What are the Benefits of Modern Press Brakes?

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Press brakes have made great strides in the past decade. They are no longer as dangerous or time-consuming as they once were.

With the incorporation of Computer Numerical Control (CNC), modern press brake machines can now help American manufacturing compete with overseas markets.

This article will show that these modern machines increase efficiency, utilize technology, and employ people of all skill levels.

1. Increased Efficiency

A modern press brake allows a company to produce significantly more bends than press brakes of the past. Older machines produced about 600 bends per hour, but CNC press brakes can produce 900 per hour.

These machines can keep running indefinitely until a worker has to change out tools for a new design. This is now done through a touch-screen program rather than manually as it used to be done.

Modern press brake tools are also becoming lighter and simpler to install to speed up manufacturing even more.

Current machines are also able to produce more unique pieces because of the variety of software designs that can be run through the CNC system.

In the past, press brake machines required extensive piping which was prone to breaking or falling. Since the modern machines do not require this system, they run much smoother and with fewer breakdowns.

2. Smart Technology

Modern press brakes create better bends much faster with current technology.

Automatic Dynamic Crowning allows angles to be uniform along the bend. In the past, the correct angle was found through trial and error. New press brake machines produce the correct angle on the first go.

Thickness detection software analyzes the thickness of the metal throughout the piece to ensure the bend is accurate and uniform.

Mechanical compensations programs take into account the temperature and weight effects of the press brake’s hydraulic system.

Designers who must enter planned cuts into the press brake before the bend is made may make mistakes in how close they place a cut to the bend. With new advances in software for press brakes, the computer will alert designers that their proposed cuts are too close to the bend.

This allows less experienced workers to perform some designing tasks as well as reducing waste due to human error.

3. Training Requirements for the Modern Press Brake

New press brakes allow for reduced training and less experience for machinists.

Previously, workers were trained and employed only to setup press brakes because the process was so time-consuming and specialized.

Now, CNC programs guide workers through the setup process, allowing anyone to do it.

Barcode scanning of press brake parts’ IDs allows workers to accurately place pieces in the setup process without having to compare all the IDs manually. This saves a lot of time and training.

3D graphic representations of the metal bending process allow workers to visualize the process and reorder the machine’s sequence if necessary without manually refitting all the tools, previously a highly skilled worker’s job.

All of these improvements allow more skilled employees to move into management positions and younger, less experienced workers to operate the press brakes, saving companies money on training and giving flexibility in hiring. These press brake innovations are definitely a benefit to the field of manufacturing.

Interested in more areas of Custom Metal Fabrication? Check out this article.

Why Lubrication Increases Machine Longevity

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According to Dr. Ernest Rabinowicz of the Massachusetts Institute of Technology (MIT), 70% of moving machine failure is the result of wear and corrosion. Both of these factors are due to ineffective lubrication. He goes on to state that 6% of GDP is lost through mechanical wear.

Who would have thought that over $1 trillion could be the size of the prize if we, as a nation, could combat this problem? If you worry about machine failure, read on to learn about the benefits of lubrication.

Machine Failure

When machine failures occur, investigations reveal causes such as contamination, misalignment, installation error or overheating. There is often a lubrication cause to these explanations.

The four features of good lubrication practice are:

  • Correct lubricant
  • Stable lubricant
  • Contamination control
  • Sufficient and sustained lubrication

Maintaining these good lubrication practices reduces the causes of a breakdown.

How Does Lubrication Reduce Wear?

When two objects are in contact, the force that resists relative motion is friction. Friction is useful in many ways, but there are times when it is not. Friction generates heat in bearings, heat results in expansion and expansion can result in bearings seizing.

Lubricating machinery minimizes the friction and the resultant heat. Any heat produced is then transferred to the lubricant and removed by a lube cooler. Friction and heat are not the only things lubrication reduces.

When two materials rub against each other, tiny imperfections in their surfaces rub and fragments break off. These fragments act as an abrasive resulting in more surface damage. A lubricant protects both surfaces.

Some lubricants contain additives. They attract contaminants such as particles worn from the surfaces in contact. These can then be filtered and the contaminants removed before they can do any damage.

How Does Lubrication Reduce Corrosion?

Many machines operate in situations where there is some level of humidity. When metal and air come into contact with water, the result is corrosion. Corrosion is one cause of machine failure.

