H-Brake B-Shear & M-ShearE-Brake 150 - 200 TE-Brake 25 - 100 T

Safan B.V., Kwinkweerd 11, NL-7241 CW Lochem, P.O. Box 96, NL-7240 AB LochemTel.: +31 (0)573 222 222, Fax: +31 (0)573 252 057, E-mail: info@safan.nl, Website: www.safan.nl

e for electronic Press Brakes

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A head start with the SAFAN E-Brake

Because the SAFAN E-Brake electronic press brake has

been developed as an integral new concept, it combines

a whole range of unique advantages compared to the

conventional hydraulic press brake. The SAFAN E-Brake

sets new standards in terms of ergonomics, efficiency,

economy and ecology. Its proven reliability and optimum

performance have been demonstrated by means of

extensive testing under the severest and most demanding

circumstances.

The SAFAN E-Brake concept is built around the completely

new servo-electronic drive based on the pulley principle.

It results in a very even distribution of forces, such that in

98% of cases no crowning table is required. Similarly, an

entirely new generation of electronics and software makes

operation and control extremely fast, easy and precise.

The SAFAN E-Brake also incorporates further advances

in ergonomics, including the user-friendly Touch Screen

control. Cycle times are shorter, the working range has

been increased, the possibility of mistakes reduced …,

in brief, a vast improvement in productivity.

The SAFAN E-Brake combines all of the above with a

pleasantly low noise level, an energy consumption that is

reduced by up to 50%, an integrated safety system and

a high degree of environmental responsibility.

Since the introduction of the first servo-

mechatronic press brake – the SAFAN SMK

– developments at SAFAN have continued.

The patented drive system has been

optimized, the electronics refined and

the range of applications considerably

expanded. The extensive work on the

further development of the SMK has

now resulted in the first all electronic

press brake: the SAFAN E-Brake.

With capacities up to 200 T and a

4100 mm working length, the SAFAN

E-Brake is the advanced alternative to

the conventional hydraulic press brake.

The SAFAN E-Brake signals the start

of the irreversible electronic evolution

in sheet metal working. Because, to

put it in one word, the advantages are:

E-normous! Which is good news for you

as a manufacturer of sheet-metal products,

particularly in staying ahead of the competition.

"Survival of the fittest" requires that you maintain

your technological edge - and preferably increase it. After

all, standing still means losing ground. The SAFAN electronic

evolution helps you make a great leap forward.

The E-volution in sheet metal working

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With the SAFAN E-Brake you obtain the most

accurate and constant bending angle along the full range

of the machine, without the need for crowning. The unique

patented pulley drive in the top beam produces a very even

and immediate distribution of forces.

A balanced combination of powerful electric

servo motors, fixed and moving pulleys, and

specially developed belts make it possible to

handle over 200 tonnes. The flexible belts,

which are only 3 mm thick and 50 mm

(resp. 100 mm) wide, are reinforced with

steel wires and coated with hard

polyurethane. This advanced technology has

been extensively tested in the demanding

elevator industry. So reliable is the

technology that SAFAN are able to offer a 5 year

warranty on the mechanical drive system, when

combined with an annual service contract

The special construction of the SAFAN E-Brake

also contributes to the even absorption of large

forces. The O-frame acts as a single unit and

deformation is kept to an absolute minimum.

It is more stable, stronger and produces less

deformation than a conventional C-frame.

E for even bending

The electronic control has been developed by

SAFAN itself and uses a new generation of

electronics and software. This results in

very short response and delay times,

yielding bending speeds of up to 20 mm/sec.

The effectiveness and precision of the

SAFAN E-Brake are increased even further

by its digital drive incorporating a ‘closed-

loop’ system and vector control technology.

The cycle times are also much shorter than

for conventional press brakes, partly due to

the fast backgauge.

Smaller bending work is no problem either,

thanks to the narrow construction of the top

and lower beams. The working range is

extremely large with a maximum top beam

stroke of 290 mm and a Qmax (daylight

dimension) of 690 mm. The SAFAN E-Brake

increases efficiency even further through a

unique and innovative backgauge system.

The system can be put to optimum use

across the entire range of the machine and

is very accurate thanks to an electronic

control system (± 0.02 mm). The system is

modular in both its construction and in its

options. The backgauge is very distinctive

because the beam extends across the full

width of the machine.

