ESA S875 Automatic Calculation is a key function designed to automatically calculate the bending sequence for press brake operations. When programming complex parts, determining a correct and efficient bending sequence is essential to avoid collisions, reduce setup time, and ensure forming accuracy. This article explains how to apply ESA S875 Automatic Calculation in bending sequence programming, including the basic principles, required conditions, and practical usage steps. By understanding how this function works, operators can improve programming efficiency, minimize manual adjustments, and achieve more stable and reliable bending results in daily production.

Accessing the Automatic Calculation Function

The ESA S875 Automatic Calculation function can be accessed directly from the drawing mask of the piece. To begin, press [Calculate]. This opens a window displaying a full simulation of the piece, including the upper and lower parts of the press brake, the punch, die, stop, and the metal sheet before bending.

On the right-hand side, three windows provide crucial information: the number of rotations for the piece, the tipping angle relative to the calculated bending sequence, and the activation of the search function to find all possible solutions. The numeric control prioritizes leaving the largest portion of the sheet manageable for the operator, and adjustments to calculation criteria allow searching across multiple potential bending sequences.

Automatic vs Manual Bending Sequence Search

The bending sequence calculation in the ESA S875 can be performed in two modes: automatic and manual, depending on operator preference and complexity of the part.

Automatic Search for Bends

In automatic mode, the numeric control identifies the optimal bending sequence. Pressing [Optimise] initiates the system’s search for the most efficient sequence. This mode reduces the need for manual input and ensures that bends are calculated to avoid collisions with the die, punch, or stops. The system automatically optimizes the bending order to maintain proper sheet handling, improve production speed, and ensure consistent bend quality. Automatic calculation is ideal for standard pieces or when multiple bends need to be completed with minimal intervention.

Manual Search for Bends

Manual mode allows operators to force specific bends within the sequence. Operators can partially or fully define bends, with the remaining bends calculated automatically by the numeric control. Navigation between bends is performed using arrow keys, and rotation of the piece can be achieved through the [Rotate] function. Forced bends can be undone by pressing the [Bend] key again. Once the operator has defined certain bends, pressing [Optimise] recalculates the remaining sequence while respecting the manually forced bends, ensuring flexibility in programming complex pieces that may require specific bend order due to tooling or handling constraints.

Optimisation Results and Feedback

Once the calculation is complete, the ESA S875 control provides immediate feedback:

• Solution Found: Indicates the bending sequence is feasible. Operators can [Accept] the solution, simulate the bending sequence, continue with alternate solutions, or stop to make changes.
• No Solution: Alerts the operator that the current piece configuration cannot be bent using the selected sequence. In this case, alternative criteria can be applied or problem bends identified manually. Collision points are highlighted, making it easier to adjust sequence or positions.

Simulation of the bending sequence is available via the [Simulate] function. This step-by-step display allows operators to visualize the piece before bending, as well as after each bend. The [Resting against/supported] function can be activated to ensure correct support positions are selected. If collisions occur, the stop moves only if axis limits allow, helping operators prevent errors and avoid potential damage to the sheet or tooling.

Resting Against/Supported Mode and Corrections

Resting against/supported mode ensures the piece is securely positioned for every bend. Once a solution is accepted, the numeric control automatically calculates the required corrections for the X and R axes. Operators can adjust support positions, navigate through bends, or stop the simulation at any step to check alignment. For pieces that might slightly collide with machine parts without causing damage, the operator can force the entire bending sequence. This mode is especially useful when dealing with complex geometries, long sheets, or specialized tooling.

Key Benefits and Practical Tips

The ESA S875 Automatic Calculation provides multiple advantages:

• Reduces programming time by automatically calculating optimal bending sequences.
• Minimizes risk of collisions and potential sheet damage.
• Improves bending precision and repeatability for complex parts.
• Supports both fully automatic and operator-assisted adjustments, offering maximum flexibility.
• Allows simulation of bends before production, reducing errors and material waste.

Practical tips for optimal results include ensuring the piece dimensions and tooling data are entered accurately, reviewing simulation results carefully, and using manual bend adjustments when dealing with unusually shaped parts or specific handling requirements.

Frequently Asked Questions(FAQ)

Conclusion

ESA S875 Automatic Calculation is a powerful tool that simplifies the creation of optimal bending sequences for press brake operations. By using this function, operators can automatically generate precise sequences, reduce material handling errors, and avoid collisions. The combination of automatic and manual bend adjustments allows for flexibility in complex programmes, while the simulation features provide clear visual verification before production.

Implementing ESA S875 Automatic Calculation improves efficiency, ensures consistent bend quality, and saves time during programming. For further guidance on maximizing the benefits of ESA S875 Automatic Calculation or troubleshooting specific scenarios, consult the user manual or contact the HARSLE support team for professional assistance.