Press Brake CNC Back Gauges Explained: Multi-Axis Systems, Installation & Troubleshooting

1.Introduction

The back gauge is a key component in the press brake that provides support and positioning to ensure that the metal sheet is pressed into the correct angle and shape when bending.As a bending reference point, it can greatly reduce manual measurement errors.For mass production, it can maintain accuracy and improve production efficiency.

CNC back gauges for press brake provide higher positioning accuracy than traditional systems, up to±0.01mm and better.It provides rapid change settings during the production process and is suitable for various production needs.With advanced computer systems, CNC back gauges directly read data, which reduces the possibility of human operation and data errors compared to traditional ones, and the overall production safety and efficiency are guaranteed.

Today, the editor will introduce the concept, common configuration, installation and use methods, common faults and back gauge selection methods of CNC back gauges one by one, and take you to have a deep understanding of this component.

2.What is the press brake back gauge?

2.1 Definition of press brake back gauge

The press brake back gauge is an important component installed at the back of the press brake to help position and support the workpiece during bending.It is because of its existence that the bending position of the plate can be precisely controlled.

2.2 Main functions of the brake press back gauge

2.2.1 Precise positioning:With the cooperation of multiple axes such as X, R, and Y, the machine can automatically adjust to the position set in advance by the system to achieve precise angles and shapes.

2.2.2 High consistency:Due to the existence of the automatic reset system, there is very little deviation, which is particularly suitable for large-scale production.

2.2.3 High automation:The CNC back gauge system is still controlled by programming to achieve more perfect automation.

3.Analysis of the types of brake press back gauges

3.1 Manual back gauge

The operator manually adjusts the positioning distance to achieve the purpose of production.This type of back gauge is usually used in small-scale production or factories with limited budgets.Its advantages are simple structure, lowest initial investment cost, and easy maintenance.But at the same time, low efficiency and large errors are inevitable.

3.2 CNC back gauge

CNC back gauge uses computer control to achieve automatic and precise positioning, reducing human intervention factors in the production process to achieve bending technology.Suitable for factories with large quantities and multiple varieties and high requirements for precision and efficiency.Generally speaking, there are few disadvantages.High efficiency, high automation and high precision are the biggest selling points of CNC backgauges.

3.3 Hybrid system

Hybrid backgauges combine manual and CNC functions.Some axes are controlled by computer numerical control, and the remaining axes are manually controlled.Suitable for projects that require flexibility and can maintain a certain degree of automation.The advantage is that it provides a certain degree of automation and can avoid budget limits.

3.4 Wireless system

Compared with wired systems, wireless systems enhance operator flexibility and are suitable for scenarios that require frequent adjustments.However, this system may bring about the problem of high costs.

4.Multi-axis configuration of CNC backgauges

4.1 Different axial functions and application scenarios such as X, Y, R, Z1/Z2, V

4.2 Comparison of advantages and disadvantages of each axis configuration

5.Installation and use of press brake CNC back gauge

5.1 Precautions for installation of CNC back gauge for press brake

First, turn off the power of the equipment to prevent the risk of leakage, and clean the surface of the equipment for subsequent installation operations.

Second, check the installation dimensions and specifications to ensure that the back gauge is fully compatible with the existing press brake.

Finally, leave enough space for operation to ensure smooth operation.

5.2 Initial setting process of CNC back gauge for press brake

First, position the equipment:fix the basic bracket to ensure that the horizontal and vertical degrees can enable the CNC back gauge to be installed smoothly to prevent the accuracy from being affected by imbalance.

Second, start installing the back gauge:the press brake operator carefully installs the guide rail, positioning frame, lead screw and servo cable of the back gauge according to the instructions, and connects it to the motor or hydraulic system.

Then, perform initial calibration:after power on, the”return to zero”and”repeat calibration”program settings are required to ensure that all axes are accurately returned to their positions.

Finally, conduct a trial run and inspection:the operator loads the mold and adjusts the gear position to the preset value position to conduct a bending process attempt.After completion, the axis positioning is checked to determine whether it is accurate and the movement is smooth.

5.3 Programming and adjustment method of CNC back gauge

Input bending workpiece parameters such as thickness and bending angle in the CNC system interface, analyze and select the appropriate bending method according to the processing requirements, select the operating axis and plan the processing path according to the design workpiece drawing, and then simulate the operation.It is wrong to use waste workpieces.If the workpiece is processed incorrectly, repeatedly adjust the zero point and stroke deviation of each axis to the expected effect.

5.4 Basic operation method of CNC numerical control system

5.4.1 Familiarize yourself with the operation interface until you can perform basic operations such as selecting molds and archiving.

5.4.2 Perform the”return to zero”and”repeat calibration”procedures after power on.

5.4.3 Set workpiece parameters such as material thickness and bending angle, and set the running program.

5.4.4 Try the first trial run, and judge whether the production meets the standard according to the running results.If it does not meet the standard, make micro-adjustments, and put it into mass production after passing.

Related technical reading : How to Choose a Press Brake Control System? Function, Brand & Buying Guide (Including Delem/ESA)

6.The importance of accuracy and calibration

6.1 The accuracy range of press brake CNC back gauge

Depending on the high-quality screw rods, guide rails and closed-loop control systems of many axes, the standard positioning accuracy of press brake CNC back gauge can reach ±0.01 mm, and the error of high-end models is sometimes even less than ±0.005 mm.