Special hinged backgauge pins are standard,

allowing a maximum sheet size of a 1000

mm and the R-axis is adjustable from the

front of the machine using a handwheel.

The backgauge has a very high positioning

speed of 350 mm/sec.

E for efficiency

The new SAFAN E-Brake is further optimised to take maximum advantage of the high

acceleration and other favourable servo-motor characteristics. For this reason, our E-Brake is

not only very fast in the rapid approach stage, but also throughout the entire cycle.

We demonstrate this by manufacturing a specimen product (see illustration on right) on an

E-Brake. As a comparison the product was also produced on a conventional press brake.

SAFAN E-Brake: 20 sec

Conventional: 28 sec

Backgauge with X-, Z1+Z2-, R- and Delta X-axes.

Increased performance in less time. No

problem at all with the electronic efficiency of the

SAFAN E-Brake press brake. The mechatronic

drive in the top beam alone, already saves a lot of

time because it requires far fewer settings.

Main drive system with 2 servo motors

E-Brake Conventional

Standard backgauge

Rollenaandrijving d.m.v. 2 servomotoren.

46 57

The SAFAN E-Brake 150-3100 and the SAFAN E-Brake 200-4100

are both equipped with a heavy-duty sized CNC-controlled backgauge

system that is equipped with two ball screws and play free ballscrew linear

guides. Even in this regard, the SAFAN E-Brake concept offers a unique

advantage: the backgauge can be used over the entire working length of

the machine.

The standard backgauge is equipped with a

CNC controlled X axis and two backgauge

fingers that can be manually moved along

the bending line (Z axes) as well as adjusted

in height (R axis). The fingers are provided

with interchangeable stops.

The backgauge system can be optionally

fitted with CNC controlled R and Z axes and

a dX axis. It is also possible to fit a fully 3D

backgauge with X1, X2, Z1, Z2, R1 and R2

axes.

Heavy-duty back gauge with full range of operation

The success of the SAFAN E-Brake with a

pressing force up to and including 100 tons has

received a logical follow-up: the extension of the SAFAN

E-brake into the segment involving greater pressure

forces and longer working lengths. The new 150 and

200 ton models now make it possible to profit from the

unique advantages of the innovative E-Brake technology

when bending heavy and long products.

Proven technologySAFAN’s servo-electronic technology has

been proving itself all over the world since

1995. The SAFAN E-Brake concept

constitutes a further improvement on this

technology, one that is resulting in ground-

breaking performances. Customers are

therefore full of praise, especially about the

much shorter cycle times, more

advantageous use of energy and

substantially lower costs for maintenance in

comparison with traditional hydraulic press

brakes. Based on this extensive practical

experience, SAFAN has effectively adapted

the technology and construction to the

segment involving weights up to 200 tons

and work lengths up to 4 metres.

In addition, a strong point of the

construction is the level foundation.

Capacity with the E of enormousSAFAN E-Brake 150 T-3100 and 200 T-4100

Various interchangeable backauge stops

5948

Options for graphical programming and representation

By extending the Touch Screen control with bending simulation software and a keyboard,

SAFAN now offers advanced graphic applications that further boost efficiency.

The optional TS2 and TS3 controls use Delem software, but can also be connected to external

packages such as SomaBEND (Radan).

Moveable and adjustable support arms

SAFAN has developed a range of support arms of modular construction for both light and

heavy-duty sheet-metal work. This makes it possible to rapidly set up the correct solution for

each application. An optimum combination of ergonomics and efficiency:

• moveable across the machine width • fitted with brushes or hardened strip

• adjustable height • fitted with (fine adjustment) front stops

• programmable height • suitable for use with safety light screen.

Control type Description Features/representation Off-line control by

TS1 SAFAN CNC Numeral product entry, - SAFAN TS software press brake control by means of Touch Screen - Delem Profile - numerical bending parameter - Delem VBend presentation - External software - symbols for sheet handling - SomaBEND (Radan)

TS2 As TS1, but with As TS1 but also with: - SAFAN TS software graphical representation - graphical representation of - Delem Profile of the bending sequence 2D and 3D products - Delem VBend - External software - SomaBEND (Radan)

TS3 As TS2, but with As TS2, but also with: - SAFAN TS software graphical programming - graphical product entry and - Delem Profile and representation of the representation by means of an - Delem VBend bending sequence additional keyboard - External software - SomaBEND (Radan)

Summary of SAFAN press brake controls TS1 – TS2 – TS3

Options for graphic programming

E for ergonomic

Electronic operation and control by means of a

Touch Screen is a typical SAFAN innovation. With its

Touch Screens, SAFAN has set a new standard for

press brake controls.

