Section 1: Potential Hazard Zones on the CNC Tube Bending Machine
The primary hazard zones on the tube bending machine are located as follows:
1. The full travel path of the bending arm; the area within the arm's range of motion—specifically between the bending arm and the stationary arm—is particularly dangerous.
2. The range of motion of the tooling (dies).
3. The area surrounding the bending angle selector.
4. The workspace in front of the machine head where tube loading, unloading, and rotation occur.
Each of these hazard zones is marked with a standardized safety label; please refer to the manual and the machine diagrams to identify these marked areas.
Section 2: Operation of the Tube Bending Machine
Operating the tube bending machine in a smart and user-friendly manner is crucial. The safety of operators and tooling technicians is just as important as the machine's service life. Proper operation and maintenance will extend the machine's lifespan. Conversely, incorrect usage can lead to accidents and serious hazards. Improper use may be unintentional, yet it accelerates component wear and functional degradation.
A safety guard is installed near the bending arm. If personnel enter the arm's operating range, the machine will trigger an emergency stop the instant contact or entrapment occurs, and an alarm will appear on the screen to prevent serious crushing injuries.
In an emergency, press the Emergency Stop button to cut off power and prevent hazardous incidents. You must restart the machine after the hazard has been cleared. Ensure the main power supply is on before attempting to restart.
1. Location of the Emergency Stop Button
On the operation panel: Pressing this button cuts power to all motors and servo drives.
2. Avoiding Overload
Misuse of the equipment can overload machine components. Excessive loads can occur unintentionally—for instance, when the torque required to bend a tube exceeds the machine's design specifications.
Monitor the operating load to prevent component overload; exceeding limits compromises both the machine's service life and operator safety.
Warning! Maximum bending capacity is rated based on standard iron pipe with a tensile strength of 40 kg/cm². Strict adherence to these technical specifications is mandatory; failure to do so may result in severe damage to the machine.
3. Safety Training
Professional pre-job training and assessment can prevent or minimize potential accidental injuries during production. Safety training programs must be supervised and guided by leadership and management personnel. Managers must maintain a high level of awareness regarding safe operating practices within their areas of responsibility.
Proper training is essential to ensure maximum protection. Employees should be instilled with a safety mindset regarding the work environment and machine operation; critical rules—such as mold installation guidelines, safety device usage, and operating procedures—must be emphasized to foster individual safety awareness.
Section 3: Electrical Safety Measures
1. Electrical circuits contain connection points; do not touch them! Even if an external auxiliary power socket has been installed, it must not be touched; only qualified personnel are permitted to access electrical components.
2. Before using the machine, ensure the transformer voltage is adjusted to match the local power supply. Warning! Before the machine leaves the manufacturer, the connection to the main disconnect switch inside the electrical cabinet is established.
3. The machine requires a three-phase power supply and must be grounded in accordance with local electrical regulations.
4. The machine must be completely isolated from the power supply before any electrical cabinet is opened. The main three-phase power switch must be turned off and clearly marked within the operator's work area.
5. The main power switch must be locked in the "OFF" position using a secure locking device. Note! Even when the main disconnect switch is turned off, live power remains at the incoming main supply line.
6. Warning labels regarding the power supply must be displayed on the machine and control cabinet to alert personnel working on the electrical system.
7. The doors of the electrical control cabinet must be securely closed before the main power switch is turned on and power is restored to the machine.
8. Personnel performing electrical maintenance or inspections must be professionally trained in electrical systems; consult the wiring diagram before commencing work.
9. Supply voltage requirement: ±5%.
10. Protective devices, such as limit switches, must not be short-circuited or bypassed.
11. Installation work must comply with the latest national electrical regulations and undergo comprehensive testing in accordance with those regulations.
Section 4: Safety Measures for Hydraulic Systems
1. This pressure can be measured using the pressure gauge equipped with the hydraulic system.
2. Do not remove any components or equipment from the machine's hydraulic system under any circumstances or system pressure conditions.
3. All high-pressure hydraulic hoses on the machine must be inspected regularly to ensure they remain in good condition. They should be free from severe abrasion or wear. If any high-pressure hose shows signs of rupture or damage, replace it immediately and stop using the machine.
