on the side or back of the machine. Rotate the switch to the “ON” position, ensuring the machine receives power. Wait for a few seconds as the system initializes. The ESA controller screen will display the startup interface, indicating that the press brake is ready for operation. Always verify that the emergency stop button is released before proceeding to the next steps in the setup process.

Connect the pedal switch to the machine

To ensure proper operation of the HARSLE Genius Press Brake with ESA S860 and S875 controllers, it is essential to correctly connect the pedal switch to the machine. Start by locating the designated foot pedal port on the machine’s control panel. Align the connector with the port and firmly insert it to establish a secure connection. Ensure that the cable is properly routed to prevent any interference during operation. Once connected, test the pedal switch by activating the machine’s control system and verifying its response. Proper installation of the pedal switch enhances operator efficiency and safety during the bending process.

Turn on the power switch

Before operating the HARSLE Genius Press Brake with ESA S860 & S875, the first step is to turn on the power switch. Locate the main power switch, usually positioned on the side or rear of the machine. Ensure that the power supply is stable and the emergency stop button is released. Rotate the power switch to the “ON” position, and wait for the control system to initialize. The ESA S860 or S875 controller will begin its startup process, displaying the main interface. Once fully booted, the machine is ready for further setup and operation. Always follow safety protocols before proceeding.

Check the main motor’s rotating direction

Before operating the HARSLE Genius Press Brake, it is crucial to verify the main motor’s rotating direction to ensure proper functionality and avoid potential damage. Start by powering on the machine and briefly running the motor. Observe the rotation indicator or check the airflow direction of the cooling fan. If the motor rotates incorrectly, immediately stop the machine and swap any two phases of the power supply to correct it. Ensuring the correct rotation direction prevents system malfunctions, enhances performance, and extends the machine’s lifespan. Always double-check the wiring and follow safety guidelines before proceeding with operation.

Clockwise Rotation Indicates Correct Operation

When operating the HARSLE Genius Press Brake with the ESA S860 or S875 controller, it is crucial to verify the motor’s rotation direction before proceeding. If the motor rotates clockwise, it confirms the correct wiring and ensures smooth machine operation. A counterclockwise rotation may indicate an incorrect phase connection, which could lead to malfunctions or reduced efficiency. To correct this, simply swap any two power supply wires and recheck the direction. Proper motor rotation not only enhances performance but also prevents potential damage to electrical components. Always verify this step before using the machine for bending operations.

Understanding the Anti-Clockwise Rotation in Press Brake Operations

If it is rotating anti-clockwise, it typically indicates a reverse movement in the motor or mechanical component. In the case of a press brake, an anti-clockwise rotation could affect the positioning of the backgauge, ram, or other moving parts. This direction is usually determined by the machine’s motor wiring or control settings. If unintended, it may signal incorrect wiring connections or parameter settings in the CNC system. Operators should check the motor phase sequence, controller configuration, and machine manual to ensure proper functionality. If necessary, consult the manufacturer’s guidelines or a professional technician to correct the rotation issue safely.

Press the emergency stop

The emergency stop button is a critical safety feature on the HARSLE Genius Press Brake with ESA S860 & S875 controllers. Pressing the emergency stop immediately halts all machine operations, preventing potential accidents or damage. Operators should press this button in case of an emergency, such as unexpected movement, malfunction, or any unsafe situation. Once activated, the machine will remain in a locked state until it is manually reset. Before resuming work, ensure that the issue has been resolved and follow proper restart procedures. Regularly checking the emergency stop functionality is essential for maintaining a safe working environment.

Exchange the two wires connection

When exchanging the two wires connection, ensure that the machine is completely powered off to prevent electrical hazards. Identify the two wires that need to be swapped, typically located in the control panel or motor terminal. Use a screwdriver or appropriate tool to loosen the connections, then carefully switch their positions. Secure the wires firmly and double-check the connections to avoid any loose ends. Once completed, restore power and test the machine to ensure proper operation. If the motor runs in the wrong direction, recheck the wiring. Always follow safety guidelines and consult the machine manual when making electrical adjustments.