Specific lubricants have additives which prevent rust. They do this by protecting the metal from coming into contact with moisture. Without rust, the metal surfaces remain sound, and the machine is less likely to fail.

Lubricating For Machine Longevity

Lubrication extends the life of machinery by reducing heat, friction, wear, and corrosion but this is only successful if the lubrication regime is fit for purpose. The right lubricant has to be in good condition and uncontaminated. It must be applied in sufficient quantity and at the right level of frequency.

Failing to adopt this standard means optimum machine life will not be achieved. Machinery manufacturers often guide the lubrication needs of their machinery. These should be followed.

The International Council for Machine Lubrication is an independent organization established to develop machine lubrication as a technical field. It provides certification for skills in machine monitoring, lubrication, as well as oil analysis. The proper application of standards in lubrication must pay dividends in reducing equipment downtime and machine failure.

To talk to someone about your machinery needs, contact us.

5 Reasons Your Industrial Brake Should Come From Svenborg Brakes

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Svendborg Brakes dominates the industrial market. Inside are the top reasons why the Danish company should be your top choice for any industrial brake.

Content

Are you in the market for industrial brakes for your machine or new application?

Industrial brakes were once known for being drum brakes that suffered wear and tear fast. But many of today’s brakes use disc braking technology, allowing you to appreciate them longer.

Svendborg Brakes is a Danish company that offers intelligent braking solutions through quality craftsmanship.

Read on to learn the top 5 reasons why Svendborg Brakes are the industrial brake you need today.

1. Premier Customer Support

Svendborg Brakes provides premier customer support. This helps to ensure you have a positive experience after you buy their products.

According to an American Express survey, 3 out of 5 Americans are willing to try a new brand or company to have a better customer service experience.

Svendborg Brakes knows that buying an industrial brake is an investment. This means you need their products to run at a high level and with an easy resolution to any issues you experience.

Svendborg is so serious about customer service they offer customer support 24 hours a day, seven days a week.

2. Superior Build Quality

At the root of Svendborg’s products is a superior build quality that comes as a result of the products and how they are designed.

They listen to their customers to identify their needs and incorporate them into new products. This allows a customer to receive the product they need and that is built to last.

But besides listening to customer ideas, Svendborg conducts demanding tests during product design. The result is a strong product built to a higher standard than their competition.

3. Strong Supply Chain Services

Your Svendborg Brakes can be shipped to you for delivery at many places across the planet.

That’s because the company uses a wide network of offices and three manufacturing facilities located in Denmark, Brazil, and China. They also have offices around the world, allowing them to serve your needs at all hours of the day.

Svendborg has a value-driven approach to industrial product design. This means you are receiving a better bang for your buck on their products. Furthermore, their culture of long-term cooperation allows them to establish strong industry relationships.

4. A Unique History

Svendborg Brakes have a long history that began in 1884. At that time, they built machines for industrial companies.

But they would soon diversify across many different industries.

In 1989, Svendborg got the rights to manufacture disc brakes from Hagglunds Drives. As a specialist in the industry, they began to offer brakes to a larger worldwide population.

Today, this Danish company with humble beginnings now manufactures products in three countries. They also have offices throughout the world, including United States, Australia, and Korea.

5. Deep Industry Knowledge

Svendborg Brakes leverages over 130 years of experience to build their products. Their diverse industry knowledge helps them build products that meet your day-to-day needs.

This also means developing products that are sustainable under your work conditions, whether this is during light or heavy use. This can help your business have peace of mind that you are getting a quality product that will last.

Wrapping Up: The Best Industrial Brake Products

Industrial brakes are a crucial part of your heavy machinery or industrial application. That’s because you will use the brakes to maintain control of these machines on your projects.

At Svendborg Brakes, they are a team of professionals and engineers dedicated to helping you find solutions to the industrial challenges you face.

Contact us today to learn more about our products and what sets us apart from the competition.

 

Why Cylinder Clamps Are Such An Important Component To Your Machinery

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Often overlooked, a cylinder clamp performs a vital role in all types of industrial-based machinery.

Let’s take a moment to explore how they work and why their performance can be directly tied to the effectiveness and safety of a machine.

What is a Cylinder Clamp

It’s always good to start with the basics. Cylinder clamps provide a precision force to hydraulic, pneumatic, and electrical systems.

