Case of Innovative solutions

2012.08.24

Type of work ： Long pipe of small dia. STKM11A forφ12.7×t0.8  R25 with no mandrel
Type of machine ： Single Robot Bender, Duel Robot Bender

 

* Application area  ：　pipe bending for Lubrication/pneumatic distribution systems,
  heat-exchanger pipe for refrigerator ,brake and fuel system for vehicles 

 

≪Point of solution≫

New investment or Replacement

・Longer machining tact needed with many bending points
　・Lengthy work piece  (ex 4450mm/overall length)
　・Frequent rotation of work piece causes swinging during machining that are resulted in uｎstable finished design.
　・Some work design needs an operator to support a work piece during machining.
　・An operator always needs to attend a machine during machining. (Client ： H). Automated production is needed..
　・One operator handles all of the bender, loading system and discharging robot.( Client ：M)
　　　→　Floor layout plan needs redesigned be more space-effected
　・Specialty machine is employed with repositionable cylinder built-in for design variation of work piece. (Client ：K)
　　　→　New machine investment is unavoidable whenever product model is changed
　Manufacturing is done by human hands to bend a work piece on the guided tool. (Client ： F)
　　　→　Small daily production output per day. Unstable finished design and high personnel cost are unavoidable.
　・Specialty machine and/or production fixtures needs be long stored for occasional after-market supply.

 

≪Helpful information for selection of bender≫

For selection of bender equivalent to the capacity of the class of type 15 

　・Bender ＋ Loading system ＋discharging robot
　・Single robot bender
　・Duel robot bender(Effective work piece length 5000mmm) +Loading system
　・T-WIN20robot bender + Loading system (To be placed in the control panel9

 

 

≪Advantages of Robot Benders≫

The machines with bending mechanism of new concept

　・The bender itself works for loading a work piece.
　 （Optional loading stocker will help to facilitate full automatic loading system designed for higher productivity.）
　・Post-machining unloading is a part of work by this bender, thus makes unloading device unneeded.
　・Productivity is doubled by enhanced three-axial motion speeds and last bending process executed while a work piece is unloading
　・Thanks to a work piece rotated and bended by the robot, a work piece can stay free or minimized swinging during machining ,
    and stable finished design is secured.  
　・Minimized swinging f a work piece leads to higher machining speed.
　・A work piece with pre-mounted parts can be machined.
　・Elimination of laborious work leads directly to cost cut.
　・Two bending robots start bending simultaneously at both ends (Duel Bender)
　・Interference of a work pieces to the machine and/or floor can be avoided by controlling the positioning of the robot.
　・Machining in design-varied and/or small lot production can easily be met simply by entering the XYZ data in the product drawing.  
　・Thanks to the power of special simulation software employed, on-the-desk but realistic bending check is executed by the off-production site computer. 

 

≪Production effects and advantages by Robot Benders≫

 

With automatic unloading executed, the total machining speed increased to 160% vs that of standard benders.

　・Machining at high- speed and- accuracy is realized for increased daily production output.
　・Space save machines allows more effective layout of shop floor.
　・Automated production directly leads to significant labor cost cut
　・A work piece can be machined with pre-mounted parts of protective hoses and/or stays etc.
　・Thanks to the versatility born in the machine, no particular specialty machine needed for effective production.
　・Full-automation system with conveyor  system has become realistic by setting an end-former, nut feeder, etc,
    in line of pre- and post-process.
　・ By the power of simulation software, pre-production testing can be held with time and materials less needed..
　・Laborious works has become unneeded for setting of three-stuck tooling.

Inquiry contact