4. All hydraulic components installed on the machine are rated to withstand the system's maximum operating pressure. Any increase in pressure beyond this limit could create a potentially hazardous operating condition and must be avoided.
5. When purchasing oil, ensure that the lubricants and hydraulic oils are non-toxic, and use only the specified oil types to meet required operating conditions.
6. Prolonged contact with organic oils may strip the skin of its natural oils, leading to dryness and localized irritation. Always wear gloves when handling hydraulic oil. Do not ingest hydraulic oil under any circumstances.
7. If oil spills onto the ground during maintenance or when adding hydraulic oil, clean it up immediately or collect the oil in a designated container.
Section 5: Safety Measures for Servo Drives
The servo drives are installed inside the electrical control cabinet. Each servo drive controls an AC servo motor for a specific rotating machine axis (e.g., the feeding axis or bending axis). The status of each servo drive can be verified via its own display. If a drive fails to operate or is overloaded, check its display; it will either be blank or show an alarm message. In such cases, the machine will not operate.
If a servo motor malfunctions, the servo drive's display will show an error code indicating the nature of the fault. In this event, please refer to the instruction manual or contact the pipe bender manufacturer.
1. The servo drives contain high-voltage circuits; do not touch them while the machine is operating. Furthermore, do not disassemble or attempt to repair the machine unless authorized by the pipe bender manufacturer.
2. For a period immediately after the power is cut off, the interior of the drive remains charged with high voltage. If you need to touch the terminal block or the inside of the drive, wait at least 5 minutes after turning off the power before proceeding.
3. The drive, motor, and peripheral equipment heat up during operation; do not touch them. External regenerative resistors, in particular, can reach extremely high temperatures; do not touch them.
4. Even after the power is cut off, components such as the drive's heat sink and regenerative resistors may remain hot; do not touch them. Be sure to disconnect the power supply when the equipment is not in use for an extended period.
5. Internal parameters have undergone safety testing; do not alter them without authorization.
6. Always disconnect the power supply before disconnecting the servo motor wiring.
Section 6: Safety Measures for Mold Installation
Mold installation is a critical task. Installers must possess the professional knowledge required to operate the pipe bending machine and properly adjust the bending molds, as this is essential for ensuring bending quality.
The molds must be compatible with the machine's specifications. Attempting to bend pipes beyond the intended limits can overload the machine, leading to mechanical failure and potential injury to personnel.
Installers must cultivate a strong sense of personal safety and approach the installation process with a safety-first mindset. All installers should recognize the importance of safety—both for themselves and in providing a safe operating environment for others—while performing their work.
1. Do not place hands, fingers, or any part of your body in the mold operating area while the oil pump motor is running.
2. Do not attempt to install, adjust, or move the molds without first reading and understanding the installation instructions in the user manual.
3. Do not wear ties, jewelry, or loose-fitting clothing while working on or near the machine.
4. If a mold is too heavy to lift by hand, use appropriate mechanical lifting equipment. Install a lifting eye bolt on the mold to maintain stability during lifting and transport.
5. Before installation, clean the molds thoroughly to remove dust, metal shavings, and other foreign contaminants. Failure to do so may result in a mismatch of components, potentially causing personal injury or damage to the machine and tooling.
6. When changing control settings for different operations, verify that the selector switch is set correctly. Before commencing the bending process, perform a test run to ensure proper operation.
7. Bending lubricant can make the surrounding area slippery and soil the tooling area; handle the tooling with care. During the bending process, insert the end of the tube—coated with an absorbent material—into the safe and designated working zone of the tooling to prevent lubricant from dripping onto the machine.
8. If the pipe bending machine is idle or unattended—even for a short period—check all switch settings before restarting the machine.
Section 7: Maintenance and Repair
To maintain machine efficiency and safety, an effective inspection and maintenance plan must be established and implemented in accordance with regulations.
The service life of relays, solenoid valves, and other electrical or mechanical components depends on usage, environmental conditions, and the thoroughness of the preventive maintenance plan.
Components may fail at any time due to wear or improper maintenance. Frequent inspections and a robust preventive maintenance plan can reduce the likelihood of failure. Worn or irreparable components must be replaced immediately.
A clean environment around the machine facilitates inspection and maintenance. It is also important to keep the floor surrounding the machine clean and free of debris.