In short, their function is to maintain the power that keeps a system in motion. When they malfunction, it can cause an erratic system behavior or even a stoppage. This holds not just production issues but also safety concerns, both of which are good reasons to perform preventative maintenance on each cylinder clamp within a system.

These clamps also work to maintain the stability of a system. When placed correctly, they can keep the extra movement in a system down and guard against quick shifts in the positioning of a pipe due to inevitable pressure surges.

System Check

Some preventative maintenance measures can be performed while a system is running. For instance, have you noticed a change in the machine output? Is there anything to indicate that it’s not running at capacity?

A visual inspection is also important, both of the cylinder clamp itself and the surrounding area. Do you notice any blemishes, rust, cracks, or other marks that might indicate the start of an issue?

Do you also see any displacement of oil, feel the excess air, or detect any pooling of hydraulic fluid that might indicate the equipment is not performing as needed.

Repair vs. Replacement

If you notice any areas of concern that a repair may not overcome, it might be time to look at a replacement. There are some variations of cylinder clamps that you could consider changing to.

Before making a decision though, make sure to do your research to ensure that changing clamps will not void the warranty of the machine or cause potential compatibility (and safety) issues.

Rod Locking Cylinders

One replacement option can be found in rod locking cylinders. These have been specifically designed to lock into place should the system fail.

So, if there is an issue that causes a loss of hydraulic pressure, the machine will not continue to operate or stop hard but essentially freeze in place. This can help prevent damage to the machine overall and, more importantly, could head off serious injury caused by a misfiring machine.

While a rod locking cylinder can add a safety component to your equipment, it’s important to note that it is not intended to be a replacement device for your entire safety system.

Next Steps

We just took a brief look at what a cylinder clamp does. If you have one machine or hundreds working for you, you’re bound to rely on this part to keep your operation running smoothly, efficiently, and safely.

We’d love to talk with you in more detail about how you can keep this key piece of machinery from causing you headaches and downtime.

How A Preventative Maintenance Schedule Saves You Big Money

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If you’ve ever been guilty of not properly maintaining your equipment, you’re not alone. Many field experience industry-wide cultures that prevent regular preventative maintenance from taking place.

Unfortunately, this can lead to many problems with your machines and equipment.

Keep reading to learn why a preventative maintenance schedule is an absolute must for all of your company’s gear.

Extending the Life of Your Machinery

Setting up and following a preventative maintenance schedule can help to extend the life of your machinery.

Most types of heavy machinery require oiling and fine tuning to stay running.

Failing to perform regular maintenance could cause your machinery to stop operating correctly. It could slow down your equipment, or even cause it to stop working entirely.

But with regular maintenance, you can extend the life of your machines by keeping them running the way that they should for longer.

Preventing Costly Repairs

Without regular maintenance, your machines’ moving parts will eventually degrade. When this occurs, it is likely that your cranes and other machinery will need costly repairs or parts replacements to get back to running order.

Regular maintenance helps to reduce the need for these types of repairs. You will spend money on regular maintenance. But you are saving money compared to replacing parts or rebuilding broken machinery.

Knowing When an Issue Arises

Even with regular maintenance, normal wear and tear will occur on all heavy machinery.

But when you follow a preventative maintenance schedule, you’ll be more likely to know when these types of repairs will be needed.

An experienced repairman will be able to judge how quickly parts are wearing. With an estimate of when more extensive repairs or parts replacements will be needed, you can better plan ahead.

This could mean planning to get temporary equipment. Or otherwise preparing for the disruption to your normal workday. It also means having the ability to somewhat plan for the cost of repairs.

For small businesses, unexpected repair costs can put a serious dent in the flow of operations. The ability to plan and save money for those repairs can be a lifesaver.

Finding replacement parts can also slow operations. Being able to plan ahead can allow you to source difficult to find parts and to help reduce how much downtime your equipment has while it is undergoing repairs.

Meeting the Demands of a Warranty

If your equipment or machinery has a warranty, it usually requires that the machine or equipment undergoes regular maintenance.

Failing to do so could cause you to violate the warranty. When the time comes that you want to put the warranty to use, you might be denied your claim if you can’t prove that the equipment was maintained properly.

