Francis Pan

Why is press brake guarding important

Current situation of industry security risks

Press brake is one of the most dangerous equipment in the sheet metal processing industry. Because during the operation of the press brake, if the press brake is not equipped with safety devices, the following dangers may occur, such as finger injuries from pressing down on the upper and lower dies, palm being pinched or cut, etc.

The rapid movement of fixtures and back gauge may also pose risks to the operation. These are all due to the complexity and speed of the press brake operation.

Necessity of press brake guarding

In modern sheet metal processing and manufacturing industry, the installation of safety protection devices on press brakes has almost become a standard configuration for CNC press brakes. Effective press brake guarding can protect the personal safety of employees, and increasing their safety awareness can also improve production efficiency.

What is press brake guarding

press brake guarding

The press brake guarding can protect the operator from being pinched or mechanically injured by the press brake. There are mainly the following types of devices.

  • Physical device: Protective shields, fences, etc. installed near hazardous areas can protect the operator’s hands or body. In the event of accidental contact with a moving hazardous area, physical barriers can provide active protection.
  • Optical detection device: One is a press brake safety light curtain, which uses infrared beams to detect whether there is intrusion in the operating area. Another type is the laser detection device, which triggers an automatic shutdown to protect the safety of workers when it detects that a target such as a human body is blocking the beam.

Statistical data on safety accidents

According to authoritative data from OSHA, NIOSH, and other organizations in the United States, about 40% of work-related accidents involving press brakes result in serious injuries such as hand disability and amputation. More than 80% of press brake accidents are caused by inadequate protection. The main causes of press brake accidents are operator fatigue, inadequate press brake safety training, and habitual bypassing of the device.

The role of protective devices in improving production efficiency and reducing the risk of accidental injury

  • Reduce risk: The protective device can recognize whether the operator’s hands are in the danger zone and stop and alarm in a timely manner, which can reduce the operator’s operational risks.
  • Improve production efficiency: After installing protective devices, the probability of safety accidents will be reduced, and the cost of maintenance and work-related injuries will be reduced, which can also improve equipment utilization.At the same time, the emergency stop function of the press brake laser guard can reduce downtime caused by accidents, which can also improve production and processing efficiency.
Operator is manually operating a press brake to test samples
Operator is manually operating a press brake to test samples

Press brake guarding requirements

Regulatory and Standard Background

It is crucial to follow the corresponding regulations and standards when implementing the press brake guarding device, which not only ensures the compliance of the enterprise, but also provides necessary safety guarantees for employees.

When installing safety protection devices on press brakes, corresponding laws and regulations should be followed. Using compliant protective equipment can enhance customer confidence and ensure employee safety.

  • US OSHA Standards: OSHA 29 CFR 1910.212 states that production equipment must have sturdy protective facilities such as physical barriers, electronic devices, or safety distances, and safety measures must cover all hazardous areas, creating a safe operating environment for operators.
  • OSHA 29 CFR 1910.217 states that press brakes must be equipped with appropriate safety devices, including but not limited to press brake safety light curtains, laser protection, etc.
  • ANSI B11.3 and B11.19: ANSI B11.3 requires manufacturers to take safety measures when using press brakes to ensure the safety of operators. Priority should be given to using active protective devices such as press brake safety light curtains, lasers, and safety speed.
  • ANSI B11.19 specifies the design standards for protective devices and safety functions, stating that protection cannot be bypassed and can automatically shut down in case of abnormal conditions.
  • Handling attitude of press brake laser guards under OSHA: OSHA recognizes press brake laser guards as compliant press brake safety measures, provided that they meet control reliability, response time, and STM requirements, and have undergone sufficient performance validation.

Comparison of Common Protection Methods and Compliance Analysis

  • Fixed Barrier and Interlocking Barrier: Fixed barriers prevent personnel from entering hazardous areas through physical isolation. Although they have a simple structure, low cost, and do not require maintenance, they lack flexibility in press brake tool replacement and are not suitable for operating large or irregular workpieces.
  • Interlocking barriers ensure that the machine can only be started when the safety door is closed through doors, barriers, and electrical interlocks, providing high safety and compliance.
  • Two hand control system and sequential mode: The dual hand control device requires the press brake operator to simultaneously press two control buttons to start the machine, thereby protecting the operator’s hands from the danger zone.
  • Sequential mode is suitable for simple processes and single person operation, which can prevent the risk of “one hand idle entering the danger zone” but has low efficiency. It is often used in conjunction with other safety measures.
  • Existence of sensing devices/electronic optical protection devices: The sensing device can sense objects entering the danger zone and stop the machine in a timely manner.
  • Optical protection devices include press brake safety light curtains and laser detection. Light curtain protection generates a protective zone, making it suitable for detecting large volume objects. Laser detection mainly detects small objects and complex shapes in a timely manner when the operator is too close to the danger zone.

