A Practical Four-Side Bending Application
Four-side bending can become challenging when the workpiece is large, repetitive and requires multiple repositioning operations.
The operator must maintain accurate positioning while repeatedly moving the workpiece between bending steps.
For a 1,200 mm square perforated panel, this handling requirement was an important part of the customer’s production challenge.
KLD developed an automated bending cell to coordinate positioning, handling and bending.
The Application
The workpiece required:
- Four-side bending
- Repeated production
- Accurate positioning
- Large-panel handling
The original process required two operators and recorded an average cycle time of approximately 126 seconds per part.
Automated Cell Configuration
The KLD solution combined:
CNC Press Brake + Industrial Robot + Automatic Positioning + Material Handling
The system was designed so that the robot could manipulate and position the workpiece during the bending sequence.
This eliminates much of the repeated manual handling required by the original process.
Production Performance
The automated system achieved approximately:
66 seconds per part
Compared with the approximately 126-second manual cycle, this reduced cycle time by around 48%.
Recorded 8-hour production also increased from less than 200 pieces manually to approximately 435 pieces automatically.
Why Four-Side Bending Benefits From Automation
Four-side bending involves more than simply pressing the sheet.
The workpiece needs to be:
- Positioned
- Rotated or transferred
- Aligned
- Supported
- Repositioned
- Bent repeatedly
When these movements are performed manually, handling time can become a significant percentage of the total production cycle.
Automation allows these movements to become part of a programmed sequence.
What Should Manufacturers Consider?
Before automating four-side bending, manufacturers should evaluate:
Part size
Can the robot safely handle the workpiece?
Part weight
Is the robot and gripping system correctly sized?
Bending sequence
Can the required sequence be automated efficiently?
Production volume
Is there enough repetitive production to justify automation?
Loading and unloading
How will raw and finished parts enter and leave the cell?
Future products
Can the system accommodate similar parts in the future?
The Key Takeaway
Large four-side panels can be strong candidates for automated bending when production is repetitive and manual handling represents a significant part of the cycle.
The objective is not simply to automate the press brake.
It is to automate the complete bending workflow.