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MOTOMAN®

Robotised press-brake operation

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Press-Brake System 3000/50 and a MOTOMAN UP-50 picking up sheets from an inpallet table. With automatic pickup it is possible, in spite of a sheet separating function, that two or more sheets are picked up at the same time. If the inpallet table is equipped with a double sheet control (shown to the left) such mistakes are easy to prevent.

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Press-Brake System 3000

Robot + press brake machine = increased productivity!

ProductivityRobotised press-brake operation will, in the long run, have a much higher production capacity than manual operation. Since the robot is working within a safe zone it will be possible to run the press at top speed, something that cannot be done with manual operation.

In order to maintain productivity when introducing new products, the standstill can be reduced by using Motoman’s predefi ned macro jobs and special software for offl ine pro-gramming.

A robot in the cell also means that a heavy, monotonous and perhaps risky task is removed from the staff ’s duties and they become robot operators instead. This is often a positive

change which increases motivation.

FlexibilityThe robot equipment from Motoman is designed for quick changes between different sheet dimensions.

The grippers can be made from standard aluminium profi les and this makes them easy to design when new products are introduced.

By mounting the robot on a servo powered robot turntable its working range in front of the press is increased. Regardless of the sheet’s size the robot can always fi nd the best position for every bend.

This means that both small and large sheets can be handled in the same cell. The increased working area also means that the press’ whole bending length can be used for bending.

Profi tabilityGenerally speaking, the larger the sheets and more bends the better profi tability in the plant. However, the smallest robot cells are designed to be profi table even for sheets with small dimensions.

A good rule of thumb is that the products to be manufactured in the cell should be a recurring production and then in batches of between 30 and 200 sheets (depending on sheet size and the number of bends).

If the opportunity for unmanned operation is used, the press brake cell will become profi table even faster. To increase the productive time in the cell during unmanned operation it is a good idea to add a system of conveyors for the fi nished products.

The increased quality, which is a result of the robot’s exact movements, also leads to higher profi ts as the number of products that needs to be discarded is diminished.

Motoman’s turnkey system with robotised press-brake operation. The turnkey systems have different options for collecting sheets and placing the fi nished products on pallet or roller conveyor.

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RobotThe Motoman robot family contains six axes servo controlled robots with a maximum payload capacity up to 500 kg. Suit-able robots for press brake applications are available with a maximum payload capacity, including gripper tools, from 6 to 200 kg.

In order to increase the robot’s reach a seventh axis, a servo powered turntable, is usually integrated to the control system. It increases the reach with up to 1100 mm and enables the robot to fi nd the ultimate position for each bend.

Work cycle

Press brake machineThe robot and press brake machine communicates during the bending with an exchange of signals. The robot controls the press’ movements and receives information from it, e.g. that the workpiece is in contact with the back gauge.

Motoman has experience with press brake systems and machines of the most common brands *) on the market: Amada, Beyeler, Darley, Edwards Pearson, Gasparini, Guifi l, LVD, Safan,Trumph and Ursviken.

1. The robot picks up a sheet from the inpallet or sheet magazine.

2. At the orientation table the workpiece is automatically positioned before bend-ing.

3. The robot takes the workpiece to the press and the bending sequence starts.

4. The regrip station, in front of the press, is used when the robot needs to change its grip between different bends.

*) The press brake’s interface must be approved by Motoman.

Robot and press brake machine

5. When the bending is complete, the robot places the fi nished workpieces in a desired pattern on a pallet or conveyer.

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Servo powered turntableThe turntable increases the robot’s reach with up to 1100 mm. Longer workpieces can be handled, and the whole press’ bending length can be used. It enables the robot to fi nd the optimal distance from the press in every moment. The turntable is integrated into the control system.

Orientation tableEquipped with a roller chain which quickly orients the sheet and a sensor which indicates when the it is in correct posi-tion. For sheet thickness from 0.7 to 14 mm. Available in width from 500 to 4000 mm and tilted to the left or right.

Regrip stationAdjustable regrip station built in modules from aluminium profi les and furnished with magnets, adjustable reference stops and built-in position meters. Can be supplied with extra support and grippers, separate vacuum cups for small sheets and fl oor fastener.

Sheet magazine (rotating)A rotating sheet magazine with two stations, for small sheets. The table can be loaded while the cell is in operation, the change of station is performed manually. It has magnetic separators and adjustable for sheet dimensions up to 500 x 500 mm.

Sheet magazine (two- or three sections)Magazine table for small sheets with adjustable magnetic sep-arators and a built-in scale. A small orientation table for small sheets is situated below the table. The table handles sheets in dimensions up to 800 x 500 mm (two section) and 500 x 500 mm (three sections).