Part 2 Machine Start-up

Turn on the power switch

To begin operating the HARSLE Genius Press Brake equipped with the ESA S860 or S875 controller, the first step is to turn on the power switch. Locate the main power switch on the side of the machine and ensure that the emergency stop button is released. Rotate the power switch to the “ON” position, allowing the system to initialize. Wait a few seconds for the controller screen to light up and complete the boot-up process. Once the system is fully powered, check for any error messages or system prompts before proceeding with machine setup and bending operations.

Releasing the Emergency Stop and Starting the Oil Pump

Before operating the HARSLE Genius Press Brake with ESA S860 or S875, ensure that the emergency stop button is released. This button is a critical safety feature that prevents unintended machine movements. Turn it clockwise to reset it. Once the emergency stop is disengaged, proceed to start the oil pump by pressing the designated button on the control panel. The oil pump is essential for the hydraulic system, ensuring stable pressure and smooth bending operations. Always verify that the pump is running properly before proceeding with any bending tasks to avoid malfunctions and ensure safe and efficient operation.

Waiting For the System Loading

When turning on the HARSLE Genius Press Brake with ESA S860 or S875, the system requires a brief moment to initialize. During this loading phase, the controller performs a self-check, ensuring all hardware and software components are functioning correctly. Users should wait until the system fully loads to avoid potential errors. The loading time may vary depending on the machine’s configuration and software version. Once the interface is displayed, users can proceed with programming and operation. Avoid interrupting the process by turning off the machine, as this may cause system instability. Always ensure a stable power supply for smooth startup.

Open the EsaBend

To begin operating the HARSLE Genius Press Brake with the ESA S860 or S875 controller, the first step is to open the EsaBend software. Ensure the machine is properly powered on and the controller screen is responsive. Locate the EsaBend icon on the interface and tap to launch the software. Once opened, the system will initialize and display the main menu, where you can access bending programs, tool settings, and machine configurations. Check that all necessary parameters are correctly loaded before proceeding. This step is essential to ensure smooth operation and precise bending performance with the ESA control system.

Tap the Editor.

The HARSLE Genius Press Brake equipped with ESA S860 and S875 controllers offers precise, efficient, and user-friendly metal bending capabilities. These advanced controllers simplify programming, enabling operators to set bending sequences, angles, and material parameters effortlessly. The intuitive touchscreen interface enhances workflow efficiency, reducing setup time and errors. With real-time feedback and automatic compensation, the ESA controllers ensure high bending accuracy. Whether you are a beginner or an experienced fabricator, mastering this press brake will improve productivity and precision. This guide will walk you through the essential steps to operate the HARSLE Genius Press Brake with ESA S860 & S875 effectively.

Locating the Reference Point in the Manual Page

On the Manual page of the ESA S860 and S875 controller, locate the reference point to ensure accurate positioning before starting the bending process. This reference point acts as the zero position, helping the machine determine the correct movement of the ram and backgauge. Navigating through the manual interface, you will find instructions on how to identify and confirm this reference point. Properly setting it ensures precision, repeatability, and alignment in every bending operation. Always verify the reference point after powering on the machine to avoid errors and enhance bending accuracy.

Testing the X-Axis Movement for Precision

Before operating the HARSLE Genius Press Brake with ESA S860 or S875, it is crucial to test the X-axis movement to ensure precise positioning of the backgauge. Start by setting a reference position in the controller and running the X-axis manually or in automatic mode. Observe its movement for smoothness, accuracy, and repeatability. Check for any deviations and recalibrate if necessary. Proper X-axis alignment ensures precise bending angles and consistent results. Regular testing helps prevent positioning errors, reducing material waste and improving efficiency. Always confirm proper functionality before beginning any bending operations to ensure optimal machine performance.

