Case Study: A Flexible Automation Solution for Large and Heavy Workpieces

Automating sheet metal bending becomes more challenging as workpieces become larger, thicker, heavier, and more diverse.

For this application, the customer was producing large and thick sheet metal components and needed a more flexible bending process.

The production requirements were not limited to increasing bending speed. The customer also needed to handle different workpiece sizes and product types while reducing manual intervention.

KLD developed a customized robotic bending cell designed around these requirements.

The Production Challenge

Large and thick workpieces can create several challenges during bending.

Operators may need to repeatedly position, rotate, support, and transfer the material during the bending sequence.

When product dimensions and geometries also vary, a conventional automated system with fixed positioning may not provide sufficient flexibility.

The customer therefore required a solution capable of handling:

• Large sheet metal workpieces
• Thick plates
• Different workpiece dimensions
• Multiple product types
• Repetitive bending operations
• Automatic positioning

The KLD Automation Solution

KLD integrated a CNC press brake with a 6-axis industrial robot and a 7th robot axis.

The cell also incorporates several auxiliary systems designed to support large-workpiece handling and flexible production.

These include:

• Adjustable-angle gravity positioning table
• Automatic adjustable turning frame
• Customized gripper system
• Automatic thickness detection
• 3D vision system
• Floor-mounted 6-axis backgauge
• Pneumatic following system
• Automatic front feeding system
• Safety guarding

The result is a complete robotic bending cell rather than a standalone press brake with a robot added beside it.

Flexible Workpiece Handling

Large workpieces often require more than simple pick-and-place movement.

The robot needs to coordinate with the bending machine while maintaining the correct position and orientation of the sheet.

The customized gripping system allows the automation cell to handle the customer's specific workpieces.

The adjustable positioning table and turning system provide additional flexibility when different workpiece dimensions or orientations are required.

Automatic Recognition

Another important feature of this application is the integration of 3D vision.

Instead of relying entirely on fixed positioning, the vision system can assist the automated process in recognizing the workpiece and its position.

Combined with automatic thickness detection, this creates a more adaptable production process for products with different specifications.

A System Designed Around Production Requirements

This case demonstrates an important principle in industrial automation:

Automation should be designed around the workpiece—not the other way around.

For large and thick sheet metal production, the robot, positioning system, gripper, backgauge, vision system, and press brake need to work as one coordinated system.

KLD Machinery develops customized robotic bending cells for manufacturers that require more than standard automation, with solutions designed around workpiece dimensions, product variety, handling requirements, and future production needs.