Setting a Preventative Maintenance Schedule

Setting up a schedule for regular preventative care can save you loads.

If you’ve recently bought a new piece of equipment and aren’t sure what kind of maintenance is needed, or if you need a replacement part to keep your gear running, contact us today.

OSHA Further Delays Overhead Crane Training Rule: What You Need To Know

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Confused by the chaos of OSHA’s crane regulations? You’re not alone.

OSHA has moved the date for these regulations twice now, along with other changes. It’s a confusing time for employers left wondering what’s required of them.

We’ve put together this brief digest so you’ll know everything you need to know about OSHA’s overhead crane training requirements.

What Happened?

OSHA devised certification requirements for crane operators in 2010, as part of their Cranes and Derricks in Construction Standard. These requirements were aimed at ensuring crane operators were properly qualified to handle lifting equipment.

Originally, these requirements were set to go into effect in 2014. But there were a few kinks to work out, and OSHA moved the date to November 2017 instead.

Now OSHA has moved the date again, a day before the revised deadline. As of Nov 9, 2017, a final rule moved the date to Nov 10, 2018.

This new delay gives OSHA more time to revise the rules of the regulation. OSHA has also identified that a large number of employers still don’t meet requirements yet, so this gives them more to seek accreditation for their staff.

The move has attracted some criticism, particularly from employers who have already invested in staff accreditation. Critics note the health and safety implications of delaying the standards by another year.

What Does it Mean for Me?

For employers, it means some confusion.

OSHA’s requirements mean employers have to provide overhead crane training to any operators under their employ – or ensure they’re otherwise qualified, such as through military training.

Nov 10, 2017, was the original deadline for employers to meet these requirements. Plenty of employers have already taken steps to meet the standards. If you’re one of these, you won’t need to worry.

If you’re not, you can breathe easy knowing you have another year to meet them. And that’s if OSHA doesn’t delay the regulations further.

What’s Next?

Now it’s a waiting game. OSHA could announce another delay anytime before Nov 10, 2018. Or they could go ahead with the revised standards. There’s no real way to tell at present.

Either way, employers should take steps to meet the standards. Employers have a few main routes to employee certification, as follows:

  • Training through an accredited third party
  • An internal audited program
  • Government-issued license meeting OSHA standards, such as a military qualification

OSHA will issue further updates as any changes to the deadline become apparent. In the meantime, you can read the exact text of the final note here.

Stay Current on Overhead Crane Training

The best move for businesses right now is to stay up-to-date on overhead crane training news. Keep an eye on the headlines for an idea of what you’ll need to do, and when. In the meantime, consider taking steps to meet the requirements in advance, so you’re not caught out when the regulations finally come into force.

Want to stay on top of industry news? Be sure to follow our blog.

The Ultimate Guide To Spotting And Preventing Machine Failure

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The productivity of your business depends on the well-being of your equipment. Any downtime due to machine failure can be devastating. Business operations become out of whack disrupting service, staff comfort, and customer relations. Not to mention that the safety and health of your workers are put at risk.

Equipment breakdown is very costly. You only have two options: repair or replace, and both can be expensive. When the motor needs replacement, you’ll have to pay labor costs for removal, costs for installment, and freight costs.

Recognizing problems with the important parts, such as the brake pads and rotors, is key to preventing machine failure. What are the things to look out for? Read on to find out.

Rattling and Squeaking, Clanking and Squealing

When you’re driving your car, you love the purring sound the engine makes. But when you hear an unusual sound, you know that it’s time to open the hood and see if anything’s wrong.

Your employees are also familiar with the normal sounds of the machine they’re working on. When they hear an abnormal sound, that is usually one of the signs of imminent failure.

Just like your car, an unfamiliar noise warrants an immediate inspection.

Worn out Brake Pads and Rotors

Machine failure is usually caused by parts showing their age. Using our eyes to look for signs of wear is part of preventative maintenance.

Examine the belt, bolts, and other important parts of your machine. Does your belt have cracks, abrasions, or fraying? Are the brake pads and rotors starting to warp or showing gouges? Are the bolts out of shape or loose?

Replacing aging parts is cheaper than replacing the equipment itself. Before machine failure happens, change the worn parts with new ones.