Test the R-axis running

Before starting full operation, it is essential to test the R-axis movement on the HARSLE Genius Press Brake equipped with the ESA S860 or S875 controller. The R-axis, responsible for adjusting the height of the backgauge fingers, ensures precise positioning for different bending applications. Begin by accessing the controller interface and selecting the manual mode to move the R-axis up and down. Verify smooth movement, accuracy, and responsiveness. If any irregularities occur, check the motor function and alignment. Proper testing of the R-axis guarantees high-precision bending results and enhances overall machine efficiency, reducing errors during actual production.

Test the Z1-axis running

Before starting full production, it is essential to test the Z1-axis movement on the HARSLE Genius Press Brake equipped with ESA S860 and S875 controllers. First, ensure that the machine is properly powered on and the control system is initialized. Navigate to the axis control settings in the ESA interface and manually jog the Z1-axis to verify smooth and accurate movement. Observe any irregularities, such as misalignment or unexpected stops. Adjust parameters if necessary to ensure precision. Proper testing ensures that the backgauge positioning functions correctly, leading to more accurate and efficient bending operations.

Test the Z2-axis running

To ensure precise operation of the Z2-axis in the HARSLE Genius Press Brake with ESA S860 and S875 controllers, conduct a thorough test before production. Begin by verifying the reference position and homing sequence. Manually jog the Z2-axis forward and backward to check for smooth, accurate movement. Monitor the alignment and synchronization with the Z1-axis to ensure parallel operation. Use the controller interface to input test commands and observe the response. If irregularities occur, adjust parameters or check for mechanical obstructions. Regular testing helps maintain precision, reduces errors, and ensures consistent bending performance in daily operations.

Testing the Crowning System Operation in HARSLE Press Brake

Before starting production, it is essential to test the crowning system to ensure accurate bending results. The A1-axis, also referred to as the V-axis, controls the crowning compensation, adjusting the table to compensate for deflection during bending. To test its operation, activate the system and monitor the movement to confirm smooth and precise adjustments. Check the synchronization between the upper and lower beams, ensuring even force distribution along the workpiece. Any irregularities should be addressed before proceeding with actual bending tasks. A properly functioning crowning system enhances bending accuracy, reduces material waste, and ensures consistent performance in metal fabrication.

Checking Tooling Parameters on the Punches and Dies List Page

On the Punches and Dies List page, you can review the essential tooling parameters to ensure accurate and efficient bending operations. This section provides detailed specifications for each punch and die, including angle, height, width, radius, and material type. By verifying these parameters, operators can prevent errors in the bending process and ensure compatibility with the selected press brake program. Additionally, checking the tooling details helps optimize bending performance and prolong tool lifespan. Always confirm that the selected tools align with your bending requirements before proceeding with machine setup.

Verify Tooling Dimensions Against System Data

Before starting the bending process, it is essential to measure the tooling and compare it with the data entered in the ESA S860 or S875 controller. Use a caliper or precision measuring tool to check the dimensions of the punch and die, ensuring they match the programmed values. Verify critical parameters such as tool height, V-opening, and radius to prevent bending inaccuracies. If discrepancies are found, update the controller settings accordingly. Accurate tooling measurement helps maintain bending precision, reduce errors, and ensure consistent results, ultimately improving overall production efficiency and machine performance.

Part 3 Bending Programming

Adding a New Bending Program in the Programming List

On the Programming List page of the ESA S860/S875 controller, users can create and manage bending programs efficiently. To add a new bending program, navigate to the Programming List and select the option to create a new program. Input the required parameters, including material type, thickness, bending angle, and tooling selection. Ensure that the bending sequence is correctly defined for accurate results. Once all settings are configured, save the program for future use. This feature allows operators to streamline workflow and improve bending precision, making the HARSLE Genius Press Brake more efficient and user-friendly.

Input the sheet width

To ensure precise bending operations, you need to input the correct sheet width into the ESA S860 or S875 controller. This step is essential for accurate positioning and optimal bending results. Navigate to the input field on the touchscreen interface and enter the exact width of the sheet metal you are working with. The system will use this data to calculate bending parameters, ensuring consistency and precision. Double-check the input to avoid errors that could affect the final bend. Once entered, confirm the data and proceed with setting other necessary parameters for the bending operation.

