Automated Bending of Sheet Metal

Folding of sheet metal can be automated using a new bending centre from Swiss manufacturer, Bystronic. It lowers production costs, promotes accuracy and consistency, and at the same time increases flexibility for dealing with batch sizes from small runs to large series.

Bending Cell is available in the UK through the group’s Coventry subsidiary. It is based on the company’s Xpert Pro press brake served by a 7-axis robot that is able to cope with a wide variety of component sizes and shapes.

A gripper changer, tool changer and magazine, and material storage unit may be either factory-fitted or retrofitted at a later time, allowing not only component handling but also gripper and bending tool exchange to be autonomous. The modular system enables existing Xpert Pro machines in the field to be automated.

Intelligent offline programming software saves time by determining the optimal bending sequence for every job. The program for the next order can be downloaded without interrupting the current process. The cell can accommodate production of kits of parts needed for a complete assembly.

While the robot is bending, staff can perform other tasks such as the supply and removal of sheet and parts, or operation of a laser cutting machine or welding system. The cell is simple to use, as both the robot and press brake are controlled using the same touch screen. The ByVision Bending user interface provides the user with an overview of the current job status and the remaining production time, even optionally on mobile devices.

Repeatability of bending is high, ensuring top quality fabrication and assembly. A precise angle measuring system known as LAMS ensures that all critical parameters are compensated during bending, from spring-back to temperature fluctuations on the shop floor.

Bending Cell is available as a turnkey automation solution for Bystronic’s Xpert Pro 100, 150, 250, and 320 press brakes. Maximum press capacity is 320 tonnes and bending length is up to three meters. Five robot types are available with handling capacities ranging from 90 to 270 kg. Everything from installation and commissioning to programming and after-sales support including maintenance, service and future system modification, if required, are provided from a single source.