Automated Sheet Metal Bending Cell With Self-Managed Tool Handling
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Solution Overview
Problem
Current robotic bending cells in sheet metal factories lack the autonomy to operate without human assistance for extended periods, limiting their productivity and flexibility, especially in producing small recurring series that require a variety of bending tools and grippers, and are hindered by inefficient tool management and handling processes.
Innovation Solution
An automated sheet metal bending cell system integrated with an automated store, featuring fully automated means for transporting and evacuating parts and tools, optical recognition for indexing control, and a compact architecture that allows for long-term operation without human intervention, ensuring the availability of necessary tools and grippers within the cell.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If automated bending cells are equipped with tool magazines and automated tool changing systems, then operator comfort and setup time reduction are improved, but the cost increases significantly and the return on investment is difficult to assess
Solution Approach 1:
The robotic cell is designed to perform multiple functions including bending, tool changing, and part handling with a single integrated system. The robot can grip different tools and perform various operations, making the system versatile and reducing the need for multiple specialized machines.
Solution Approach 2:
The system enables automated tool changing and part handling without operator intervention. The robot autonomously performs tool magazine operations, gripper changes, and part loading/unloading, allowing the cell to service itself during operation.
2Extent of automation
If panel bending machines are used, then automation level is improved, but implementation possibilities are limited to less than 5% of parts
Solution Approach 1:
The system uses a robotic cell with dynamic reconfigurability. The robot can adapt its gripper and tool selection based on the specific part geometry and bending requirements, allowing it to handle a wide variety of parts rather than being limited to fixed automation for specific part types.
Solution Approach 2:
The system changes operational parameters such as gripper type, tool selection, and robot path based on the part being processed. This allows the same hardware to adapt to different part geometries, materials, and bending specifications, greatly expanding implementation possibilities.
3Adaptability or versatility
If apron press brakes are used, then forming capabilities are improved, but the presence of an operator is essential and automation is limited
Solution Approach 1:
The system separates the forming function (press brake) from the handling and tool management functions (robot). The robot handles tool changing, gripper changes, and part loading/unloading, while the press brake focuses solely on the bending operation, enabling full automation without operator presence.
Solution Approach 2:
The robotic system acts as an intermediary between the operator and the press brake. It automates the intermediate tasks of tool management and part handling, allowing the press brake to operate fully automatically while maintaining the versatility of apron press brakes.
4Adaptability or versatility
If conventional press brakes operated by human operators are used, then flexibility and cost-effectiveness are improved, but productivity and operational burdens are limited
Solution Approach 1:
The system merges the flexibility of conventional press brakes with automated robotic handling and tool management. This combination maintains the adaptability of operator-controlled press brakes while eliminating operational burdens through automation of repetitive tasks like tool changing and part handling.
Solution Approach 2:
The automated system enables continuous operation without the interruptions caused by manual tool changing and part handling. The robot can perform these tasks during machine cycles or between bends, maintaining continuous productive action and eliminating operational burdens.
Data Source
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AI summary
The present invention relates to a method for operating an industrial plant comprising an automated store as well as an automated sheet metal bending cell (1), with a view to significantly increasing the operating autonomy of the cell without human assistance, as well as the flexibility and productivity thereof.