Press brakes are difficult to guard because the part’s flange profile changes from one bend to the next. A standard light curtain can’t adjust to that. The Merlin 4000 Press Brake Guarding System can. Developed by ISB, it learns each flange profile while your first sample part is made and opens a window sized exactly for every step. I.M. Services LLC supplies, installs and supports it.
How the Merlin 4000 Press Brake Guarding System Works
The Merlin 4000 recognizes the part profile for each bend and blanks only the beams needed for that step. The processor makes the call, not your operator or setup crew.
Programming follows the bend sequence:
- Select program mode and position the part for the first bend.
- Press the remote learn foot switch to teach the profile.
- Cycle the press brake, then repeat for each bend until the part is finished.
Jobs are saved and recalled with a numeric code, usually the drawing number. Built-in muting, interfaced with the machine control, ignores the part rising as it bends once the ram reaches the mute point.
Key Features
- Compact touch screen HMI
- Unlimited job storage with job sharing, up to 99 steps per job
- USB backup and restore
- Select-stop programmable stroke stop for small or narrow parts
- Password-protected setup and supervisor levels
- Dynamic flange monitoring to prevent fake parts or permanent blockages
- Floating beams (up to 3) for flat sheets, and blanking tolerance for slight mispositioning
- Bumping mode for cones, cylinders and odd-shaped parts
- On-screen diagnostics in English, Spanish and French
Who It's For
The system suits any shop running mechanical, hydraulic or servo press brakes, up-acting or down-acting. It doesn’t change rapid advance or slow speed, and adds little to setup time. It’s also the upgrade path for shops still on the discontinued Merlin 3000.
Our Installation Process
- On-site assessment of your machine, tooling and workflow
- Engineering and integration to suit your parts and production
- Functional safety verification, including stopping performance
- Documentation with test results and compliance alignment to ANSI B11.3 and B11.19
- Operator training on daily checks and safe use
Common Questions
Which light curtains does it use? It operates only with ISB’s MX4200 safety light curtains, in 14 mm or 22 mm detection, with up to 10 metres of coverage.
What does it cost? Pricing depends on your press brake and coverage needs.
Book a Merlin 4000 Assessment
Call 267-718-7349or email support@im-services.net to discuss your press brake. You can also download the Merlin 4000 brochure.