Lazer Safe Pty Ltd  

27 Action Road
Malaga,  WA  6090

Australia
+61 8 9249 4388
https://www.lazersafe.com

• Booth: A3331

Lazer Safe specialises in the development and manufacture of control, safety and operator protection systems for press brakes and related sheet metal machinery. 

We design, develop and manufacture a range of safety control systems, optical laser protection and image processing systems specifically for application to hydraulic and electric press brakes, for both OEM and retrofit markets.

Our primary path to market is through the press brake manufacturers who we collaborate with to embed systems and technology into press brake designs to achieve the highest possible level of functionality, safety and performance.

We also supply optical laser guarding systems for the press brake retrofit market. These systems improve the safety of existing machinery to protect operators from injury, while maintaining the highest possible level of machine functionallity and performance. Our network of retrofit dealers and distributors provide retrofit sales, support and installation services throughout the United States, Canada and Mexico.

Aside from press brakes we offer safety and guarding solutions for other types of sheet metal processing machinery including folding machines and hydraulic presses. Development of systems and technology to support the wider sheet metal industry continues through our ongoing research and development programs.

We are also committed to the development and understanding of international safety standards and participate in several international standards committees including CEN/TC, ANSI and ISO. We are actively involved in the education and promotion of standards and their correct application.

 Press Releases

• Autonomous Guarding: Press brake automation takes another step forward. (Jul 10, 2023)

  Press brakes have seen significant advancements in automation as technologies such as automatic tool changing cells, automated material handling and robotic bending have becoming increasingly common over the last decade.

  However, for the most part, press brakes are still manually operated machines that require trained and skilled operators to achieve safe, efficient, and productive bending. Aside from bending parts, press brake operators are required to manage the setup and configuration of the machine safety and guarding devices and systems. An incorrect, or poor setup can not only result in a potential reduction in safety function but can also lead to a significant reduction in machine efficiency that results to lower productivity. 

  A press brake with an automated safety and guarding solution eliminates the need for manual adjustments to be performed by the operator by automatically driving the optical components to the correct position, then automatically making any necessary adjustments based on the tooling that had been installed. In addition, secondary processes automatically check and confirm the positioning and setup, thereby ensuring that the machine is always safe to operate. 

  The team at Lazer Safe, who are the industry leading specialists in the field of press brake safety and guarding solutions, are improving the way in which machine operators interact with the press brake through more advanced levels of Autonomous Guarding technology. Lazer Safe is leading the industry in Autonomous Guarding and have defined five levels of automation ranging from Level 0 through to Level 4.

  Press brakes designed to Level 0 essentially offer no automation, and therefore completely lack any automatic functions. The safety and guarding system and processes that are integrated with the machine are purely manual and rely solely on the machine operator for any adjustment, setup, and alignment of the guarding system, plus safety performance testing and mode selection. This generally applies to press brakes that are designed and manufactured to achieve a lower cost or supplied into economy markets.

  Level 1 progresses to low automation, where we start to see the introduction of press brakes with automatic functions such as automatic verification of the optical sensor position to the upper tool, verification of the tool height and material thickness, plus automatic guarding mode selection for each step in the bend program. This typically requires the press brake manufacturer to adopt integrated functions where processes are embedded in the CNC system software to facilitate more streamlined and user-friendly operation.

  Press brakes designed with Level 2 Autonomous Guarding take a larger step forward to where all the of the safety and guarding setup, adjustment and operating functions are now automated. This presents the ideal solution where the operator turns on the machine, installs the tooling and starts bending parts – all without have to setup, adjust, or check any of the safety and guarding functions, and provided that the bend program has been optimised, there is very little to no interference when forming parts. 

  Streamlined configuration and optimisation of the bend program can eliminate or drastically minimise interference with the sensing zone, which results in fewer pedal presses, no unnecessary stops in the bending cycle and significantly more time in high-speed, resulting in faster and more efficient production. The only part of this process that is not automated (at Level 2), is optimisation of the bend program, which requires a higher level of automation. 

  Press brake manufacturers are already offering machines designed with Level 2 Autonomous Guarding, which has been widely available for around the past 5 years, and this has already driven positive results for the sheet metal industry.

  Optimisation of the safety and guarding functions within the bend program is a significant factor that determines the true productivity output of the machine. If the bend program is not optimised, or is poorly configured, then this can result in an increase in cycle times and therefore a reduction in the number of parts produced per hour. 

  Without optimisation, we see several factors that impact productivity since there is no synchronisation between the guarding system’s optical sensing zone and the part profile. The effects of this are amplified when bending more complex parts that comprise multiple steps with side flanges. The lack of optimisation results in interference between the optical sensing zone and the work piece, that requires the operator to make additional pedal presses either before or during each cycle. In addition, there is often an increase in the slow speed travel distance before the upper tool reaches the material. 