The SAFAN TS1 control is the most simple

and effective Man/Machine Interface

available at present; and a shining example

of the electronic evolution in sheet metal

working. The control is PC based and runs

under Microsoft Windows®.

An intelligent feature of the SAFAN TS

control is that it only displays those buttons

that are required at the particular stage of

operation. The system is so simple that it

makes bending sheet metal almost literally

child’s play. The adjustable height of the

control unit ensures optimum ergonomics

for any operator, whether short or tall.

A standard accessory is a 100 MB Ethernet

UTP network connection that opens up

unlimited possibilities. The instructions from

the SAFAN TS control are sent to a central

processor, which in turn activates the

various axes by means of a so-called

CAN-BUS (Control Area Network). The

advantage of this system is that the

electronics are of a modular construction,

requiring fewer components. This means a

high degree of flexibility and compatibility, as

well as great reliability.

The system can be programmed very quickly

and accurately thanks, among other things,

to a "self-learning" database of materials,

tools and previous (corrected) bendings.

The standard SAFAN TS1 control uses a

numerical bending-parameter entry and

representation.

SAFAN TS1 in Run mode.

SAFAN TS3 control

410 511

1 2 1 2

SAFAN E-Bend L The E-Bend L system is an angle

management system that uses two laser

sensors to make measurements. The two

sensors are equipped with fastening magnets

and are placed in pairs on the front and back

of the standard bottom tool. During bending,

the sensors project a laser beam on the

sheet and measure the value of the angle in

relation to the bending tool in use.

The SAFAN E-Bend L enables the operator

to keep the bent angle constant and to do so

independently of differences in sheet

thickness and rolling direction.

SAFAN E-Bend M The E-Bend M system can be used as an

angle management system and an angle

measurement system. The SAFAN E-Bend M

consists of two pneumatic sensors on a rail

that can be programmed for any arbitrary

position. Both sensors are in contact with

the sheet during the bending cycle.

Before the final angle is bent, the spring

back of the sheet is measured. This

measurement is used to make a correction,

after which the definitive angle is bent.

The measured values can be adopted for

bending procedures in which the geometry

of the product makes angle measurement

impossible.

Quick, easy and reliable angle measurement can

be essential to your bending process. The SAFAN

E-volution also allows you to take the lead in this

regard. Two SAFAN E-Bend systems, electronically

linked to the SAFAN Touch-Screen control, increase

your efficiency by enabling exact angle measurement

and constant monitoring of angles.

... and the efficiency of SAFAN E-Bend angle measurement

With the electrically-driven E-Mate from SAFAN,

you prevent angle deviation when bending thin sheets

with large dimensions. The bending aid provides the

operator with a simple and ergonomic means to remain

within set angle tolerances.

It is often not easy for an operator to

position large sheets. Certainly during the

return movement of the top beam, it is

difficult work to keep everything in hand.

Instead of having a second operator provide

assistance, it is frequently more efficient to

install a SAFAN bending aid. In most cases,

it can be used by a single man to position

larger products. In brief, along with

accuracy, productivity is increased by the

SAFAN E-Mate, the best partner for your

operator.

Bending with the E of E-Mate…Servo-mechatronic bending aid

In order to relieve the operator in the case

of long, routine, heavy duty work, SAFAN has

developed an extremely powerful and highly

accurate bending aid.

The bending aid supports and follows the

sheet with great accuracy throughout the

entire bending process.

SAFAN E-Mate SAFAN E-Mate plusProgramming SAFAN E-Mate

APS

513412

E for ecological and economical

Integrated safety

Working at lightning speed without risk:

SAFAN makes this possible with an active

safety system integrated in the control.

It uses a safety light guard that is

automatically controlled from the Touch

Screen.

In addition, the SAFAN E-Brake has another

built-in safety provision. The application of a

spring-return system means that in the case

of an accident the top beam will always

move upward.

The absence of hydraulics means that the

problems associated with environmentally

harmful and risky oil are now things of the

past. Furthermore, your SAFAN E-Brake

uses much less energy, namely only when

the beam actually moves. This can result

in energy savings of 50% compared to

conventional hydraulic press brakes.

