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.
Select-stop programmable stroke stop for each step to allow efficient bending of small or narrow parts.
Password protected set-up and supervisor levels.
Operates exclusively with ISB’s MX4200 Safety Light Curtains, either 14 mm or 22 mm detection capability, and a maximum of 10 meters of coverage.
Built-in 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 beams 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
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)
Operates in English, Spanish and French.
How does the 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.
- 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. (see step 1)
- Position the part in place for the next bend and teach the profile with the remote learn foot switch. (see step 2)
- Cycle the press brake.
- Continue until the part is complete. (see step 3)
Step 1
Step 2
Step 3
Floating beam and blanking tolerance.
What if a bending step does not have a flange and the part does not consistently block a beam?
- The floating is automatically enabled when needed.
- The floating beam function allows up to 3 beams.
- The 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 a numeric code, usually a drawing number.
How does the Merlin 4000 allow part movement during bending? Simple... built in muting.
Merlin 4000 is interfaced to the machine control to receive signals when the ram is at the top position and at the mute point (usually 6 mm above the pinch point). Once at the mute point, 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.
The Merlin 3000 series press brake guarding system as of January 31, 2021 will be discontinued.
Replace parts for the 3000 series subject to component availability.
If you need replacement parts, contact us about the price and availability.
Press brake side guards
Press Brake Side Guards
We offer custom-fabricated welded steel square tube swing side guards equipped with light curtain mounting brackets. These guards are fully adjustable and feature swing side panels to facilitate efficient die changeovers. Each panel includes clear Lexan infills to maximize visibility. All units are finished in standard safety yellow powder coating for enhanced durability and compliance.
Press Brake Rear Guarding offers effective protection for the rear access area of press brakes, reducing risks associated with unauthorized entry and enhancing safety for personnel in hazardous zones.
Our steel mesh panels are equipped with electrically interlocked doors, preventing machine operation whenever a guard door is open.
To configure and price your guard, simply contact us .
Featuring robust construction and a built-in safety interlock, this rear guard provides OSHA compliance while ensuring convenient access for maintenance and routine operations.