Sheet metal processing is a labor-intensive industry. With the continuous development of science and technology and the increasing competition in the industry, the application of automated processing technology in the field of sheet metal processing is also rapidly popularizing. Automated processing reduces the labor intensity of workers, making sheet metal processing safer and more efficient, with higher precision and more stability.

As an important part of sheet metal processing automation, although bending automation has obvious advantages in efficiency, quality, labor costs, etc., there are still many technical and application difficulties in its implementation process. The following is an analysis of several core difficulties in sheet metal bending automation.

1. Difficulties in Bending Automation

1) Analysis of technical difficulties

- High requirements for sheet metal positioning accuracy

During the bending process, the initial positioning of the sheet metal has a great impact on the final bending accuracy. The automation system needs to solve:

Precise alignment of sheet metal loading.

Displacement error compensation during the bending process.

Stability and anti-interference ability when using visual recognition or sensor positioning.

- Weak flexibility

Sheet metal products are diverse in variety, small in batches and change quickly, while automation equipment is usually optimized for standard parts, and it is difficult to adapt to the following situations:

Quick switching of multiple varieties and small batches.

Processing of special-shaped parts and multiple bends.

Workpiece size, bending angle and sequence vary greatly.

- High programming difficulty, process depends on manual experience

Although the automated bending equipment has CNC functions, it:

The bending program requires manual input or simulation, and the learning curve is steep.

Material elasticity, rebound control, mold selection, etc. still rely on experience.

Lack of intelligent parameter automatic generation system.

- The clamping and flipping mechanism is complex

Multiple bending requires multiple flipping of the workpiece, and different structural parts exist:

Automatic clamps are difficult to adapt to multi-shaped sheets.

Flipping and handling actions require precise coordination to avoid interference and accidental collision.

The control system and mechanism design requirements are extremely high.

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2) Difficulties in cost and economy

- High equipment investment cost

Automated bending units generally include:

• CNC bending machine

• Robot arm system

• Feeding, unloading, positioning, and flipping units

• Intelligent control system

The whole system has high investment and is not friendly to small and medium-sized enterprises.

- Long ROI payback cycle

For non-standard and variable products, sheet metal bending automation is difficult to improve efficiency.

If the product is updated quickly and the bending process changes frequently, it is difficult to improve the utilization rate of the equipment.

The payback period is difficult to control.

3) Difficulties in system integration

- Complex coordination with other processes

Bending is usually closely related to processes such as laser cutting, welding, and stamping.

The automation system needs to be connected to MES, ERP and other systems to ensure seamless process connection.

The requirements for workpiece information transmission, task scheduling, and traceability functions are complex.

- Immature safety control and fault handling mechanisms

Bending automation involves multiple moving parts and there are safety risks.

The detection, feedback, and fault-tolerant processing systems for abnormal situations are still imperfect.

Intelligent protection, laser scanning, limit devices, etc. need to be fully integrated.

4) Summary of Difficulties

Summary table:

2. Strategy for difficulties in sheet metal bending automation

Although there are many difficulties in bending automation, there are corresponding solutions and optimization methods for each pain point. The following are common difficulties and strategies for dealing with them.

1) Insufficient flexibility → Improve the adaptability to multiple varieties

Difficulty:

Slow switching of multiple varieties and small batches.

Special-shaped sheet materials cannot be universally grasped.

Strategy:

Use flexible fixtures and adjustable grippers: Adapt to different sizes and shapes.

Introduce modular mold library: Quickly switch molds.

Deploy MES system to manage process parameters: Automatically match programs, molds and tasks.

2) Difficulty in positioning and clamping and flipping → Achieve precise handling and intelligent alignment

Difficulty:

The sheet needs to be repositioned multiple times before and after bending.

Robot grasping is prone to offset and interference.

Strategy:

Integrate high-precision visual positioning system: Automatically identify the edge and hole position of the workpiece.

Design linkage multi-axis robotic arm: Synchronous handling, flipping and positioning.

Use electric permanent magnetic chuck or vacuum gripper: Improve clamping adaptability and stability.

3) Programming and process rely on manual labor → Promote the construction of intelligent programming and process knowledge base

Difficulty:

Bending program and sequence need to be manually input.

Material rebound requires manual judgment and correction.

Strategies:

Introduce 3D simulation bending software (such as Delem, CNC Pro): automatically generate bending sequence and collision detection.

Establish material database and process parameter library: automatic springback compensation and bending angle correction.

Support automatic programming of drawing import (such as DXF): realize "one-click program generation".

4) Long investment and return cycle → Phased construction and combined investment

Difficulty:

Automation equipment is expensive.

The return cycle is greatly affected by product types.

Strategies:

Prioritize the automation of "highly repeatable" product bending: improve utilization rate.

Adopt modular construction ideas: first install robots + bending machines, and then add vision and flip systems later.

Select economical collaborative robots instead of large six-axis: reduce initial investment.

5) Difficulty in integrating upper and lower processes → Build digital connection and unified platform

Difficulty:

Lack of information sharing between cutting, welding and bending.

MES/ERP system cannot link equipment.

Strategy:

Deploy intelligent manufacturing central control platform (SCADA/MES): open up process data flow.

Standardize equipment interface protocol (OPC UA, etc.): realize equipment interconnection and interoperability.

Use QR code/barcode to track workpiece status and process nodes: realize full process visualization.

6) Difficulty in safety and abnormal response → Strengthen safety protection and intelligent diagnosis

Difficulty:

Multi-axis collaboration space is complex and easy to collide.

Faults cannot be quickly troubleshooted.

Strategy:

Install laser scanning and force control sensors: realize anti-collision and automatic emergency stop.

Use collaborative robots (with force control sensing): human-machine collaboration is safer.

Deploy remote operation and maintenance and fault diagnosis system: fast positioning and recovery.

Summary: Comparison table of difficult points in bending automation