  If the bend program is optimised, then the optical sensing zones are dynamically and automatically managed according to the part profile. Not only that, but the configuration of the bend program is optically verified against the physical part profile to ensure a higher level of safety. When starting a new job, the machine operator only needs to change the tools, start the bend program, then begin bending parts immediately. The addition of an Automatic Tool Changer in combination with Autonomous Guarding (Level 2 or above) eliminates another manual process and improves efficiency even further.

  Currently with Level 2 automation, press brake operators and CNC programmers, are required to manually configure and optimise the safety and guarding functions in the bend program. This process involves analysing the part profile as is changes from one program step to the next, then selecting the most efficient guarding mode, or combination of modes, as well as inputting the parts dimensions such as the height of side flanges. Provided that the bend program is optimised correctly, then maximum efficiency and production output can be achieved.

  Feedback from the sheet metal industry consistently identifies a common issue with this optimisation process, is that press brake operators may not always receive the necessary information or training. This is compounded due to frequent turnover of machine operators, or when experienced operators leave, taking valuable knowledge and skills with them. Another issue is the general shortage of skilled sheet metal workers which continues to present a challenge for employers. 

  To address these issues, Lazer Safe has identified the next stage of automation, with a transition to Level 3 Autonomous Guarding. This represents a significant development in press brake efficiency and productivity that was previously not possible.

  Level 3 automation introduces a new process where the safety and guarding system in collaboration with the CNC system, share information to automatically learn the part profile and determine the optimal modes and settings for each step of the bend program. This takes the manual process and decision making out of the operator’s hands, saving time, and ensuring that bend programs are always optimised for maximum bending efficiency.

  The learning process is automatically activated when a new bend program is run for the first time, and active only when the first part is formed. As each bend is processed, part profiles are optically detected, and the CNC displays a message to the operator confirming the optimal mode and parameter settings that will be automatically applied to each step of the bend program. Once the first part is completed, the bend program is now optimised, and the settings are automatically saved in the CNC. All subsequent parts can then be formed with maximum efficiency. Since the bend program is now optimised and settings automatically saved, the learning process does not need to be repeated the next time the operator runs the same program. 

  Level 4 Autonomous Guarding takes optimisation a step further, where software analyses the bend program and part profile in 3D, then automatically determines and applies mode and parameter settings without the need for a learning cycle. Level 4 is a more advanced process that will evolve over time, as Lazer Safe continues to drive innovation for the press brake industry. 

  Users that currently own and operate press brakes with Level 2 Autonomous Guarding are already realising the benefits of reduced setup times, less reliance on machine operators, and improved machine efficiency. The transition to Level 3 Autonomous Guarding will offer users even greater levels of productivity.

  Many of the industry’s leading press brake manufacturers are already in the process of implementing Level 3 Autonomous Guarding and Lazer Safe anticipates rapid market adoption of this technology over the coming months.

  To learn more visit Lazer Safe at FABTECH: Stand A3331.

  www.lazersafe.com

• Sentinel Plus Automatic - Press brake guarding with automatic motorised adjustment (Jul 10, 2023)

  At FABTECH in Chicago, Laser Safe will present the Sentinel Plus Automatic press brake guarding system. The system features automatic motorised brackets that completely automate the process of adjusting and positioning the guarding system laser transmitter and receiver during tool change. The Automatic Brackets incorporate a compact motorised drive system that is controlled via a graphical user interface panel with simple one-touch operation.

  During tool change, the system drives and parks the laser transmitter and receiver at the upper position so punches can be easily removed and loaded from the ends of the machine. Once the new tools have been installed, the brackets automatically drive the transmitter and receiver to the punch position using a high-speed image scanning process to detect the upper tool. The system dynamically adjusts and aligns the protection zone relative to the punch profile eliminating reliance on the machine operator to make any manual adjustments.

  Sentnel Plus Automatic significantly reduces reliance on the press brake operator and eliminates producion delats that can occur due to an incorrect or inefficient setup of the guarding system.

  Lazer Safe will present interactive demonstrations of Sentinel Plus Automatic at booth A3331.

• Wireless Freedom for Press Brake Operators (Jul 10, 2023)

  Machine operators can now experience greater freedom and benefit from improved ergonomics and safety when operating press brakes, thanks to the latest advancements in wireless foot pedal technology. While hardwired pedals are the current standard method for a safe and reliable connection to the machine, foot pedal cables running across the floor tend to get in the way of machine operators, create potential tripping hazards and can make it difficult to move the pedal to a comfortable working position.

