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DBT America manufactures world-class mining and tunneling machinery that is typically tailored to customer requirements. It needed a large press brake that could handle tough fabrication matters, such as working heavy plate components with quick setups and providing changeover flexibility with the operator ease of touch-screen Windows-style control.
The company uncovered a mine of solutions in a Proform hydraulic brake by Cincinnati Incorporated. This machine uses an advanced PC-based touchscreen control and "see first, then do" simulation graphics. In a welcome surprise, Cincinnati recommended against buying its biggest 2000-ton Proform, instead proposing a 1500-ton brake with quick-change tooling and a bumping bolster to handle 2-in thick AR plate.
"We initially felt we"d need an even larger press brake due to the AR plate requirements," notes production operations manager Bill Herstine. "But sales engineer Joe Campa suggested using a bumping bolster to form or straighten the AR plate. By utilizing a bumping bolster, this rugged 1500-ton press brake is more than adequate. It's the most cost-effective solution."
The press brake was installed 15 miles south of Pittsburgh in the company's Houston, Penn. plant at the end of 2003. The plant produces armored face conveyors, stage loaders and belt tensioning mechanisms for longwall mining operations, plus continuous miner and belt systems. It also supplies components for transportation equipment and roof support systems made at other DBT locations.
The press brake has a 16-ft bed that can form or straighten any material used on DBT's varied product lines. "We commonly run 1/4-in to 1-in thick A572-50 or ASTM A514 steel, but certain components require AR400 and AR450 plate ranging from ¾-in to 2-in," says Herstine.
Its PC-based control and quick-change tooling provide the right combination of power and flexibility for custom mining solutions. "Customers primarily drive our systems configuration, so very few parts are the same," explains Herstine. "The tooling package allows three different tooling configurations to be set up at once on the press brake. If a different punch or die is required, it takes only minutes to change it." An adjustable vee die in the tooling also improves setup speed by reducing die changes.
The Proform replaced a manual press brake with a control that combines a 3D graphic interface with a simple touchscreen operation that optimizes bending productivity with fast setups and programming. Advanced control software and simulation graphics allow helpful 3D rotational viewing of the part, including detailed presentation of part shape and gage fingers.
Its 15-in LCD touchscreen control uses a simple Windows operating system to eliminate the need for keypads and key switches. "The operators transitioned to the touchscreen control without any "old dog/new tricks" issues," reports Herstine.
New part programs can be generated through manual data entry or by drawing the part in cross-section or flat pattern, then selecting the tooling and bend sequence. A special job setup page displays tool segment lengths and tool locations, plus notes to reduce setup time. The control can access jobs from its internal hard drive, floppy disk or network connection.
Thought operators currently program parts directly on the PC, DBT is exploring offline programming for various machines in the plant, including the Proform. Its PC-based networking capability enables easy download of programs.