Input the sheet thickness

To ensure accurate bending results, it is crucial to input the correct sheet thickness in the ESA S860 or S875 controller. Navigate to the material settings menu on the touch interface, then locate the “Sheet Thickness” field. Enter the precise thickness of your metal sheet in millimeters or inches, depending on your preference. This step allows the press brake to calculate the required bending force and adjust parameters accordingly. Accurate input prevents overloading, ensures consistent bends, and prolongs the tool’s lifespan. Always verify the sheet thickness before proceeding to the next step in the bending process.

Setting Measures to Zero for Outer Dimensions

To ensure accurate bending results on the HARSLE Genius Press Brake with ESA S860 and S875 controllers, it is essential to set the measures to zero, which corresponds to the outer dimensions of the workpiece. This step eliminates any discrepancies caused by offsets or tool tolerances, ensuring precision in metal bending operations. To do this, navigate to the measure settings in the ESA controller, select the reference point, and adjust the values to zero. Verifying these settings before each operation prevents misalignment and guarantees consistent bending angles, improving efficiency and accuracy in sheet metal fabrication.

Selecting the Right Material for Bending

Choosing the right material is crucial for achieving precise and high-quality bends with your HARSLE Genius Press Brake equipped with ESA S860 and S875 controllers. Different materials, such as stainless steel, aluminum, and mild steel, have unique bending properties, including tensile strength, elasticity, and thickness variations. Before starting, ensure that the selected material is compatible with the press brake’s tooling and bending force capacity. Additionally, consider factors like grain direction, hardness, and potential springback to adjust the bending parameters accordingly. Proper material selection not only enhances bending accuracy but also extends the lifespan of your machine and tools.

Make the program to be numerical

To ensure precise and efficient bending operations, the ESA S860 and S875 controllers allow users to convert their bending programs into numerical data. This process involves defining key parameters such as bending angles, backgauge positions, tool selection, and material thickness. By inputting numerical values, the controller can automatically calculate the best bending sequence, reducing manual adjustments and ensuring consistency across multiple jobs. This feature improves production efficiency, minimizes errors, and enhances repeatability. Operators can easily modify or fine-tune the numerical data to optimize each bending step, making the entire process more reliable and user-friendly.

Choose the punch and die

Selecting the appropriate punch and die is crucial for achieving accurate and high-quality bends with your HARSLE Genius Press Brake. First, consider the material thickness and bend angle to determine the correct tool shape. The punch should have the necessary tip radius to avoid excessive material stress, while the die opening must be wide enough to prevent cracking but not too large to cause inaccurate bends. Additionally, ensure that the tool material is durable enough for the workload. Using the ESA S860 or S875 controller, you can input tooling specifications to optimize bending precision and reduce setup errors.

Enter into the Editor page after confirmation

After confirming your settings, proceed to the Editor page to begin programming your bending operations. The Editor page allows you to create, modify, and manage bending sequences with precision. Here, you can input material specifications, select tooling, and define bending angles according to your project requirements. The intuitive interface of the ESA S860 and S875 controllers ensures smooth navigation, making it easy to adjust parameters as needed. Before proceeding, double-check your inputs to ensure accuracy and efficiency in the bending process. Once everything is set, you are ready to execute the program and optimize your press brake performance.

Entering Bending Length and Angle on ESA S860/S875

To achieve precise bending with the HARSLE Genius Press Brake equipped with the ESA S860 or S875 controller, you need to input the bending length and angle correctly. Start by selecting the bending program, then enter the exact workpiece length in millimeters. Next, specify the desired bending angle, ensuring it aligns with your material and tooling specifications. The ESA controller will automatically calculate the ram depth and adjust the backgauge position accordingly. Double-check the inputs before executing the bend to avoid errors. This process ensures consistent, accurate bends, reducing material waste and improving efficiency in your metal fabrication workflow.

