THE MOST ADVANCED MERLIN PRESS BRAKE GUARDING SYSTEM JUST GOT BETTER!
Merlin 4000 Controller
Press brakes are difficult machines to guard, simply because the part’s flange profiles generally changes from step to step during the fabrication process. A standard safety light curtain can not provide protection because of these varying part profiles. Only the unique MERLIN concept, pioneered by ISB, can learn each flange profile while making your initial sample part and automatically create a window exactly the proper size required for each specific cycle. This opening may change from stroke to stroke automatically, completely determined by our processor, not your operator or set up personnel.
- No Decisions.
- No Errors.
- No Complications.
Merlin 4000 Features
• New compact touch screen based HMI panel for easier use.
• Unlimited job storage with job sharing.
• Each job can have up to 99 steps.
• Easy jobs back-up & restore using a USB memory stick.
• USB & Ethernet networking capability.
• Select-stop programmable stroke stop for each step to allow efficient bending of small or narrow parts. *optional items may be required.
• Password protected set-up and supervisor levels.
• Operates exclusively with ISB’s MX light curtain columns, either 14 mm or 22 mm detection capability, and a maximum of 10 meters of coverage.
• Built-in light curtain muting using two external inputs.
• Easy teaching of the part flanges and support arms by simply following the HMI’s step by step instructions and pressing the provided remote learn foot switch as initial sample part is being fabricated.
• Part flanges are dynamically monitored to prevent teaching of fake parts / operator abuse /permanent blockages.
• Stationary support arm size limits to prevent abuse. (adjustable & password protected)
• Floating beam to allow flat sheets of metal without flanges to pass through the light curtain.
• Blanking tolerance to allow for slight misposition for taught flanges.
• On screen diagnostics / troubleshooting.
• Each beam of the light curtain uses an indicator LED to display a blockage, and a blinking LED to show the size and location of the taught flange during each step.
• Bumping mode is included to allow for bending of the cones, cylinders or other one of a kind off shaped parts.
• No significant addition to set-up time
• No altering of rapid advance or slow speed of press brake.
• Can be used on any type of press brake.
(mechanical, hydraulic, servo-brakes, up-acting or down-acting)
• Available in English, Spanish and French.
Merlin 4000 Indicators Now Interactive
When running a programmed job in the press brake, the Merlin 4000 LED indicators now flash from step to step to give the operator a visual aid of where to hold the proper flange size and location. Once the part is properly located, the LED’S stop flashing and the machine can then be operated.
Unsatisfied Flashing Blanking Indicator
Incorrect Object Size and Placement
Correct Object Size and Placement
How Does Merlin 4000 Work
Merlin 4000 will recognize the change in part-profile for multiple bends, and sequentially negate only the beams necessary for the current step to allow the press brake to complete its cycle.
How is a Merlin 4000 programmed? Simple…Remote Learn Foot Switch.
Remote learn foot switch.
• Select the program mode and place the part in position for the first bend.
• Teach the part profile by pressing the remote learn foot switch.
• Cycle the press brake making the first bend.
• Position the part in place for the next bend and
teach the profile with the remote learn foot switch.
• Cycle the press brake.
• Continue until the part is complete.
Floating beam and blanking tolerance.
What if a bending step does not have a flange and the part does not consistently block a beam?
• Floating is automatically enabled when needed.
• The floating beam function allows up to 3 beams.
• Blanking tolerance allows small mispositioning at the edges of the flange up to 3 beams.
Run Job.
Once your part has been programmed, you can then store the program sequence in memory and recall it by using numeric code usually a drawing number.
How Dose The Merlin 4000 Allow Part Movement During Bending?
Simple, Built In Muting.
The Merlin 4000 is interfaced with the machine control to receive signals when the ram is at top position and at the mute point. (6mm above the pinch point)
Once at the mute point, the Merlin 4000 ignores the interruption of beams by the part moving upwards while being bent, thus enables the ram to return to the top stop position.
Contact I. M. Services today to discuss you press brake guarding needs.
I. M. Services offers turn-key installation, sales and service for the Merlin 4000 light curtains.
For more information on ISB products click this link.
