Automated Sheet Folding Cell With Modular Tool Storage
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Solution Overview
Problem
Current sheet metal forming machines, particularly robotic bending cells, lack the autonomy and productivity to operate continuously without human assistance, limiting their efficiency and profitability, especially in producing small recurring series with diverse bending tools and grippers.
Innovation Solution
An autonomous installation comprising an automated sheet metal bending cell coupled with an automated store, featuring modular and interchangeable storage elements, including metallic attachment walls, perforated fixing plates, and a system for automatic supply and evacuation of parts and tools, utilizing AGVs and optical recognition for enhanced automation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If robotic bending cells are automated to operate without human assistance, then productivity and continuous operation capability are improved, but device complexity and initial investment cost increase
Solution Approach 1:
The automated bending cell is divided into distinct functional modules: robot manipulator, press brake unit, tool magazine, gripper storage system, and control system. Each module operates independently but coordinates through standardized interfaces, allowing the complex system to be managed as separate manageable units that can be maintained and replaced individually
Solution Approach 2:
The system employs universal tooling interfaces and standardized gripper mounting systems that allow different tools and grippers to be used on the same machine through the automated tool change system. The press brake is designed with universal tool holder configurations that accommodate various bending tools without requiring machine modification
2Adaptability or versatility
If a wide variety of bending tools and grippers are stored in the automated system, then adaptability to different parts is improved, but device complexity and storage space requirements increase
Solution Approach 1:
The tool magazine and gripper storage system are designed with dynamic retrieval capabilities where tools and grippers can be automatically fetched and delivered to the press brake and robot respectively. The system adapts its tool selection and retrieval sequence based on the specific bending operation requirements, optimizing the workflow for different part geometries and tool combinations
Solution Approach 2:
An automated tool change system acts as an intermediary between the tool storage magazine and the press brake, and similarly between gripper storage and the robot. This intermediary mechanism handles the complex tasks of tool identification, retrieval, mounting, and calibration, simplifying the overall system architecture while maintaining high versatility
3Productivity
If the system operates fully autonomously for extended periods, then productivity is improved, but reliability requirements and maintenance needs increase
Solution Approach 1:
The system performs preliminary tool changes and gripper exchanges during idle periods or between production batches, preparing the next required tools in advance. The control system pre-loads the tool magazine with required tools based on the production schedule, and the robot is pre-equipped with appropriate grippers for upcoming operations, minimizing downtime and maintaining continuous productivity
Solution Approach 2:
The automated bending cell incorporates self-diagnostic and self-maintenance capabilities where the control system monitors tool wear, gripper condition, and machine parameters in real-time. The system automatically adjusts operating parameters to compensate for tool degradation and can identify when maintenance is required, allowing extended autonomous operation while maintaining reliability
Data Source
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Figure 3A
AI summary
The invention relates to a stand-alone facility, consisting of an automated sheet-metal-bending cell (1) and an automated warehouse comprising: walls for securing tools (7), said tool-securing walls each comprising a rigid panel provided with a grate having perforations arranged at a regular pitch, and support structures for holding the securing walls.