Adding the Second Bending Step

To add the second bending step, ensure that the metal piece is properly positioned in the HARSLE Genius Press Brake with the correct die selection. The first bend should be completed with precision, and then the material is carefully shifted to the next position for the second bend. It is crucial to double-check the angles, material thickness, and press brake settings before proceeding. The ESA S860/S875 controller can be programmed to automatically calculate the optimal position and force needed for the second bending step, ensuring accuracy and efficiency throughout the process.

Re-enter the Bending Length and Angle for Accuracy

To ensure precise bending, it’s essential to input the bending length and angle correctly in the HARSLE Genius Press Brake with ESA S860 or S875 controllers. If adjustments are required, simply re-enter the bending length and angle values into the control panel. This will help avoid errors and ensure that each bend is accurate according to your specific requirements. Double-checking these values before starting the process can save time and material, improving the overall quality and efficiency of your metalworking operation. Always make sure that the dimensions are inputted correctly for optimal machine performance.

Import the program name and save.

To begin using the HARSLE Genius Press Brake with the ESA S860 or S875 controller, you need to import the program file into the system. First, ensure the program is prepared on your computer or external device. Connect the device to the ESA controller via USB or network connection. On the controller’s interface, select the “Import Program” option and browse for the desired program file. Once the file is selected, click “Import” to upload it into the system. After importing, don’t forget to save the program to ensure it is properly stored for future use. This will allow you to easily access and run your bending operations with precision.

Start Bending with HARSLE Genius Press Brake and ESA Controller

To begin bending with the HARSLE Genius Press Brake using the ESA S860 or S875 controller, start on the Automatic Page of the control panel. This page is where you can set up your bending parameters and select the required bending program for your project. First, load the correct material type, thickness, and bend angle. Once you’ve configured the settings, you can enter the automatic mode, which will guide the press brake to complete the bending process automatically. Ensure all toolings are correctly installed, and adjust the back gauge for the desired position. After this, you are ready to start the bending process.

Part 4 Bending Products

Ensure Proper Sheet Placement with Stop Fingers

To begin the bending process, place the metal sheet securely onto the press brake bed. The metal sheet should be aligned so that it rests against the stop fingers, ensuring accurate positioning. The stop fingers act as a reference point, guiding the sheet into the correct position for bending. Make sure that the sheet is straight and fully in contact with the stop fingers to avoid any misalignment during the bending process. Proper placement is crucial for achieving precise bends and maintaining the quality of the final product.

Step the pedal

To begin the operation of the HARSLE Genius Press Brake with ESA S860 or S875, step on the foot pedal to activate the machine. When the pedal is pressed, the machine will initiate the bending process, allowing the ram to move downward. The speed and force of the ram’s movement are adjustable through the control system, ensuring the precision and quality of the bend. Keep your hands clear of the work area while stepping on the pedal to avoid any potential accidents. For safety, always ensure the machine is set up properly before starting the bending operation.

Complete Step 1.

Before operating the HARSLE Genius Press Brake with ESA S860 or S875 controllers, it’s essential to perform a proper setup. First, ensure the machine is securely positioned on a level surface to maintain stability during operations. Next, check the hydraulic system for any leaks and verify fluid levels to ensure optimal performance. After the press brake is physically prepared, connect the ESA S860 or S875 controller to the machine, ensuring all necessary cables and electrical connections are in place. Finally, power on the system and perform an initial diagnostic check to confirm the controller communicates correctly with the machine.

Press the pedal. And complete Step 2.

Pressing the pedal is the initial step in engaging the bending process on the HARSLE Genius Press Brake with ESA S860 or S875 controllers. Once you press the pedal, the machine activates the hydraulic system, causing the ram to descend and engage with the material. It’s crucial to maintain consistent foot pressure on the pedal to ensure steady movement. As the press brake tool starts to bend the sheet metal, ensure the material is properly aligned and securely clamped. Once the bending is completed according to your set parameters, release the pedal to halt the movement. This method ensures precision and safety during the operation.

