Opton product delivered：WIN Robot Bender G-WIN100 System

【New installation】：Loader/stocker for parts assembly, Automatic 3D profiler for external shape

1.Current production problem

   ①Many parts of driving- and control-system of pipe bender are getting old or worn.
     With frequent machine failure and/or replacing parts discontinued, product
     accuracy and scheduled production are becoming hard to maintain.

   ②Daily set-up counts as many as 13 times in frequency and 3.5 hours in time,
     causing poor production efficiency.

   ③Current production system is rather large scaled with heavy tooling and work pieces
     involved, and this often gives an operator heavy and risky duty.

   ④Nipple-insertion is needed in the process right before machining to be started.
     At this pre-machined stage,the production machine is kept stopped,
     bringing the 8H daily runtime efficiency down to 30% or less.

   ⑤Bending is trusted to sub-contractor at the cost of tens of millions yen per annum,
     affecting bad to profitability.

   ⑥Sampling inspection is observed but is not successfully functioning when the
     production causes varied quality output of work pieces.   

 

 2.The points to be achieved and the conditions to be overcome.

   ①Two alternative choices existing, new investment for an entire production line,
     or remodeling of the machine currently in service by replacing failed parts
     with available equivalents to refresh driving-, control- and mechanical systems.
 
   ②Set-up frequency and time need be decreased.

   ③Heavy-weight work piece needs be handled by robot t not by an operator to keep
     him away from danger.

   ④Nipple insertion needs be processed while the machine is running.

   ⑤New facility needs be invested to make bending at the client's in-house facility.

   ⑥Inspection needs be paid to all production pieces with simplified but quick verification.

 

3.Opton's proposal for solution

  ①Features of the proposed production system

    Opton has invented the original robot bender that performs pitching and rotation
    of a work piece plus many other operator jobs that including dangerous and/or heavy
    works. By this production system can be totally reviewed for a new and simplified
    and labor?saving production system yet with enhanced performances that could not
    be achieved in the traditional production style.
 
  ②Itemized summary of the proposal 

    １－①：Because of the system newly introduced to the line, parts and components
            of the latest quality available in the standard market are employed as many
            as possible but with the least employment of those of special features.
            Thanks to this, most machine fault except physical ones are normalized by
            software changes,thus leading to easier maintenance than before even by
            client himself.

    １‐②：Thanks to the minimized size and more simplified travelling routes of the
            bender having been achieved,5-stucks of tools can be mounted. Thus, one
            production case with as many as 13 frequent tooling set-up per day now
            only needs twice or tripled frequencies. Tooling set-up time should possibly
            be reduced remarkably if 5-stuck tooling capacity is fully enjoyed.

    １－③：By implementing external facilities to supply/collect the molds, safe and
            easy tooling set-up can be held even when the machine at its operation,
            and with set-up time being remarkably reduced.

    １－④：Thanks to the robot performing loading/unloading of work pieces, an operator
            can stay freed from his personal handing of those heavier than 20 kg,
            This will make an operator less-involved in dangerous and heavy-duty works.
            Because of the machine running long and steady, the production can be easily
            planned for steady output.

    １－⑤：As the loading and unloading stocker being facilitated to the production system,
            the production continues automatically as long as work pieces being supplied
            with the part nipple being mounted to the work pieces before-hand.

    １－⑥：To machine high-tensioned thickness material like for steering parts, standard
            benders normally causes faulty production from poor sliding of clamp die due to
            limited specifications given to clamp- and pressure-dies. To overcome this,
            mechanical rigidity has been increased of clamp- and pressure-die to meet stable
            machining of high-tensioned thick material.

    １－⑦： By connecting 3D profiler sensor camera to the production line, 3-dimensional
             testing can be made against old version restricted to plane inspection only.
             With the profiler power-enhanced for quick OK/NG judge over the measured data,
             all production volume are now tested in line for quality inspection 

4.Expected benefit from the system employed

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