Unveiling the Key Requirements for Operating a Robotic Press Brake Cell in Fabrication

Renowned for his TV infomercial success and inventive gadgets, Ron Popeil once coined the catchy phrase "Set it and forget it!" to sell his Ronco Showtime rotisserie/barbecue devices by the thousands. While this approach works wonders for kitchen appliances, the realm of robotic bending cells demands a more nuanced understanding. Achieving efficient bending automation in metal fabrication requires dedicated effort and a bit more than a simple "set and forget" attitude.

In 2021, Hickey Metal Fabrication took a leap by incorporating a TRUMPF TruBend 5230 press brake along with a BendMaster 150 robot. This venture marked the beginning of an enlightening journey into automated bending. The experience proved so fruitful that the company is now in the process of installing a TruBend 5170 press brake paired with a BendMaster 60 robot at the other end of Building 7, a fresh addition to their Salem, Ohio campus. The original 5230 press brake holds its position at the opposite end of the facility.

However, this triumph was not an overnight sensation. Hickey Metal invested over a year in meticulously crafting the most fitting parts for their robotic cell, selecting the right employees to operate it, and ensuring seamless integration with their downstream fabrication processes.

Adam Hickey, a vice president of the company, candidly stated, "From a personnel perspective, this poses a challenge. It takes almost half a year to prepare someone to manage this cell." He contrasted this with the relatively shorter span required to train individuals on modern fiber laser cutting machines, which takes merely a couple of weeks. This disparity underscores the complexity of overseeing a sizable robotic press brake cell.

The Genesis of Robotic Revolution

The decision to delve into automated bending arose from Hickey Metal's identification of a range of hefty parts, about 10 to 15 in number, perfectly suited for the capabilities of a robotic press brake. These components, while requiring the attention of two individuals, didn't necessitate the use of a crane throughout the day. The deployment of a crane, if needed, had the unfortunate consequence of slowing down production.

"After thorough scrutiny of these parts, we narrowed down our focus to approximately 10 pieces that, after crunching the numbers, made the best sense for the robotic press brake. We could effortlessly fill the cell with just those items," Hickey explained.

With a lifting capacity of up to 240 lbs, the robot confidently managed tasks such as achieving a 45-degree bend in a 220-lb workpiece. This marked the closest approach to its maximum lifting capacity observed by the company.

Nevertheless, larger parts would have presented equally daunting challenges for human brake operators. Hickey illustrated this with a case of a 115-lb, 102-inch-long steel part requiring five bends, and having to be flipped over and rotated twice during the forming process. Previously, the fabrication of 130 of these parts in a week required manual labor. Now, the robotic assistant has seamlessly taken over.

Safety emerged as the paramount motive for this transformative installation. Hickey elaborated, "Safety is unequivocally the prime reason behind this venture, but it has also bolstered our productivity. For instance, we moved from a scenario where two of our most skilled personnel crafted 40 to 50 units of the [115-lb. part] in a shift to the current state where the robot produces 130 in the same timeframe."

Dedicated to redundancy, Hickey Metal decided to expand their robotic press brake deployment after witnessing its positive impact. The establishment of another cell on the opposite end of Building 7 became a clear path forward. However, this new addition would be primarily tailored to handle lighter parts compared to the initial robotic bending cell.

Nurturing Automation's Blossom

As Hickey Metal readies itself for the launch of their latest robotic bending cell, a young and enthusiastic individual has taken the initiative to acquaint himself with the ropes. Despite limited exposure to metal fabrication, he has invested time into manually bending parts on a press brake, showing promising aptitude. However, the complete independence to operate the cell will only arrive after several months of gradual learning. Mastering the various variables and cultivating the ability to make real-time decisions that maintain a smooth workflow are skills best cultivated on the job, under the guidance of an experienced mentor in the realm of bending automation.

In the interim, Hickey Metal is actively nurturing the growth of their bending automation. While not as intuitively user-friendly as programming a robotic welding cell, their expertise accumulated over decades in the industry has allowed them to forge ahead. Their confidence in automated bending is unshaken, as evidenced by their plans to introduce a third automated bending cell specifically for parts measuring 4 to 5 feet and weighing under 40 lbs.

Nick Peters, Vice President of Hickey Metal, optimistically remarked, "We foresee immense benefits, particularly for repetitive, cyclical tasks. When you're dealing with parts required on a monthly basis, you can entrust those to the robot and let it handle the bending. On the other hand, for smaller orders consisting of just 25 parts, the robot's involvement might not yet be justified."

Though automated bending remains a relatively fresh concept in the landscape of metal fabrication, the path to improvement is clearly visible on the horizon. It is technicians who are passionate and well-informed that will likely expedite the progress for some metal fabricators over others, leading the industry toward a more automated future.

Source : the fabricator (Written by Dan Davis)