Part 5 Measurement And Calibration

Measuring the First Bending Distance

To ensure accurate bending, it’s crucial to measure the first bending distance properly. Start by setting the press brake and positioning the sheet metal accurately on the machine. The distance between the punch and die is critical to achieving the desired bend angle. You can use a caliper or ruler to measure this distance and ensure it matches the specifications for the specific material thickness and bend radius. Regularly check this measurement during the bending process, as slight adjustments can improve precision and prevent errors in your final product. Proper measurement leads to higher-quality results and reduced rework.

Accurate Measurement of Second Bending Distance

To ensure accurate results when using a HARSLE press brake, measuring the second bending distance is crucial. After completing the first bend, measure the distance between the top of the material and the press brake die. This distance will affect the final angle and precision of the second bend. Use a caliper or other precise measuring tool to get an accurate reading. Adjust the back gauge or die position as needed based on your measurements. Properly measuring the second bending distance helps prevent material distortion and guarantees consistent results throughout your fabrication process.

Measuring Bending Angles with an Angle Ruler

To accurately measure the bending angles on the HARSLE Genius Press Brake, begin by using an angle ruler to check the angle in two positions: the left side and the right side of the bend. Ensure that the press brake is properly calibrated before taking measurements. Position the angle ruler against the metal sheet at both ends of the bend, making sure it aligns with the surface correctly. By comparing both measurements, you can confirm if the bending angle is consistent and precise. This simple step helps achieve high-quality results and ensures the machine’s accuracy during operation.

Error Found: One Side Measured at 91°

During the inspection of the bend angle, an error was detected. One side of the bent material was measured at 91° instead of the expected 90°. This deviation could be caused by several factors, including tool wear, incorrect calibration of the press brake, or inconsistencies in the material. Such an error can affect the overall accuracy of the bending process, leading to potential issues in the final product’s fit or functionality. It’s crucial to address this immediately by recalibrating the machine, checking the tool condition, and verifying material specifications to ensure precise bending and consistent quality.

Enter the calibration parameters -1.

To ensure optimal performance and precision, it’s essential to properly enter the calibration parameters on your HARSLE Genius Press Brake with ESA S860 or S875 controllers. Start by accessing the machine’s control panel and navigate to the Calibration Settings. Input the correct values for factors such as tool offsets, bending angle, and material thickness. These settings will allow the machine to adjust for specific requirements, ensuring accurate bends. Always verify that the parameters match the specifications for the material being used. Regular calibration ensures consistency, reduces errors, and maximizes machine lifespan.

Bend again for testing.

After setting up your HARSLE Genius Press Brake with the ESA S860 or S875 controller, it’s important to perform a test bend. This step ensures that all settings, such as bend angle, force, and position, are correctly calibrated. Start by selecting the appropriate tooling and material thickness, then input the required parameters into the ESA controller. Once the setup is complete, execute a test bend to verify the precision and quality of the bend. If necessary, make adjustments to the machine settings until the desired result is achieved. This process helps ensure that your press brake performs optimally and meets production standards.

Measure again

When working with a HARSLE Genius Press Brake using the ESA S860 or S875 controllers, precision is key. One of the most important steps is to measure again before finalizing any bending process. Proper measurements ensure that the materials are correctly positioned and the bend is made at the exact angle needed. Rechecking measurements minimizes the risk of errors and material waste. This extra step also helps in adjusting the tooling setup, particularly when using advanced features like the ESA S860 or S875’s automatic correction functions, ensuring optimal accuracy throughout the bending cycle.

It is correct now

“It is correct now” signifies that all adjustments, measurements, and setups have been thoroughly checked and aligned. When working with a HARSLE Genius Press Brake and the ESA S860 or S875 controllers, precision is essential for achieving perfect bends. Once the necessary steps are completed—such as verifying material placement, tooling, and machine settings—it’s time to confirm that everything is correctly calibrated. The ESA controllers often display real-time data to help operators ensure accuracy. After double-checking, you can confidently proceed with the bending process, knowing that the machine is set up properly for consistent and high-quality results.

