Automated Sheet Metal Bending Cell with Integrated Magazine
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Solution Overview
Problem
Current automated sheet metal bending cells lack the autonomy and productivity to operate without human assistance for extended periods, limiting their efficiency and profitability, especially in comparison to cutting machines which have achieved higher levels of automation.
Innovation Solution
An automated sheet metal bending cell with a spatial and functional organization that includes a press brake, bending robot, rail, mechanical or optical indexing system, automated magazine, and fully automated means for conveying and storing parts and tools, enabling the cell to operate independently for 48 hours or more by integrating with an automated magazine for supply and drop-off areas.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Extent of automation
If conventional press brakes are operated manually with operator control, then flexibility and adaptability are maintained, but productivity and autonomy are limited by human intervention requirements
Solution Approach 1:
The system is divided into distinct functional modules: automated magazine for material storage, robotic manipulator for tool handling, press brake for forming, and control system for coordination. Each module operates semi-independently, allowing high automation while maintaining manageable complexity through modular design.
Solution Approach 2:
The automated magazine serves multiple functions: storing blank sheets, storing bent parts, and providing a buffer between supply and production. The robotic system handles both tool changing and part removal. This multi-functionality reduces the number of separate systems needed, balancing automation with complexity.
2Productivity
If automated magazine integration is implemented, then productivity and continuous operation are improved, but device complexity and initial investment increase
Solution Approach 1:
The automated magazine pre-stores multiple blank sheets and bent parts before production begins. This preliminary preparation allows the press brake to operate continuously without waiting for material supply or part removal, significantly boosting productivity while the magazine manages the complexity of material handling.
Solution Approach 2:
The automated magazine acts as an intermediary buffer between material supply and the press brake operation. It decouples the production rate from material handling speed, allowing the press brake to operate at optimal speed while the magazine manages material flow, thus improving productivity without proportionally increasing system complexity.
3Loss of time
If robotic manipulator with tool magazine is used, then assembly and disassembly times are reduced, but device complexity and cost increase
Solution Approach 1:
The robotic manipulator provides dynamic, programmable tool changing capabilities. Instead of fixed tooling arrangements, the robot can quickly swap between different punches and dies based on production requirements. This dynamic adaptability reduces setup time while the programmable control manages the complexity of tool management.
Solution Approach 2:
The manual mechanical process of tool changing by operators is replaced with an automated robotic system. The robotic manipulator uses grippers and programmed movements to remove and install tools, dramatically reducing assembly and disassembly time. The complexity is managed through automated control systems that coordinate the robotic movements with the press brake operation.
4Duration of action of moving object
If fully automated operation for 48 hours is achieved, then autonomy and productivity are significantly improved, but device complexity and operational requirements increase
Solution Approach 1:
The system maintains continuous operation through coordinated automation: the automated magazine continuously supplies blanks and receives bent parts, the robotic manipulator continuously changes tools when needed, and the press brake continuously forms parts. This uninterrupted workflow achieves 48-hour autonomy while the integrated control system manages the complexity of coordinating all automated functions.
Solution Approach 2:
The control system incorporates feedback mechanisms to monitor the status of the automated magazine, robotic manipulator, and press brake. This feedback enables automatic adjustment and coordination of all systems to maintain continuous operation. The feedback loops manage the complexity by allowing the system to self-regulate and coordinate multiple automated functions without proportionally increasing operational complexity.
Data Source
AI summary
An industrial installation having an automated sheet metal bending cell and an automated magazine, having a spatial and functional organization for automating flows of materials entering and leaving the cell, aimed at increasing, in a reduced enclosure, autonomy of operation of the cell without human assistance, as well as flexibility and productivity of the cell, the installation including: a press brake; a bending robot; a rail, generally called a “track,” on which a carriage supporting the robot moves; a system for dropping off and retrieving parts during operation; a mechanical or optical system for controlling indexing of parts to be bent; a magazine or a set of racks for bending tools comprising punches and dies; at least one attachment device for grippers; a programming and monitoring system for the press brake; a control console; an automated magazine; and a supply area for parts to be bent.