E-Brake 160-200T Ultra

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E-Brake
160-200T Ultra

Noisless high tonnage press brakes

SafanDarley is the only manufacturer of the, 176-330 US Tons, high tonnage electronic press brakes. We were encouraged by our existing clients to provide them an electronic press brake to meet their higher tonnage needs as well. They especially love how quiet these high tonnage brakes are for their operator’s work environment.

The SafanDarley E-Brake concept constitutes a further improvement on servo-electronic technology, one that is resulting in ground-breaking performances. Based on extensive practical experience, SafanDarley 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.

Full electric drive

Up to 30% higher productivity

Up to 50% energy saving

No harmful hydraulic oil, low CO2 emissions

Noiseless operation

Full working length backgauge

User friendly touch screen control

Key Features

Efficiency

Up to 30% shorter cycle times

Bending test product

The SafanDarley H-iBrake is further optimised to take maximum advantage of the high acceleration and other favourable hybrid drive characteristics. It is mainly the combination of integrated safety systems, which are programmable per bend step, to optimize the operators every step what makes the H-iBrake the fastest in cycle time.

SafanDarley’s self-developed controls make use of a new generation of electronics and software. This results in incredibly short reaction and stop times, through which bending speeds of up to 20 mm/sec can be achieved. Cycle times are also far shorter than with conventional press brakes, partly through the fast backgauge. In comparison tests, the SafanDarley H-iBrake is shown to be up to 30% faster than a conventional press brake.

SafanDarley H-iBrake 125T	Cycle time 20 sec
Conventional hydraulic press brake	Cycle time 35 sec.

Economy

Up to 50% energy saving

The SafanDarley E-Brake only uses energy when the top beam is actually moving. With a conventional hydraulic press brake, the hydraulic pump motor is running all the time.

This can deliver an energy saving of up to 50% compared with conventional hydraulic press brakes.

The graph 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, machine set up and intervals - this will mean a further saving with the E-Brake up to 3000 kWh a year.

Reliability

Mechanical drive system with 5 year warranty

Even distribution of forces

The unique, patented roller drive system in the upper beam ensures a uniform and even distribution of forces. A balanced combination of powerful electro-motors, fixed and movable rollers and specially developed belts facilitate capacities of up to 300 ton.

The flexible belts, which are only 0.12 inch thick and 2 inch 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 SafanDarley are able to offer a 5 year warranty on the mechanical drive system, when combined with an annual service contract.

Stability

Reinforced O-frame for optimum stability

E-Brake VS Conventional C-frame

The special construction of the SafanDarley E-Brake also contributes to the even absorption of large forces. The machine has a very stable O-frame construction with a reinforced bridge and side frames. 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.

The bending tools remain in a straight line even under maximum bending loads. In addition to optimal stability, there is another advantage to this construction: the backgauge can be used across the entire working length of the machine.

Safety

Integrated safety system and absence of hydraulic oil

Work fast without risk: SafanDarley makes that a reality with the safety system integrated within the controls. It works with a safety light screen that is automatically directed from the SafanDarley E-Controls. Its first function is to secure the bending zone, its second function allows the axis to move while the operator turns, picks up or removes the product. These simultaneous actions of the operator and machine lead to lightning-fast cycle times, with the highest level of safety. Particularly in the serial production of small parts, this integrated system facilitates an unrivalled work speed with optimum ease of operation.

In addition, the SafanDarley E-Brake Premium has an additional in-built safety provision. The application of a spring return means that the top beam will always move upwards in the event of a failure.

The SafanDarley E-Brake contributes perfectly to your sustainable business, while at the same time making your business operations much more economic. The absence of hydraulics means that the problems associated with environmentally harmful and risky oil are a thing of the past. No overpressure valves need to be set – with a chance of errors and narrowing – and no filters need to be checked and replaced. The servo-electronic system is therefore much more reliable than the hydraulics, due to the lack of oil, tank, pump, seals, valves, and filters. You’ll never have to deal with a cold start.

