Page 31 - MetalForming August 2019

er press brakes provide the flexibility to form any part in a production environ- ment, design criteria for these machines have never considered operator com- fort. On the other hand, press brake manufacturers have considered oper- ator comfort in designs of smaller press brakes—usually electric and incorpo- rating less than 60 tons of pressing force.
These machines are the first of their kind to not only focus on machine speed and efficiency, but factor in oper- ator ergonomics and functions that aid in daily production routine. Design elements in these smaller press brakes mimic those traditionally considered for people working in office environ- ments and in front of computers. Con- siderations such as posture, lighting and temperature greatly impact the daily productivity of employees. Now, fabricators are integrating these design requirements on their press brakes. A common sight: a couple of large hydraulic press brakes paired with a small ergonomic press brake, with the small brake usually the most sought- after machine on the floor.
Design Improvements Target Physical, Mental Fatigue
Running a press brake for hours is exhausting work, especially when standing, which makes posture a crit- ical design consideration. Seated oper- ation represents the most innovative change in press brakes, with newer machines designed to split between seated and standing operation.
This arrangement has greatly alle- viated back pain—a constant struggle for operators—as well as fatigue across a shift. The ability to sit and stand inter- mittently fits well with American Indus- trial Hygiene Association (AIHA) advice: “You need to move and change posi- tions regularly throughout the day. Flex, extend and wiggle your legs. This will greatly reduce the risk of lower back pain and injury.”
Seated operation also has been cou- pled with adjustable tables, seats and footrests. Small adjustments allow operators to find the ‘sweet spot’ of optimal comfort. The goal of the adjust-
ments: Obtain an ideal posture with neutral arm position, as this position has been proven to reduce fatigue and long-term injuries. As described by the Cornell University Ergonomics website, in a neutral arm position, “the elbow position is open to promote circulation to the lower arm and hand. This posi- tion also is ideal to minimize static and dynamic loads in the arms and hands.”
Lighting represents an often-over-
looked ergonomic feature on press brakes. Operators are required to hit the same backgauge positions repeatedly throughout a shift. Poor lighting makes this task almost impossible. Dimly lit work areas cause eye fatigue and headaches—such mental fatigue is just as potentially harmful as muscle fatigue.
Easing the process for operators helps ensure that they stay sharp, thus reducing mistakes and scrap rates. A
Fabrication: Press-Brake
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