Part 6 Graphic Programme&3D Simulation Bending

Graphic Programme

The Graphic Programme in a HARSLE Genius Press Brake equipped with the ESA S860 or S875 controllers is a powerful tool that enhances the bending process. This feature allows operators to visually map out the bending sequence on a graphic display, ensuring each step is clear and accurate. It provides a real-time view of the part being bent, helping to detect potential issues before they occur. With the Graphic Programme, operators can optimize tool settings, reduce errors, and improve overall efficiency. It is an essential feature for achieving high precision and maintaining consistent quality in sheet metal fabrication.

Add a New Bending Program on ESA Controllers

To start, navigate to the Programming List page on your HARSLE Genius Press Brake with the ESA S860 or S875 controller. Click on Add New Program to create a fresh bending program. After this, input the necessary parameters, such as bend angle, material type, thickness, and punch/die specifications. Make sure these settings match the ones provided in the previous steps to ensure consistency and accuracy. Once the parameters are set, save the program, and you’re ready to load it for production. This method guarantees precise and repeatable bending results.

Generate the Final Bending Program from the Graph

Generating the final bending program from the graph is an essential step when using the HARSLE Genius Press Brake with the ESA S860 or S875 controllers. The graph, which visualizes the bending sequence, helps operators understand the exact positioning of the material and tooling needed for each step. By carefully analyzing the graph, you can create a precise program that takes into account the material thickness, bend angles, and tooling specifications. The controller allows for easy input and adjustments, ensuring that the final bending operation is carried out smoothly and accurately, reducing errors and improving overall production efficiency.

Click “Calculate” on Editor Page for Accurate Bending

On the Editor page of the HARSLE Genius Press Brake with the ESA S860 or S875 controllers, one of the key steps to ensure the correct bend calculation is to click “Calculate”. This function allows the system to automatically determine the optimal bending parameters, including the required force, back gauge position, and tool setup. After entering all the necessary parameters such as material type and thickness, clicking Calculate provides real-time data that helps operators make precise adjustments. This step is critical in preventing errors and ensuring that the bending process runs smoothly, saving both time and material costs.

Click the Optimize

To ensure optimal performance of the HARSLE Genius Press Brake with the ESA S860 or S875 controllers, it is essential to click the Optimize button. This feature helps in adjusting and fine-tuning the bending parameters for the most efficient operation. When you activate the Optimize function, the controller automatically analyzes the machine’s current settings, compensates for any discrepancies, and adjusts for the most accurate bending results. By using this feature, operators can significantly reduce setup time, improve production efficiency, and achieve higher quality bends with minimal effort. It’s a simple yet powerful tool for maximizing machine performance.

Click the Simulate

After setting up your HARSLE Genius Press Brake with the ESA S860 or S875 controller, the next crucial step is to click the Simulate button. This function allows you to visualize the bending process without physically engaging the machine, offering a preview of the results. By simulating the operation, you can identify potential issues such as incorrect angles, tool misalignment, or material interference. This preventive step helps reduce costly mistakes and downtime. It’s a quick and effective way to ensure that the machine is operating as intended, providing confidence before executing the actual bending process.

Click Continue until the bending is finished

Once the setup is complete and all parameters are entered into the ESA S860 or S875 controller, the next step is to click “Continue” on the interface until the bending process is finished. This simple action will trigger the machine to start the bending operation according to the programmed parameters. During the process, the machine will automatically perform the bends at the specified angles and force settings. It’s important to monitor the process to ensure everything is running smoothly. Once the machine signals the completion, the material will have achieved the desired shape and angle with high precision.