  Wireless technology for remote operator controls, while not a new concept, has presented challenges for press brake manufacturers in terms of the development and implementation of reliable communications hardware, the safe processing of wireless commands, responsiveness and high energy consumption that requires high-capacity batteries and frequent recharging. 

  A new wireless safety communications technology has been developed by Lazer Safe, that now enables press brake manufacturers to easily incorporate wireless functionality into their existing foot pedals. The new wireless safety communications technology employs a unique SIL3 communications process that provides remote input and output connections between a remote wireless module and the press brake. The wireless system comprises a compact wireless remote module that houses the dual-channel communications hardware and antennas, an e-paper display, solar charging cell, customisable hardware inputs and a lithium-ion battery pack. The wireless module is incorporated into the foot pedal pedestal together with an array of ultrasonic sensors. 

  Wireless foot pedals offer several advantages over their wired counterparts in terms of improved ergonomics, reduced operator fatigue, eliminating down-time caused by damaged cables and removing tripping hazards for a safer work environment.

  Flexibility to incorporate additional functions

  The wireless remote module is incorporated into the design of the foot pedal pedestal and contains physical inputs for the foot pedal contacts plus auxiliary controls. The wireless pedal is paired with a module on the press brake that is interfaced with a machine safety controller that processes the incoming foot pedal signals. 

  The addition of remote wireless inputs in the foot pedal now gives press brake manufacturers the flexibility to incorporate additional functions to wireless foot pedal stations. While most wired pedals will include the same base functions such as the down and up pedal switches, manufacturers have also incorporated additional wireless controls including buttons for upper and lower tool clamping, an illuminated emergency stop button, machine reset, machine start / stop, and more.

  Extremely low power consumption

  A major advantage of the wireless technology is the extremely low power consumption. The method in which the data is transmitted is one of the keys in significantly reducing power consumption and thus eliminating the need for a heavy high-capacity battery and frequent recharging. In addition to the energy efficient design, the indoor solar cell that is incorporated into the wireless module uses ambient light as an auxiliary power source to extend the time between recharges by up to 20%.

  Up to one month use from a single charge

  A single charge can power the wireless foot pedal up to one month of normal usage. The operators are alerted when the battery level is low and down to a few days of charge remaining, giving them sufficient opportunity to recharge the battery. When the foot pedal does need to be recharged, a USB charging port on the foot pedal pedestal makes it relatively simple to plug the pedal into a charging port on the machine or through a standard USB charger. 

  E-Paper display

  Also incorporated into the wireless module is a 25mm x 65mm E-Paper display. This active display presents a range of useful information for the machine operator including the connection status, battery level, and the status of optional auxiliary functions. Again, in keeping with the low-power design, the E-Paper display consumes very little energy, putting almost no additional load on the power supply.

  Flexibility for multiple machines

  Users can take advantage of sharing foot pedals across multiple machines, with the ability to pair them to the required machines for certain jobs. This means that fewer foot pedals would need to be purchased as they can be easily shared among multiple machines in a production facility. The paring process is simple and takes only a matter of seconds by pressing and holding the pairing buttons on the machine module and the foot pedal until the two are connected.

  Of course, there are a few situations that could arise that may be cause for concern with wireless technology. Questions such as “What if the foot pedal is removed and operated from a remote location?”, or “Wouldn’t it be dangerous if the pedal was taken into the back of the machine where the machine could be operated?”. While both are valid concerns, additional safety technologies have been developed to provide both range and line-of-sight monitoring that ensure the distance and location of the foot pedal is always within pre-defined safety limits before the machine can be operated.

  Range monitoring

  Range monitoring enables the press brake manufacturer to set a maximum operating distance for the pedals used on each machine. The range can be configured and set by the manufacturer, adding an extra level of safety by ensuring the machine can only be operated when the foot pedal is within a predetermined range. This eliminates the possibility of the machine being operated from a remote and potentially unsafe distance or location, that may otherwise put anyone within proximity of the machine at risk. Say if an operator was changing tools, or a worker was performing machine maintenance, they may be at risk of injury if another person attempted to cycle the machine from a remote location without their knowledge.

  Line-of-sight monitoring

  The addition of line-of-sight monitoring technology also enhances the level of safety. Ultrasonic sensors are integrated into the wireless foot pedal pedestal as well as into the lower frame of the press brake. A set of sensors are installed on each end of the machine, with the option of a centrally mounted ultrasonic module that maintains line-of-sight in case of obstacles such as sheet followers and material loading tables. 

  Line-of-sight monitoring also prevents the machine from being operated if the pedal breaks line of sight with the ultrasonic sensors on the machine. For example, the press brake cannot be operated if the pedal was moved to the rear of the machine or hidden behind a wall or screen.