Inpallet tableAdjustable side guides and sheet separating with magnets or brushes and air. The table is designed for loading with forklift truck or a truck with supporting beam. Available in width from 1500 to 3000 mm. Double sheet control equipment as an option.

Other equipment

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GripperThe robot’s gripper is built by standard aluminium profi les and this makes them easy to design or modify to a low cost.Quick plug-in contacts for electricity and air makes it easy to change between several grippers. The grippers have an inductive sensor which reacts to the closeness of metal, this function is used when searching for a new pile of sheets. Each gripper has two vacuum zones and single vacuum cups can be turned off. This makes it possible to handle sheets of different dimensions.

The gripper can be equipped with electric magnets or gripper fi ngers instead of vacuum cups. These are necessary when handling perforated sheet or other materials where vacuum cups are unsuitable.

An automatic tool changes is an optional accessory. It can be practical if products of different dimensions are manufactured simultaneously.

It is easy to change from one gripper to another with the plug-in contacts for electricity and air.

A productions which consists of many articles of varying sizes, makes it necessary to have several grippers. It is important that these can be manufactured as simply and economically as possible.

Other equipment

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Sheet feederLetting the sheet feeder pick up and transfer sheets from the inpallet table to the orientation table helps reduce the cell’s cycle time. The robot is freed from that particular task and can concentrate on the bending sequence.

The sheet feeder is designed to fi t into the Motoman standard system for robotised press brake operation. It is integrated into the robot’s control system.

The vertical movement is performed by a cylinder equipped with piston rod brake which quickly brakes the movement both going up or down. The gripper has three vacuum zones and it is possible to turn off certain vacuum cups which makes the gripper adjustable to different sheet dimensions.

The sheet feeder can handle sheets with a dimension from 400 x 400 mm to 2500 x 1250 mm. It manages a maximum sheet weight of 35 kg.

When not in use, it can be put into a parking mode which lets the robot pick up the sheets from the inpallet table by itself.

1. The sheet feeder picks up a new sheet from the inpallet table.

2. With a quick twist the sheet feeders transfers the sheet to the orientation table, while the robot is busy at the press.

3. The orientation table is tilted into orientating position, from which the robot collects the sheet and takes it to the press.

Other equipment

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MotoPBMThe software is designed for programming and testing robot jobs for press brake applications offl ine. The offl ine program-ming leads to less standstill and an opportunity to minimise cycle times which makes the production much more effi cient. By knowing beforehand the cycle time it is possible to calcu-late with the manufacturing costs for certain products in the cell.

The cell’s stations can be chosen from ready made models included in the software. New grippers, punches, dies and some stations can also be created or modifi ed.

Drawings of the workpiece is imported as 2D-fi les. Bend lines and bending information are then added in MotoPBM.

The cell can be generated either from draw-ings or by using reference points in an exist-ing cell.

Robot jobs are automatically generated and the result shown as a simulation in MotoSim, which is included. The fi nished job can then be downloaded to the robot’s controller.

MotoSim is a tool for offl ine programming and real time simulation in 3D environment. Being integrated in MotoPBM it makes it possible to test the robot jobs offl ine and make adjustments before downloading to the cell.

The robot job is visualised as a simulation in MotoSim. This is also a chance to make changes before the job is downloaded to the robot cell.

A 3D-preview makes it easier to create gripper tools.

Offl ine programming

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Press-Brake System 3000/6

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1. MOTOMAN industrial robot2. Robot controller3. Sheet magazine table (rotating)4. Orientation table5. Regrip station6. Press brake7. Outfeed pallet8. Outfeed pallet with small belt conveyor9. Interlocked service door10. Operator’s panel

Required fl oor space approx. 4x4 meter

The alternative with a small conveyor is particularly suitable for small workpieces that can be dropped into a pallet with a collar.

Press-Brake System 3000/6Turnkey system for robotised press brake operation with MOTOMAN industrial robot UP6. The smallest standard cell, well designed for optimal effi ciency when bending small prod-ucts. Suitable press bending length is 1.2 to 2 m.

Incoming sheets are fed from a rotating sheet magazine table.Finished products can be placed on a pallet, or a small belt conveyor down to a Euro-pallet with a box. The latter is very practical for small products where a placing pattern is not required.

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1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake 8. Pallet9. Interlocked sliding door10. Operator’s panel


Press-Brake System 3000/20Turnkey system for robotised press brake operation with MOTOMAN industrial robot UP20. A system for a produc-tion mainly of smaller details but where larger sheets are handled occasionally. Several options enables the cell to be tailor-made to the production. Suitable press bending length is 2 to 3 m.