There is also no need to adjust the settings

of pressure relief valves – with the inherent

risk of mistakes and drift – nor are there

filters to be checked and replaced. The

absence of oil, tanks, pumps, seals, valves

and filters means that the servo-electronic

system is much more reliable than an

hydraulic one. And you will never again have

to face the inconvenience of a cold start.

Electronic evolution of the SAFAN E-Brake helps

you to run your business much more economically, while

maintaining environmental awareness for the future.

Labour is expensive, especially in Western Europe.

In the e-volution to a stronger competitive position,

automation is the answer. SAFAN is one of the pioneers

in this field, working together with partners in the areas of

robotics and software. SAFAN installed the first robotic

press brake in Europe as early as 1988.

Automation as expertise

Intergrated safety light guard

Automated Production Solutions from SAFAN (APS)

Since then, SAFAN has become an

experienced specialist in the field of

automated bending cells. With Automated

Product Solutions (APS), SAFAN gives

this e-volution new impulse. SAFAN offers

integrated solutions for your production

process that go further than stand-alone

solutions can. Not only the robotised

loading, operation and unloading of the

bending cell but the entire routing of the

sheet-metal material through your machine

park can be automated.

With SAFAN’s APS, you remain flexible with

a view to new products or changes in your

production process. You are also flexible

in linking with external systems and in the

choice of your robotics. The SAFAN E-Brake

and SAFAN H-Brake are particularly well

suited to serve as the focal point of each

automated bending cell. SAFAN’s control

system operates on the Windows® platform

and uses it to create a legion of possibilities

for links, networks, software packages and,

via the internet, remedies for any stagnation

in the unmanned production process.

SAFAN supplies complete, fully tested

programmes for both new and existing robot

cells. Of course, you can entirely outsource

the programming to SAFAN.

From advice and consultancy to turn-key

SAFAN makes the automation of sheet-

metal working simpler than you think. This

already begins with the convenience of

one contact person for the entire project.

Our APS consultants give you clear advice

on the complete range of possibilities, so

that you can make the best choice for your

production process.

SAFAN develops and realises turn-key

solutions for bending and cutting systems

with guaranteed cycle times. This allows

you to determine your costs per product.

Based on these fixed costs, the time needed

to recover investment can be accurately

established. With the aid of a simulation

model, you are given in advance a reliable

indication of the return on investment to be

expected.

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SAFAN E-Brake 25 - 100 T

SAFAN E-Brake 150 - 200 T

HS = High Speed

Technical specifications SAFAN E-BrakeSAFAN E-Brake tool adapters

On the SAFAN E-Brake, the main drive

motor is used only when the E-Brake has to

actually perform a movement. With a

conventional hydraulic press brake, the

hydraulic pump motor is running all the

time. The graph below only covers the time

while the press brake is actually in

operation. During the standby time - which

can be as much as 90% on account of sheet

handling, conversion and intervals - this will

mean a further saving with the E-Brake up to

3000 kWh a year.

SAFAN E-Brake energy consumption

Q =

415

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AdapterNSCL-I+

AdapterEuropean

AdapterAmerican

AdapterNSCL-II

Table OB-3

Table OB/S-3

Table European

Table OB/EUR-1

Table DD006

STANDARD 3.0.8080 3.0.8090 3.0.8130 3.08140Q

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Q =

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Stro

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Q =

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Stro

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290

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Q =

690

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Stro

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E-BrakeConventional

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25-1250 250 115/215/290 110 20

110 4 3250 2280 1250 2485 2585

25-1250 HS 250 290 180 180 7 40-1600 400 115/215/290 130

20 130 7

3950 2630 1600 2485 2585

40-1600 HS 400 290 180 180 11 50-2050 500 115/215/290 110

20 110 7

4750 3080 2050 2485 2585

50-2050 HS 500 290 160 160 11 65-2550 650 115/215/290 90

20 90 7

5950 3580 2550 2485 2585

65-2550 HS 650 290 140 160 11 80-2550 800 115/215/290 90 20 90 11 6050 3580 2550 2485 2585 80-3100 800

115/215/290 90

20 90

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6350 4130 3100 2485 2585

100-3100 1000 75 75

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150-3100 1500 300 100 20 100 22 11.400 4350 3100 2885 2885

200-4100 2000 300 75 20 75 22 14.200 5350 4100 2885 2885

Subject to modifications

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