Slumps in the Efficiency

A decrease in production speed affects your bottom line. But more importantly, it signals that the machine is starting to break down. And when it eventually fails because you neglected the warning signs, you’re going to lose a great deal more.

A slowdown in production usually indicates resistance in the machine. This could be due to lubricant leakage or due to damaged parts causing friction.

Speaking of friction, another byproduct of inefficiency is unexplained heat. Of course, heat is normally created as the machine works. However, when heat is produced in areas that should be cool, that is a problem.

Another hint of impending machine doom is when the temperature shoots up higher than normal. You should also suspect electrical failures for unexplained heat.

Address these issues immediately, or the heat could lead to a fire.

Dirty Machine

A clean machine runs smoothly. Dust and debris clog up the important parts and can cause the machine to seize.

Filters keep the dirt off of your equipment but must be routinely changed. Seals, when damaged, can’t perform their protective duties. When seals are compromised, you’ll spot leaks and wetness in areas where you don’t find them under normal conditions.

You should schedule a regular inspection of the important parts. Repair or replace them when necessary.

An Ounce of Prevention

Your production equipment is critical to your business. Once you recognize these warning signs, preventing further problems from happening will save you money in the long run.

Request a quote for our equipment repair services right now.

 

These Servicing Tips Could Help You Avoid A Brake Replacement

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The most important safety function of any piece of industrial machinery is the ability to stop. Brakes are an essential part of any crane, wind turbine or any industrial machine.

It is essential to have every component of the brake system in top working order to avoid costly replacements and repairs.

How costly is a brake replacement? Count time out of service, the time of your engineer, mechanic and other labor. Had enough?

Read ahead for servicing tips to avoid unscheduled brake replacement.

Proper Maintenance = Long Life

Even the highest quality systems need regular maintenance for longest effective life.

Some brake systems have a predefined interval of time for how often you should schedule maintenance and replacement. We recommend keeping the manufacturer’s suggestion as the maximum amount of time between servicing.

Every site has unique operating conditions. Only you can determine how frequently you use your equipment, under what load, and in what weather.

Stay vigilant to changes in performance, even gradual ones. Changes in noise or movement also indicate something is wearing.

Check Your Friction Lining

Every set of brakes has a certain safe residual lining surface. Brake pads and linings should be serviced before they become unsafe, as damage to rotors and other parts will result.

A regular check of the air gap between the plate and the brake coil is necessary for most brakes. As the friction lining starts to wear down, the air gap increases. Adjust the brakes as necessary to prevent damage.

Metal hitting metal means an expensive repair.

Contamination = Brake Replacement

Grease, oil, and debris have no place inside your brake system. Not only will they burn in the heat generated by braking, they irreparably damage the surfaces.

Contamination kills stopping power.

When your brakes are contaminated with grease or moisture, the safety of your equipment is at risk. Brakes can’t do their job of stopping motion if they can’t grab.

Contaminated brakes must be replaced. Cleaning and rebuilding is possible, but cannot be undertaken as a less than a major repair.

Inspect and Change

Any excessive vibration, hesitation, uneven load or dangerous condition is a threat to life and safety. Keep track of time, condition and use of brake systems. A basic visual inspection at every use and regular maintenance service prevents costly repairs.

Brake pads, linings, rotors and all components should be checked at manufacturer recommended intervals or sooner. Replace as necessary. Brake fluid should also be checked and changed as necessary.

Keep contaminants out of the brakes. Water, oil, grease or brake fluid can cause downtime and replacement. Never let metal hit metal.

Need to Know More?

Keep reading this blog for more information about the best equipment for your needs or contact your Kor-Pak representative today!

5 Tips For Picking The Right Custom Fabrication Company

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Everything you look at only fills half your needs. You’ve got a tight budget and tighter timetable. Nothing quite fits.

Does this sound like you? While a stock piece is standardized and available almost immediately, a custom fabrication can meet 100% of your needs.

Custom fabrications have increased useful life since they can be customized to the environment and particular wear pattern. Backward compatible for machinery no longer in production, non-standard processes? No problem.

Are you sure that custom fabrication is what your business needs? Then you need to choose the right company to make what you need. Here’s the breakdown of what to look for in the right custom machine shop.

What’s Their Experience?

You want someone who can execute your ideas or reverse-engineer a worn piece. For that, you need someone with practical experience in your field, whether it is an oil-rig or hospital. There isn’t a field manual for pieces that don’t exist in catalogs.

