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"info-forum" - data M's informative newsletter:
A new issue of our newsletter has been released - with many info about news, progresses, trends und customer reports. Here you can download the newsletter (PDF):   info-forum-English (2,3 MB)   or    info-forum-"Indian Issue"-English (1,1 MB)                                   ...go to the Newsletter Archive    

Fully automatic laser-based bending angle measuring device for press brakes (COPRA® LaserCheck) and controller for CNC bending presses (BendingOffice®) presented at the BlechExpo 07:

Our efforts were a success - some developments got ready for this year's BLECHEXPO exhibition in Stuttgart, Germany.
Our emphasis was the new sensor COPRA® LaserCheck TT (Top Tool) which is measuring in the upper tool mounted like a tool and can be adapted to all major tool systems. The sensor is ideal for retrofitting press brakes.   ...more info
Furthermore we presented a novel controller for CNC bending presses which OEM customers, as well as manufacturers of bending presses have been waiting for. It is based on the innovative SIMOTION system by Siemens and offers an open PC system (open to programmers) with integrated add ons like angle measurement.
   ...contact data M  

COPRA® LaserCheck / MetalBender Seminar & Workshop 2007:

The sheet metal industry has been changing drastically in recent years. Computer controls have entered the sheet metal bending technology at a large extent improving accuracy and performance of sheet metal press brakes. On the occasion of the release of our new COPRA® LaserCheck TT bending angle measuring system for press brakes – especially the possibility of retrofitting existing machines – data M Engineering had organised a seminar on this topic on May 23rd at our office.
...
more info (PDF 1,56 MB)   or   ...contact data M  

New laser check versions:
COPRA® LaserCheck 6 and COPRA® LaserCheck TT available:

The new fully automatic laser-based bending angle measuring device for press brakes got reengineered and it is in the version 6 out now. The new features comprehend for example a higher-resolution USB-camera and a drive computer with Windows XP embedded without a disk memory. There are new features for operation of tandem-machines, a faster interface to the Delem control unit and the connection to Simotion with BendingOffice®. Revised is also the spring back measurement. The new system has a twice as high resolution, which allows you to get accurate measures, also when there are only small bending forces used. The LaserCheck TT is the new version for mounting in the upper die. Its mounting is like the one of a tool kit and it has an adapter for all other normal tool types. In oder to use the LaserCheck TT the machines doesn’t have to be changed - perfect for refitting.   ...contact data M  

 

The COPRA® LaserCheck 6:       
2 sensors for accurate results

Fully automatic laser-based bending angle measuring device for press brakes

The COPRA® LaserCheck 6

Manufacturing sheet metal parts with properly bending angles that are kept constant all times often meets a problem during the actual production process: different parameters in material thickness and stresses. In order to solve this problem and to make the uses also of minor quality materials safe for the user data M Engineering has developed a powerful solution for measuring bending angles in press brakes – the COPRA® LaserCheck 6.

COPRA® LaserCheck 6 enables the user to determine the exact bending angle for press brakes by a built-in semiconductor laser with line optics and the 1/3” CMOS-camera together with strain gauges – and it works contactlessly.

The COPRA® LaserCheck 6 has an integrated positioning drive to keep the working distance constant after changing the die width. It can be directly connected to a free USB 2.0 and a free printer port of control units working with Windows XP. 

Weinbrenner, Germany - alpha correct system
Weinbrenner, Germany - alpha correct system

 

Working Principle

The bending angle is measured by scanning the projection of the laser beam to the surface of the sheet metal with the CMOS camera. The angle between the laser and the viewing axis of the camera defines the correlation between the position of the line in the camera image and the angle between the sensor and the sheet metal. With a second sensor at the opposite site the bending angle is calculated.

COPRA LaserCheck an einer Biegepresse von F. lli Vimercati S.n.c. Italy
F. lli Vimercati S.n.c. Italy

COPRA® LaserCheck 6: 
2 sensors for accurate results

COPRA LaserCheck an einer Biegepresse von Accurpress, Canada
Accurpress, Canada

 

Springback

The resulting bending angle is highly influenced by the springback. Measure springback and to define the overbending is made with strain gauges, that are glued to the frame of the press brake. These strain gauges are connected to a strain gauge amplifier. The output is either analogue (0-10V) or digital (RS232). For the wide range of bending forces the amplification of the amplifier can be adjusted to four different levels to achive a 17 bit resolution.

 

 

Process

The machine bends to an estimated prebend angle. Now the sheet thickness is corrected and the sheet metal is bent to the programmed angle (Point A). In this position a second angle is checked by the COPRA® LaserCheck (alpha1). At this point the stress forces are measured by the forces sensors (F1). After relieving the sheet metal part to a defined remaining force 
a second pair of figures (F2, alpha2) are calculated by taking into acount the actual angle and force. Based on these valued the control unit calculates the springback and bends the sheet metal part in one step in the defined way. 
With this method the sheet metal is always clamped and it doesn’t lose its bending position. This is important, because otherwise the spring back changes.

 

Result

The result is a bending angle with a never seen precision just after one bending step regardless if differences in material properties such as thickness or other. And all is done fully automatically.

Highest accuracy at every bend

 

Mounting

The COPRA® LaserCheck 6 is mounted on the press brake under an angle of 45° to the die in a working distance of 160-300 mm below the die. It is moveable along the die either manually or automatically. Due to its mounting position the measuring range is 0° to 180°. For each measuring position there are 2 sensors needed. Four sensors enable an independent correction of the cylinders to compensate angle differences in long bends.

Mounted on a press with hydraulic crowning

 

Accuracy

The sensor accuracy is better than ±0.1°. The system accuracy is influenced by the control, the machine accuracy, the tools and the material. 
To increase the bending accuracy the sensors were calibrated after mounting. So the mounting errors are reduced.

 

Surfaces

The optical system can measure most of the common surfaces. Limits are grinded surfaces, if the grinding pattern is parallel to the laser beam and highly polished surfaces. The software includes a plausibility test package that enables the LaserCheck to measure also perforated metal plates, plates with crimping, and parts, where only one side is visible.

Strain gauge amplifier

 

Strain gauge DA 40

Highlights:
COPRA® LaserCheck 6
  • Laserbased device for measuring bending angles 
  • Works contactless
  • Integration in existing press brakes possible
  • No modifications of stamp or die necessary
  • Parallel use of up to 4 sensors at a time
  • Force detection for spring-back calculation
  • Connection to Cybelec control unit via serial 
    interface
  • Connection to Delem with ethernet interface
  • Easy to use
  • Delivered fully wired and calibrated
  • Automatic adjustment to different die widths


Technical Data: COPRA® LaserCheck 6
 Computer  IBM compatible with P4 processor
 Case  Wall mount
 Operating system  MS Windows XP embedded
 Laser  5mV-diode laser
 Camera  1/3" CMOS USB camera module
 Measuring frequency  approx. 5-6 values/s
 Precision  better then 0.1°
 Supported 
 control units

 Subject to change without
 notice

 Cybelec DNC 1200, ModEva, via NLR-card,
 Delem DA 65/DA 69, DA 66W/69W 
 via ethernet card, Siemens Simotion with
 Bending Office®


 
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data M Engineering GmbH  .  Am Marschallfeld 17  .  D-83626 Valley/Oberlaindern, Germany
Fon: +49 (0) 8024 640-0  .  Fax: -300

Internet: http://www.datam.de  .  e-mail: datam@datam.de
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