  Ergonomic design

  The need for good ergonomic design is becoming increasingly important for press brake operators. Spending several hours each day standing in front of a press brake and manually handling material puts a great deal of physical strain on an operator. This can lead to physical and mental fatigue which can be dangerous as a loss of concentration could lead to an operator making a mistake that could cause them an injury. Press brake manufacturers are constantly looking for ways to improve machine design and operating techniques to alleviate the strain on workers. While reductions in operator fatigue and improvements in accident minimisation is beneficial to a worker’s wellbeing, better ergonomic design will also have the added benefit of improved productivity. 

  Wireless technology now gives operators greater freedom to position the foot pedal anywhere across the front of the machine without the frustration of being tethered to a cable. This also helps with having the ability to easily set the pedal at a comfortable angle and especially beneficial when working with multiple tooling setups along the machine. With a wireless option, the operator can more easily move the pedal along the machine as they progress though each tooling station. Eliminating the foot pedal cable also frees up floor space so trolleys or carts used to transport and store material or completed parts can be positioned and moved around the press brake without restriction. Potential tripping hazards from cables lying across the floor are also eliminated, making for a safer and more efficient working environment.

  Anyone that has ever experienced the inconvenience of a damaged foot pedal cable will know all too well the potential for significant machine downtime and lengthy production delays. Cable damage can be caused by heavy metal sheets being accidentally dropped or falling from the machine at the completion of a bend, striking and severing the pedal cable. While this may only damage the cable itself, in some cases this could potentially damage electronic components in the machine cabinet as well. In either case, any sort of cable damage causes major disruption to production until repairs are carried out and, in some cases, it could take several days before the machine is up and running again.

  Improved ergonomic design, flexible functionality and improved productivity are just a few of the benefits that will be realised through wireless press brake foot pedal controls. 

  Lazer Safe will present interactive wireless foot pedal demonstrations during FABTECH at stand A3331.

• FoldGuard : Safety & Guarding Solution for long folding machines (Jul 20, 2023)

  FoldGuard is a complete safety and guarding solution designed for long folding machines and provides optical protection for the clamping operation, monitoring of machine performance, plus management of additional machine safety functions.

  The FoldGuard laser transmitter and receiver are positioned either side of the machine with floor mounted brackets and a continuous laser field protects the zone between the clamp to protect the operator as they hold the material while it is being clamped. If an obstruction is detected, the clamp motion is automatically stopped. The machine stopping performance is automatically monitored to make sure that the clamping device stops within a safe distance. By providing this extra protection, FoldGuard enables the machine to operate without the need for a safety stop on each clamping cycle for faster operation. A special hemming mode also enables parts to be formed safety without unnecessary safety stops.

  FoldGuard also provides optional monitoring of additional machine safety function such as emergency stop buttons, foot pedals, light curtains, area laser scanners, safety mats, interlock switches and emergency kick bar.

  FoldGuard retrofit packages are avaiable from our dealer AMS Controls Inc. To see an interactove demonstration, visit the AMS Controls booth A3422 at FABTECH. 

• Sentinel Plus : Press Brake Retrofit Guarding (Jul 20, 2023)

  The Sentinel Plus guarding system provides optimal protection and performance for press brake retrofit applications. Through advanced camera imaging hardware and BendShield safety technology, the system automatically scans the upper tool profile and dynamically adjusts its safety zone to envelop the tool tip with a protective field that has no gaps, keeping operators safe while operating the machine at high speed. 

  Where Sentinel Plus provides a significant advantage, is through its unique RapidBend Plus performance technology. RapidBend Plus employs a patented progressive muting process that enables performance press brakes to close safely at high speed until the punch is just 2mm above the material, irrespective of the machine overrun distance. The active protective zone is progressively muted within the camera receiver software and reduces in vertical size as it approaches the material surface. This, coupled with dynamic overrun monitoring, maintains optical protection right down to the material surface and effectively eliminates the excessive slow speed travel that is imposed by other types of laser guarding devices. RapidBend Plus can save operators up to two or more seconds per bending cycle and on most press brakes, especially high-end performance machines, the savings in time and operating costs are quickly realised.

  Another advantage of RapidBend Plus is that it enables this higher level of machine productivity with both flat and box profile parts. When forming box profile parts with side flanges, there are two box bending modes available that can be selected by the operator and these modes enable a portion of the protective zone to be temporarily blanked, enabling the machine to close at high speed then transition to forming speed at just 2mm. Faster forming speeds are also possible as Sentinel Plus provides optical protection to a 2mm opening which is well within the required closed tools opening of 6mm.

  Lazer Safe will present interactive demonstrations of Sentinel Plus Automatic at booth A3331.

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