Press brake guarding systems (safety system technology and categories)

Press brake safety light curtain

The press brake safety light curtain system uses transmitters and receivers to form a protective area to protect the operator. The key components include the transmitter, receiver, controller, as well as the housing and mounting bracket, which can stabilize the position of the press brake safety light curtain and fix signal transmission.

The advantage is that it is easy to install and compatible with most press brakes. However, it is susceptible to strong light and smoke environments during use, which may affect the sensitivity of the press brake safety light curtain when detecting small objects. There may be false alarms when detecting complex and irregular workpieces.

Laser Grating

Laser grating is a system that emits a laser beam to irradiate the upper and lower edge areas of the press brake tool to detect objects in the interior space of the tool. Once the laser beam recognizes an object, the system promptly reflects and triggers a shutdown.

The laser grating system is mainly composed of a laser emitter, a receiver, and a controller. The advantage of using a laser grating is higher accuracy because it can monitor smaller and more complex workpieces, with shorter response time, and is also suitable for environments with faster movement. But the disadvantage is that the cost will be higher and there are requirements for installation and debugging techniques.

Safety speed protection

Safe speed protection is mainly aimed at hydraulic or servo driven press brakes. When the speed of the equipment exceeds the safe speed, the system will forcibly limit the speed, automatically slow down or stop the machine and give an alarm. Safe speed protection is more suitable for high-speed press brakes, but it is generally not used separately and is usually used in conjunction with laser protection measures.

Backend Protection and Surrounding Protection

Rear protection device is a physical isolation device that generally includes interlocking, chains, railings, protective nets, warning tapes, etc. It can be used to prevent workers from accidentally entering the rear end of the machine, especially in the high-speed moving area of the back gauge device.

The advantage is that it is easy to install and the setting of prominent press brake safety signs is easy for operators to understand. However, the efficiency of physical barriers is not as high as that of press brake safety light curtains, laser protection, etc.

Illustration of press brake safety system
Press Brake Cascading Light Curtains

Press Brake Laser Guard

What is laser protection? How does it work?

The laser guarding system monitors the area below the press brake tool by emitting a laser beam. Once a foreign object is detected, the laser guarding system will immediately respond and shut down.

Legal Compliance of Laser Protection Systems

According to OSHA and ANSI standards in the United States, machines must have effective laser safety protection, and the use of laser guarding systems for press brakes must be verified. Regular safety testing and maintenance of the laser guarding system are required.

Comparison between Laser Protection and Light Curtain Systems

The laser guarding system can maintain a safe distance, while the press brake safety light curtain system needs to maintain a safe distance. The laser guarding system is suitable for operating small workpieces, with high flexibility, installed near the press brake tool, fast response time, and high cost.

It is suitable for hydraulic servo press brakes and has high maintenance costs. The press brake safety light curtain system is not suitable for operating small workpieces and has a slower response time, but its installation position is more flexible and can be installed on the outer frames of both sides of the machine. It has a lower cost and is suitable for various types of press brakes.

Implementation and maintenance suggestions

Installation and Setting Specifications

  • Distance Calculation: To ensure the personal safety of operators, a proper distance should be maintained between the operator and the press brake to reduce safety risks.
  • Downtime Measurement (STM): An STM verification should be conducted at least once a year, which involves regularly recording downtime and performing multiple tests under conditions such as full machine load and maximum speed to obtain the maximum value to ensure accurate measurement results.
  • Regular Verification: The press brake safety devices must be functionally verified regularly, generally conducted quarterly or semi-annually, including safety system audits such as press brake safety light curtain or laser sensitivity testing, machine emergency stop interlock testing, and speed protection.
  • Documentation Requirements: Records of equipment inspection, maintenance results, and operator training records need to be kept. These documents should be well preserved and updated quarterly, preferably with cloud document storage for easy data traceability.

Operator press brake safety training and System Construction

  • Provide operators with the use of protective systems and emergency training to ensure they are familiar with the operation.
  • Clearly stipulate that safety devices cannot be disabled, removed, or bypassed.
  • There should be obvious shutdown or disable signs around the equipment to prevent the one key protection function from malfunctioning.
  • Design emergency stop procedures, conduct regular safety emergency drills every quarter, and provide emergency contact numbers.
  • Provide emergency first aid training for operators and keep a regular first aid kit.