Incoming sheets are fed from a pallet or sheet magazine. Finished products can be placed on a pallet, on the fl oor or on a PLC controlled roller conveyor.

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1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for Euro-pallet (without collar)9. Infeed magazine (max 15 pallets)10. Interlocked sliding door11. Operator’s panel

Required fl oor space approx. 9x7.5 meter(including conveyer)

1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for Euro-pallet (with or without collar)9. Interlocked sliding door10. Operator’s panel

Required fl oor space approx. 10x7.5 meter(including conveyer)

The large conveyor has room for six fi lled Euro-pallets without collar.Infeed magazine for 15 empty pal-lets.

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UP501

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1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for EUR-pallets

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Required fl oor space approx. 10x8.5 meter (including conveyer)

The roller conveyor has room for up to four fi lled Euro-pallets without collar, or three fi lled Euro-pallets with collar.

Press-Brake System 3000/50Turnkey system for robotised press brake operation with MOTOMAN industrial robot UP50. A fl exible system with several options that makes it very adaptable. Both small and large workpieces can be effi ciently produced in the same cell. Suitable press bending length is 2.5 to 4 m.

Incoming workpieces from pallet or sheet magazine. Finished products can be placed on a pallet, on the fl oor or on a PLC controlled roller conveyor.

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1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for Euro-pallet (Without collar)9. Infeed magazine (max. 15 pallets)10. Interlocked sliding door11. Operator’s panel

Required fl oor space approx. 9x8 meter (including conveyor)

Press-Brake System 3000/50, with the rotating sheet magazine. The magazine has two stations and can be loaded while the cell is in operation.

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Press-Brake System 3000/130, -165

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Press-Brake System 3000/130 and 3000/165Turnkey system for robotised press brake operation with MOTOMAN industrial robots UP130 or UP165. The biggest standard cell for large and heavy workpieces. The UP-robot’s mobility means that the cell maintains the fl exibility of the smaller systems. Suitable press bending length is 3 to 4 m.

Incoming workpieces from infeed pallet. Finished pro ducts can be placed on a pallet, on the fl oor or on a PLC controlled roller conveyor.

1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Pallet9. Interlocked sliding door10. Operator’s panel


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Press-Brake System 3000/130, -165

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1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for Euro-pallet

(without collar)9. Infeed magazine (max. 15 pallets) 10. Interlocked sliding door11. Operator’s panel


1. MOTOMAN industrial robot2. Robot controller3. Servo powered turntable4. Inpallet table5. Orientation table6. Regrip station7. Press brake8. Roller conveyor for Euro-pallets

(with or without collar)9. Interlocked sliding door10. Operator’s panel


®

Motoman Robotics Europe ABBox 504, SE-385 25 Torsås, Sweden Phone: +46 (0)486-488 00 · Fax: +46-(0)486-414 10www.motoman.se

a YASKAWA company

Group Companies: France: MOTOMAN Robotics, Nantes +33-2-40131919, Germany: MOTOMAN Robotec, Allershausen +49-8166-90-0 • MOTOMAN Robotec, Frankfurt +49-6173-6077-30, Great Britain: MOTOMAN Robotics, Banbury +44-1295-272755, Italy: MOTOMAN Robotics, Modena +39-059-280496, Netherlands: MOTOMAN Benelux, Breda +31-76-5424278, Portugal: MOTOMAN Robotics Iberica, Aveiro, Slovenia: RISTRO, Ribnica +386-61-861113, Spain: MOTOMAN Robotics Iberica, Barcelona +34-93-6303478, Sweden: MOTOMAN Robotics Europe, Torsås +46-486-48800 • MOTOMAN Mecatron Robotic Systems, Kalmar +46-480-444600

Distributors: Czech Republic: MGM Spol, Tabor +420-361-254571, Denmark: Robia, Vejle +45-79428000, Finland: Robia Suomi, Turku +358-22145600, Greece: Kouvalias Industrial Robots, Kallithea +30-1-95892436, Hungary: REHM Hegesztéstechnika, Budapest +36-30-9510065, Israel: KNT Engineer-ing, Kfar Azar +972-39231944, Norway: Robia, Hokksund +47-32252820, South Africa: Robotic Systems, Bertsham +27-114943604, Switzerland: Geiger Handling, Schwarzenburg +41-31-7343111 • Messer SAG, Dällikon +41-18471717

Reg. 9C

-04-02-02 INT

MOTOMAN - Pagrindinis | profibus.lt · much higher production capacity than manual operation. ......

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