The sheet metal processing industry is under pressure: The production costs must be kept low without affecting quality. Simultaneously, the increasing variability of shapes, dimensions, and batch sizes demand an ever higher degree of flexibility. Companies that want to remain competitive have to increase the flexibility of their processes and above all, they also have to automate. Bystronic’s Bending Cell achieves both at the same time.
The fully automatic Bending Cell offers a maximum degree of efficiency and flexibility for both small and large manufacturing companies. The Bending Cell is just as ideally suited for the processing of long job lists as for changing orders – from small batches right through to large series. In combination with the tried and tested Xpert press brake, the agile robot processes bending jobs fully automatically and without errors.
Save time thanks to automation
The Bending Cell reduces manual interventions to a minimum and makes the most of the available resources. The 7-axis robot not only autonomously changes the grippers and bending tools, it also knows how to process the job most efficiently: The intelligent software autonomously determines the optimal sequence of the bending tools for every job list. This saves up to 30 percent of the processing time.
After the initial offline programming, the Bending Cell operates completely autonomously. While the robot is bending, operators can perform other tasks, for example the supply and removal of sheet metal and parts or operating a laser cutting system or welding system. Night shifts consisting of changing jobs with different parts are no problem for the Bending Cell. It can also handle kit production, which entails recurring cycles during which all the parts for a complete product are produced.
Operating the Bending Cell is remarkably simple, because both the robot and the press brake are controlled using the same touch screen. The ByVision Bending user interface always provides the user with an overview of the current job status and the remaining production time, upon request also on mobile devices. Data for new jobs can be imported without interrupting the running production process.
Repetition accuracy for perfect parts
The quality standards in the sheet metal processing industry are high. Angle errors even of a few tenths of a degree can result in customer complaints. However, thanks to the Bending Cell’s very high degree of repetition accuracy, nasty surprises during the quality control are a thing of the past: The first part is just as perfect as the thousandth.
The Bending Cell reliably implements the parameters that are programmed offline. The extremely precise LAMS angle measuring system ensures that all the critical factors are compensated during the bending process – from diverging spring back factors of the processed sheet metal through to temperature fluctuations in the production hall. Thanks to the logging of the final angles by the software, quality control is an integral part of the Bending Cell
Modular design for increased flexibility
Changing order situations demand flexible automation solutions. The Bending Cell’s modular design ensures a high degree of flexibility and availability. In addition to the Xpert press brake, the fully equipped version consists of a robot with gripper changer, tool changer, a generous material storage unit, and a tool magazine. The individual modules can also be purchased separately in order to upgrade the system depending on the user’s requirements. Thus, the gripper changer and tool changer or the material storage unit and the tool magazine can be integrated at a later time.
This modular design allows the Bending Cell to be individually adapted to the requirements of the production environment, also in terms of performance. Five different robot types are available with lifting capacities ranging from 90 to 270 kilograms. The automation solution is available for the Xpert and Xpert Pro 100, 150, 250, and 320 press brakes. This means that the maximum press capacity is 320 tons, and bending lengths up to 3 meters are possible. Users who already own an Xpert can simply upgrade it with the automation solution at any time.