3D simulation bending

3D simulation bending is a powerful tool integrated into modern press brake systems, including HARSLE Genius Press Brakes with ESA S860 and S875 controllers. This technology allows operators to visualize the bending process in a virtual 3D environment before performing the actual operation. It helps in verifying the accuracy of the bend angles, positioning, and tooling setup, ensuring that the final product meets the required specifications. 3D simulation not only reduces errors but also improves efficiency by optimizing the process and minimizing material waste. It’s a vital feature for achieving high precision and quality in sheet metal fabrication.

Click the Icon on the Lower Right Corner to Activate Automation

To begin using the automatic functions on the HARSLE Genius Press Brake with the ESA S860 or S875 controller, navigate to the Automatic page. Once on this page, look for the icon located in the lower right corner of the screen. Clicking this icon activates specific automation features designed to simplify the setup and improve bending accuracy. These features may include automatic adjustments for material thickness, bending angle, and press force, ensuring a faster, more efficient production process. By utilizing these automated functions, operators can save time and reduce the risk of manual errors.

Choose the Extrusion Viewer

Choosing the Extrusion Viewer on the ESA S860 or S875 controller is an essential step when operating the HARSLE Genius Press Brake. This feature allows operators to visualize the bending process before it occurs, providing a 3D simulation of the tool’s path and the material deformation. By selecting the Extrusion Viewer, you can verify the accuracy of the bend, ensuring that the material won’t deform in undesired ways. This helps in making real-time adjustments, improving the overall efficiency and precision of the operation, and preventing costly errors in the final product.

Click the First Bend

Once your material is properly set up and measurements are accurate, the next step is to click the first bend on your HARSLE Genius Press Brake. This action initiates the bending process, where the ESA S860 or S875 controller comes into play, guiding the machine to apply the correct force. It’s essential to ensure the first bend is precise, as it sets the tone for the rest of the operation. If done correctly, it helps in aligning the material perfectly for subsequent bends, minimizing errors and improving overall efficiency in your bending process.

Click the Start

Once you’ve properly set up your HARSLE Genius Press Brake with the ESA S860 or S875 controller and double-checked all measurements, the next step is to click the Start button. This action initiates the bending process, allowing the machine to execute the programmed sequence. Before clicking Start, ensure that all parameters, such as material thickness, bend angles, and tooling, are correctly configured. The ESA S860 and S875 controllers offer a smooth and user-friendly interface, allowing you to monitor the entire process in real-time. By starting the machine, you’re ready to efficiently produce high-quality bends with precision and minimal error.

Part 7 Switch Off

Step the pedal switch to lower the punch against the die

To begin the bending process with the HARSLE Genius Press Brake, step on the pedal switch to lower the punch toward the die. This action initiates the press cycle, allowing the punch to align precisely with the material placed on the die. The controlled descent ensures that the punch applies the correct force to the material, resulting in an accurate bend. It’s essential to maintain a steady and controlled foot pressure on the pedal to ensure smooth operation and avoid sudden movements, which could cause irregular bends or damage to both the tooling and the workpiece.

Press the emergency stop buttons

Always ensure safety first when operating the HARSLE Genius Press Brake with ESA S860 or S875 controllers. If any unexpected situation arises, such as a malfunction or safety concern, press the emergency stop buttons immediately. This action halts the machine’s movement and prevents potential damage or injury. The emergency stop is designed to be easily accessible, ensuring quick response in urgent situations. Once the machine is safely stopped, assess the issue, and follow proper troubleshooting or maintenance procedures. Never resume operation until you’re confident the machine is safe to use, prioritizing safety at all times.

Turn off the power switch

Before performing maintenance or making adjustments to the HARSLE Genius Press Brake with ESA S860 or S875 controllers, it is essential to turn off the power switch. This ensures safety by preventing accidental activation of the machine during any setup or repair work. Turning off the power also helps avoid electrical shocks, component damage, and ensures the system resets properly before any adjustments. Always follow this step to protect both the operator and the machine. By making it a standard procedure, you ensure a safer working environment and prolong the lifespan of the equipment.

This is all about today’s tutorial and feels free to contact us if you have further questions.

Video Demo