Experienced metal fabricators know their materials and techniques. They can recommend solutions and handle customization with efficiency. More experience means fewer errors.

Check Their Work

Get to know the quality of a company’s work by checking out their portfolio. Talk to past customers and view past projects. You want to know about the durability and quality of their custom fabrication.

What is their safety record and how do they handle remanufacturing critical parts? It will also give you an idea of how they handle the specs of individual designs and their capacity for large or small size jobs.

Capacity for Work

Can your fabricator build in the material you need? What kind of machinery do they use? For high-quality steel welds that lives depend on, no one wants to see a 90 amp Home Depot special! The right tools and technique can mean lives.

Location is relevant. Consider fuel costs and control over your fabrication. Will you be able to communicate with your machine shop? How quickly can your shop turnaround? Will time and distance affect your costs?

Get to Know the People

You want a long-term relationship with your company. Each project is unique and your business is like no other. You want a metal fabricator who recognizes that!

Compare Quotes For Custom Fabrication

Of course, you have to follow procedures and get quotes from many shops. For the best possible outcome, you want a custom fabrication shop that can give you what you need, at a reasonable price, and on your timeline.

Take the time to get to know your vendor and their capabilities before deciding on price alone.

For more interesting and informative articles, keep reading our blog. If you want to know more about the most qualified and experienced metal machining and fabrication shop, contact your Kor-Pak representative today.

Top 5 Advantages Of Our Servo Motors And Drives

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People realize that the common hydraulic motors today aren’t cutting it anymore. They can be expensive, cause oil problems, and occasionally leak.

But luckily there’s a better option out there.

Electric servo motors and drives have been evolving for some time now. And they seem to be great for all different industries. That’s why we’ve gathered the top 5 advantages of servo systems to show you exactly how great they really are.

Speed of Servo Motors and Drives

Many people debate the speed and acceleration of servo motors and drives compared to those of hydraulics. The truth of the matter is that hydraulics aren’t the fastest because of its compressions of oil and flexibility of its hoses and lines that expand.

If hydraulic systems were designed better, then the speed may be better and closer to that of a servo system. But for the time being servo motors and drives are more impressive in the category.

Versatility

The next advantage of these systems is the versatility servo technology. They can be used for so much, and there are different kinds as well.

Usage

Servo motors are in a wide range of machines.

Inside of a servo system is a motor that toys also often come with. This motor is called a small direct current motor, and it runs on electricity from a battery.

They are also in cameras. Specifically, in it’s Auto Focus to help the camera’s lens sharpen images. Automatic door openers also use the motor to help signal it to open.

Another use of this system is the robotic arm that helps move along assembly lines. The servo motor helps make the joints of the robotic arms move.

Types

The servo motors in the servo system come in many different forms.

  • Positional- this is the most common and can rotate in certain directions.
  • Continuous- this one is similar to positional but can rotate in all directions.
  • Linear- this one has the features of the previous ones but has additional gears.

Something that varies in the different types is how they are used as well and their availability. The positional servo motor can be found in smaller applications, while the continuous and linear motors are geared towards larger projects.

Exerts Less Heat

Hydraulic machines let out a large amount of heat. This is mainly through its work with oil and overall design of the machine.

Servo motors and drives release such a small amount of heat. So small in fact, that operators usually need to employ another system that keeps the oil at temperature.

Service of Pumps

Another large difference between hydraulic machines and servo motors and drives is maintenance.

While hydraulic machines are generally cheaper to buy the servo systems will give you your money’s worth in how much it saves, as well as cut down costs on maintenance.

Hydraulic machines will need to be serviced often as their pumps will need to be changed. And their pumps are also more expensive than those of a servo system.

Simplicity

Servo motors and drives are also extremely simple machines. This makes work and maintenance a lot easier to carry out.

An all-electric motor will have fewer parts than those that are hydraulic-based. As a result, an electrician will be able to work on it without needing hydraulic knowledge.

These servo systems also use technology that will make repairs easier. They use feedback devices that help catch errors and correct them to help better performance.

More Motor Tips

It’s important to choose the best parts for any project that you’re doing. Especially when it comes to motors as they can be a big part of the system you’re working with.

For more information on motors, check out this blog post.