Justifying a Robot in Your Metal Forming Applications

While the operator performs a setup on one of the machines, the other three machines are producing parts. By the time the first machine is set up, the second machine may be ready for a setup change and so on. By utilizing automation, the employee becomes more efficient and is able to diversify his or her training, including having the capability to program the robots.

The programming of a robotic press brake system has become easier over time. Most of the programming is done offline (or away from the machine). This allows the programmer to keep the machine producing parts while a new part is programmed.

Utilizing a standard library of operations, the operator simply picks the functions such as picking, turning, bending, positioning and palletizing from the library. The robot can also sense whether it has picked up two parts instead of one, and can detect a faulty part that it will set aside and continue operating without interruption.

INTEGRATION SUCCESS
Ellison Technologies Automation (Council Bluffs, IA) has automated a press brake system that had previously been tended manually. The example video shows the operator demonstrating a 40 second process cycle, requiring (5) 8-hour days (40 hours) to process the weekly requirement of parts.

The robot operates on an 80-second cycle (twice) and completes the same weekly part requirement in (2.5) 8-hour days (20 hours). The robot takes twice as long per part but completes the total part requirement in half the time using the same hours available to the operator (the robot works through lunch and breaks).

Do not over-emphasize process cycle times when evaluating robotics. Instead, the shop needs to understand that with robotic automation, the throughput from the work cell is what really matters. In addition, while labor savings contributes greatly to the return on investment, the profits from the sale of the additional parts produced impacts the bottom line.

This is a great example of increasing machine utilization through robotic automation.

The photo to the right shows a system that was installed that contains two press brakes, each set up to form different portions of the same part. The robot is track-mounted, increasing its work envelope and providing multiple station access.

This system is the only known robotically-tended dual brake production cell. This work cell also provides multiple inbound blank storage stations providing quick changeover capability, and the execution of multiple part number runs, or kitting. Please note that Robowave software allows Ellison to easily program and control powerful work cell configurations.

SOFTWARE
RoboWave bending off-line programming is a complete solution dedicated to robotized bending processes, such as verifying cell layout feasibility and 3D simulation.

Efficient off-line programming is the best way to maximize investment returns of robotized system, including:

• Reduced time for cell configuration and programming activities
• No production stops during programming and cell configuration
• No risks for cell layout configuration
• Immediate integration with press brakes and robots
• Higher quality – time and production quantity independe-nt

The decision to automate is a question that most North American manufacturers have faced or will have to face in the near future. Understanding everything that goes into automating a process and more importantly, recognizing all of the benefits that the automation brings will hopefully make the decision much easier and successful.

[1] North American Robotics Market Sets New Records in 2012; Robotics Online, posted February, 5, 2013, www.roboticsonline.com.

FANUC Robotics America, 3900 W. Hamlin Road, Rochester Hills, MI 48309-3253, 248-377-7570, www.fanucamerica.com.

Ellison Technologies Automation, 2906 21st Avenue, Council Bluffs, IA 51501, 712-388-6300, www.ellisontechnologies.com.