Press Brake Maintenance and Inspection Process

  • Daily inspection of equipment to ensure that all press brake components are in normal condition.
  • Regularly test replacement components.
  • Comply with lockout/tagout procedures to ensure long-term reliable operation of the system for subsequent data traceability.
Lazer Safe's press brake guarding system
Lazer Safe’s press brake guarding system

How to choose the appropriate press brake guarding system?

Evaluating Risk Scenarios

  • Equipment type: Choose the protective system based on the type of press brake. For example, ordinary mechanical press brakes have simple operation and control, and can use physical protective devices or dual hand control methods. The electro-hydraulic servo press brake has a high degree of automation and faster speed, and can use press brake safety light curtains or press brake laser guards.
  • Workpiece dimensions: Fixed barriers or press brake safety light curtains can be used to protect large and single batch items, which is cost-effective. Laser protection can be used for more precise production of small parts.
  • Operator flow line: If the operator needs to operate the machine close to the press brake tool, laser zero distance protection is more suitable.

Matching regulatory requirements and international standards

OSHA regulations require that press brakes must be equipped with physical or electronic protection. Laser protection manufacturers or equipment should be certified, and machine testing reports must be compliant. Regularly inspect protective devices and keep electronic records.

Key Performance Parameters

  • When selecting the protective device for the press brake, ensure that the response time of the protective device does not conflict with production efficiency.
  • All press brake guardings require a certain level of detection accuracy to accurately determine whether an object has entered the danger zone.
  • If the production environment is changing, try to choose protective equipment with strong adaptability.
  • If there is a possibility of equipment expansion in the future, it is best to choose a scalable and compatible guarding system.

Summary of Advantages of Raymax’s Laser Protection Solution

RAYMAX’s laser guarding system provides easy to operate and flexibly configured safety protection through advanced technology and high-precision AOPD system, while also having low failure rate and long service life, ensuring economic efficiency.

Summary

Characteristics and applicable scenarios of different protection methods

Fixed Barrier

Fixed barriers prevent operators from coming into contact with machine press brake tools through physical isolation, making them suitable for small equipment and simple tasks. The structure is simple, the maintenance cost is low, and it can effectively prevent injuries, but it limits the flexibility of the equipment, especially when replacing press brake tools, it is suitable for basic press brakes and simple bending tasks.

Light Curtain System

The press brake safety light curtain system forms a safety protection zone through infrared sensors, suitable for small and medium-sized mass production and high repeatability scenarios, with high-speed response and non-contact protection, but low sensitivity to small objects, high installation requirements, and susceptibility to interference.

Laser Detection

The laser detection system accurately monitors hazardous areas through laser beams and can identify workpieces and human bodies in real time. It is particularly suitable for processing high-speed, large, or complex products and can flexibly respond to the need for frequent replacement of workpieces.

It has the characteristics of high sensitivity and fast response, and has strong adaptability, but compared to press brake safety light curtain systems, it is more expensive and requires professional personnel for installation, debugging, and regular calibration.

Safety speed protection

The safety speed guarding system is generally applicable to servo hydraulic driven press brakes, which reduce risks by controlling the operating speed of the machine. The safety speed protection can be used in conjunction with other systems, but it requires high compatibility and settings of the device.

We recommend selecting the protection method based on the type and requirements of the press brake. No matter which protection method you choose, RayMaxTech will provide you with a professional press brake safety assessment to help you choose the appropriate configuration.

FAQ

Overall, laser guarding system is currently the safest way to protect press brakes on the market. The high response speed and monitoring capability of laser guarding systems can better prevent injuries.

The press brake safety light curtain system is more suitable for processing workpieces with relatively single dimensions, with low precision requirements but a safety distance must be set. Laser protection is suitable for monitoring fine workpieces, providing more assurance and higher efficiency for close range operations.

Using the formula S (minimum safe distance)=K (approach speed) × T (total downtime of the press brake)+C (compensation constant)

Generally, downtime measurement should be conducted and archived at least once a year.

Not allowed to start. The safety protection device must be set up before the press brake starts working. Once the guarding system is disabled, the press brake will also be prohibited from starting.

Yes, the backend needs to set up some physical protections, such as fences, warning signs, chains, etc., to avoid entering dangerous areas.

OSHA requires that machines must be equipped with protective devices, and both the front and back ends must be equipped with compliant safety protection.

The safest protective device is the laser guarding system, which has the highest precision and response speed.

Of course, as long as the compatibility update of the press brake is evaluated, an exclusive protection plan can be customized.

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Hello, Customers!

Francis

Author introduction

My name is Francis Pan, and I am the foreign trade manager of RAYMAX. I have been engaged in the fields of metal manufacturing and CNC machinery for over 10 years. Welcome to contact us, I am more than happy to provide you with the best service and products.

Email：   [email protected]  | Wechat：  13645551070

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