Usability

The most functional and intuitive Man-Machine interface

The SafanDarley E-Control is fully touch screen, whereby the only buttons visible on the screen are those that are needed during operation. The controls simply run on a PC under Microsoft Windows®, the software was developed based on Microsoft.net Framework. The unit is fitted with a 100 MB Ethernet UTP network connection as standard. The instructions are transmitted to a central processor from the SafanDarley E-Control controls, which in turn regulates the various axis via a so-called CAN-BUS (Control Area Network).

The system can be programmed quickly and accurately thanks to a ‘self-teaching’ database with data on materials, tools and previous, already corrected bending. The SafanDarley E-Control can be coupled to the majority of off-line programming systems.

The controls are set-up for web-based communication such as online diagnoses and loading software updates via the web. Machines can also be coupled to each other in a group and tooling databases can be shared. By monitoring and analysing your operating data online, SafanDarley will be in a position to optimize your production process remotely in the near future.

Technical Data

Model	160-3100	200-4100
Pressure force in US Ton	179	220
Bending length in inches	120	160
Maximum stroke in inches	12	12
Q size in inches	23	23
Closing speed in inch/min	236	177
Bending speed max. in inch/min	48	48
Return speed in inch/min	236	177
Motor power in kW	22	22
Machine weight in lb	33.0	40.7
Machine length in inches	177	216
Machine height in inches	122	122

Standard equipment

SafanDarley EC20 Touch Screen CNC press brake controls

1 Hold to Run operating console

CNC-controlled R-axis

CNC-controlled Y1-Y2 axis (top beam adjustable inclined +/- 0.1 inch)

CNC-controlled back gauge (X-axis) with a wide range

Manual adjustment of 2 back gauge fingers across a linear parallel guide

Build in size of 23.22 inch (Q-dimension)

NSCL II MC Premium top tool mechanical clamping system

NSCR II MC Premium with CNC crowning

2 Support arms (11.81 inch)*

Programmable and integrated safety light guard*

Safety in compliance with CE*

* Standard only for CE countries

Options and Product Enhancements

Control

SafanDarley EC 20	touch screen CNC press brake controls
SafanDarley EC 3D by Autopol	complete 2D and 3D graphic programming incl. import of 2D and 3D files.
Extra Hold To Run operating console	compulsory with 2 machine operators

Axis / Backgauge System

CNC-controlled back gauge	X-axis
CNC-controlled 3D back gauge	X1-X2-R1-R2-Z1-Z2
CNC-controlled Delta X-axis	horizontal repositioning of one back gauge finger
CNC-controlled Z1-Z2 axis	horizontal repositioning back gauge fingers

Daylight (Q-Size)

590 mm
650 mm
690 mm

Tool System

NSCL II MC Premium	top tool mechanical clamping system
European Style	only in combination with a Q size of 650 mm
New Standard NSCL-l HC pro	hydraulic tool clamp system

Support Arms

Fixed support arms (11.81 inch)	standard only for CE countries
Moveable front sheet support arms
Moveable front sheet support arms (INOX) with hand wheel adjustment in height
Moveable front sheet support arms (INOX) with pneumatic hight adjustment

Bending Aids

SafanDarley I-Mate	maximum plate weight 30kg
SafanDarley E-Mate 2000	maximum plate weight 500 kg

Measurement Systems

SafanDarley E-Bend S	Sheet Thickness Measurement System (Accuracy of ± 0.01 mm)
SafanDarley E-Bend L Blue	Laser angle measurement system

Assessories

Integrated tool cabinet
Machine lighting

Offline 3D-programming

The design program includes an ingenious simulation and control module for using the press brake that can be remote-controlled, from the office for example. This limits the time during which the machine is at a stand still, thus maximising productivity.

Offline programming offers you plenty of ways to do 3D Design and to import and correctly produce 3D drawings. If the employee using the program is also the one controlling the press brake, an NC code for the system may be generated instantly. The program will then select the necessary tools and optimise the machine. A work planner can even switch to a different press brake at the last moment, re-generate the NC code and run a collision check.

SafanDarley offline 3D programming stands for complete and reliable process management. As opposed to several widely used CAD/CAM systems, our system is very user-friendly and requires only a short 2-day training period.

Explore our Software

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+1 262 259 0369

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SafanDarley Products

SafanDarley Products