6.2 Common sources of error

6.2.1 Material rebound: After bending, the material returns to its original shape, resulting in a slight dimensional deviation between the actual bending angle and the preset angle, which requires compensation setting.

6.2.2 Guide rail/screw wear: When the machine runs for too long, gaps will be generated between the moving parts, and they will become larger and larger, resulting in axis positioning errors.

6.2.3 Loose fixture: If the fixture is not tightened or the main material is frequently replaced, the fixture will become loose, resulting in unstable repeated positioning.

6.3 Calibration steps overview

6.3.1 Check the lubrication status of the guide rails and screws and the looseness of the fixtures to confirm that all parts are in a reasonable state.

6.3.2 Use precision tools such as standard block gauges or laser measuring instruments to detect positioning accuracy.

6.3.3 Compare the CNC system display with the actual situation, input error compensation at the insufficient position, and adjust to the correct parameters.

6.3.4 Repeat the calibration command, return to zero through the CNC controller and run the standard program to detect the error.If the zero point is incorrect, the manufacturer’s supporting software or instrument should be used to automatically correct the servo zero point.

6.3.5 Continue to fine-tune the program compensation value after multiple verifications until the tolerance requirements are met.

Related technical reading : Proper setup steps for Press brakes and analysis of common calibration issues

7.Common faults and solutions for press brake CNC back gauge

7.1 Noise, positioning deviation, abnormal electronic control, etc.

Noise: If the back gauge makes abnormal friction noise during operation, it may be caused by insufficient lubrication, loose blocks or wear and aging of parts.Lubricating oil should be actively added.

Position deviation: Position deviation is caused by hardware failure or CNC program error.

Electronic control abnormality: Servo overload or voltage fluctuation are factors that cause electronic control abnormality.After the problem occurs, the power supply and program settings should be checked.

7.2 Maintenance suggestions

Tightening inspection:Regularly check and tighten the back gauge screws to ensure that the mechanical connection and transmission structure are stable and avoid noise and positioning deviation caused by looseness.

Lubrication maintenance:Use special lubricants to drip on the guide slider or screws to avoid jamming and excessive wear and keep the mechanical parts moving smoothly.

Check the synchronous belt and CNC system:The synchronous belt generally has a service life of 2-3 years.It needs to be replaced in time after wear to ensure synchronization and coordination.When the CNC system fails, the manufacturer should be contacted to eliminate encoder, drive or communication abnormalities and call back parameters.

7.3 Daily maintenance suggestions

Cleaning: The back gauge structure accumulates a lot of dust.Dust and chips should be removed in time after use to keep the machine running fast for a long time.

Lubrication: Refer to the manufacturer’s recommendations to regularly add an appropriate amount of grease to the guide rails, screws and other components to ensure the normal operation of each component and avoid wear.

Regular calibration: Calibration, zero return and repeated positioning accuracy detection are essential.It is recommended to implement them every once in a while to improve the working accuracy of the equipment.

Safety training: Conduct electrical isolation training for operators, basic requirements for wearing protective gear, and standardized operations for power off during maintenance and debugging.

8.What are the key considerations when purchasing a press brake back gauge?

8.1 Type selection

8.2 Selection of the number of axes

8.3 Accuracy and speed

The positioning accuracy of CNC back gauge is related to the quality and accuracy of the product.Good positioning accuracy can make the error reach ±0.01mm or finer, reducing the loss caused by processing.The controller movement speed and axis drive performance determine the speed of the entire process.High efficiency meets the production requirements of the enterprise.The faster the bending speed, the less likely it is to drag down the entire process manufacturing.

8.4 Compatibility

Before purchasing, confirm whether the back gauge matches the machine tool interface, sensor, etc., and whether it is harmonious with the machine tool control system.If necessary, contact the original manufacturer for technical details to avoid unnecessary modifications.

8.5 Durability:Material/Design Structure and Maintenance Ease

Prefer highly durable guide rails, ball screws and other materials, branded servo components, industrial-grade synchronous components and modular structures to ensure long-term stability and maintenance ease.

8.6 Cost Budget and Return on Investment

The initial investment cost of CNC backgauges is high, but the long-term efficiency is quite high.It plays an excellent role in improving production efficiency, reducing waste, and reducing labor costs.Before purchasing, it is necessary to analyze the long-term production volume, combine factors such as labor costs and maintenance costs, and comprehensively consider them within the budget to seek a better solution.

9.Conclusion

As a key auxiliary equipment for press brakes, the backgauge system provides high precision and high efficiency for sheet metal bending, greatly reducing labor costs.If you already have a press brake, you can consider upgrading to a CNC backgauge to improve the degree of digitization and automation of existing processing to meet increasingly complex production needs.If you currently do not have equipment and want to find a new system, it is recommended to configure a reasonable number of axes according to the workpiece requirements and choose a reasonable control method.

The above is a detailed introduction by the editor today about the press brake back gauge and its subdivision into the CNC back gauge. For more knowledge about press brakes and fiber laser cutting machines, you can follow our blog updates. As a manufacturer of fiber laser cutting machines and press brakes, RAYMAX is committed to expanding its influence while also providing more, more professional, and more comprehensive knowledge of CNC machinery for friends in the metal processing industry. If you experience any unresolved issues or are interested in purchasing related machines, please feel free to contact us at any time. RAYMAX offers free technical support services 24 hours a day, 7 days a week! Looking forward to your letter ~~~

10.FAQ ( Frequently Asked Questions )