The folding of sheet metal can be automated by using a new bending centre from the Swiss manufacturer Bystronic (www.bystronic.com).

This system is designed to reduce production costs, promote accuracy and consistency, and accommodate batch sizes ranging from small runs to large series.

Available in the UK through Bystronic’s Coventry-based subsidiary, the Bending Cell is based on the company’s Xpert Pro press brake, ‘served’ by a seven-axis robot that can handle a wide variety of component sizes and shapes.

Furthermore, a gripper changer, tool changer and magazine, and material storage unit can be either factory-fitted or retrofitted later, allowing not only component handling to be autonomous but also gripper and bending tool exchange
(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.

Furthermore, the cell can accommodate the production of kits of parts needed for a complete assembly; and while the robot is bending, staff can perform other tasks — such as the supply and removal of sheet and parts, or the operation of a laser cutting machine or welding system.

The cell has been designed for ease of use, as both the robot and press brake are controlled using the same touch-screen.

Furthermore, Bystronic’s ByVision bending interface gives the user an overview of the current job status and the remaining production time (as an option, this data can be accessed via mobile devices).

The system also offers a high level of bending repeatability, while 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 shopfloor.

The Bending Cell is available as a turn-key automation solution for Bystronic’s Xpert Pro 100, 150, 250 and 320 press brakes, offering a maximum press capacity of 320 tonnes and bending lengths up to 3m.

Five robot types are available, with handling capacities ranging from 90 to 270kg.

Everything from installation and commissioning to programming and after-sales support — including maintenance, service and future system modification, if required — is provided by Bystronic as the single source.