Bending cells ASTRO-100 II NT series

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1 Bending cells ASTRO-100 II NT series Automation Lasertechnologie Stanztechnologie Software Storing Schneidtechnologie Bending technology Abkanttechnologie Automation Automation Lasertechnologie Stanztechnologie Software Storing Schneidtechnologie Abkanttechnologie

2 The second generation the ASTRO-100 II NT robotic bending cell series The proven ASTRO folding cell was continually developed on the basis of experience and adapted to the relevant market requirements. The result is a series of fully automatic press brakes conforming to the last state of technology with a variety of models that can be used for various different tasks. The second-generation ASTRO-100 II NT series of bending cells are able to meet the highest quality standard and impress with their excellent performance characteristics. Even small batches can be economically manufactured. Economic bending with high degree of automation General performance features: Servo-hydraulic drive on the press brake ASTRO-CAM external software Short programming times Bending cells specialised for fully automatic and economic bending of complex workpieces are available as: ASTRO-100 II NT HP-20 loading and unloading robot ASTRO-100 bending robot Loading table with sheet metal thickness control Tool gripping station Repositioning stand Transfer table, manual adjustment ASTRO-100 II NT PLUS with increased degree of automation Automatic tool change Automatic gripper change HP-20 loading and unloading robotics, linear movementable on mm axis ABT transfer table with automatic adjustment Enlarged working area by ground tracks ASTRO-100 II NT TELUL for highly complex part geometries With integrated safety lock for manual loading and unloading Active backstop sensor with potentiometers on the HDS press brake Automatic tool change Automatic gripper change 2

3 Internally consistent All components from one supplier All parts of the bending cells, including the AMNC multimedia network controller and the external ASTRO-CAM software originate from AMADA. This all-in-one concept forms the solution for automatic bending for a coherent interface management that has been optimised for parallel processing. By combining robotics systems with the modern HDS series press brakes, a bending cell was developed that always provides correct bending results with all materials, material thickness, geometries and bending lengths. Automatic bending of small, complex workpieces Calculable, constant part costs High precision and consistent quality Economic production even for smaller batch sizes Staff capacity becomes free for more qualified tasks 3

4 Automatic tool change for different workpiece geometries and sheet metal thickness ASTRO-100 II NT PLUS for continual product flow ASTRO-100 II NT TELUL for complex geometries ASTRO-100 automatic gripper change The degree of automation was further increased with the ASTRO-100 II NT PLUS version: The bending cell can perform setup procedures automatically and is therefore in a position to process various different orders in direct sequence without the intervention of the operator. This is made possible by the automatic gripper changer which can handle various different components as well as the automatic tool changer which makes numerous punches and dies in the magazine available for different workpiece geometries and sheet metal thickness. In addition, there is also an enlarged work area in the PLUS version of the loading and unloading robotics, that is linearly movable along a 5,000 mm long ground axis. Finished parts are temporarily stored on the ABT transfer table, whose supporting bars in the PLUS variant are movable and can therefore accommodate different workpiece geometries and sizes. All components of the ASTRO-100 II NT TELUL are perfectly compatible with each other and a flawless interface management ensures smooth-running processes. Because of the integrated safety lock it is possible to load and unload parts manually with this model, which may not be bended automatically on other systems. The operator uses the external ASTRO-CAM software (on Windows basis) for convenient automatic calculation of all tool layouts and bending sequences. This allows the shortest programming times and the practical production of small batch sizes starting at less than 50 parts. The active backstop sensor with potentiometers on the HDS press brake ensures the highest accuracy. Thanks to the servo-hydraulic drive with active deflection compensation, the best bending results are achieved irrespective of the material and the position on the machine. Even parts that cannot be bend automatically because of their complex geometry can be conveniently produced now with the ASTRO-100 II NT TELUL. 4

5 HDS-1030 NT press brake Servo-hydraulic hybrid drive guarantees accurate folding results In order to achieve accurate bending results every time, AMADA implemented a new drive system concept in the HDS-1030 NT press brake: the hybrid drive of the upper press beam moves with the help of a servo-electric concept. Servo motors driving the hydraulic pumps, that deliver oil into the cylinder. The motor only works during the movement of the press beam and this results in a considerable reduction in energy requirements. Further advantages are the reduced requirement for hydraulicoil, longer oil change intervals and decreased warming of the oil, which guarantees a uniform bending quality because this can no longer be influenced by fluctuations in the oil temperature. Compensation cylinders on the lower press beam of the press brake ensure uniform bending results along the entire length of the machine. Depending on the material thickness and the length and position of the workpiece on the press beam, the controller calculates the setting values for all cylinders. The press brake is equipped with the AMADA AMNC controller that is connected with the AMADA AP-100 technology network, in which all AMADA machines are operated in together. All relevant data such as parts drawings, tool type, bending sequence and part programmes are stored in the network and can be made available to all connected AMADA machines on call. High process speed Correct bending angle Constant bending quality Reduced energy requirements Low requirement on hydraulic oil Longer oil changing intervals Low noise emission 5

6 ASTRO-100 II bending robot Complex bending accurately under control The ASTRO-100 bending cell was developed by AMADA to bend complex workpieces quickly and with the highest accuracy. It is mounted on the the lower press beam and can be moved linearly along its entire length. Even complex workpieces can be produced that require several tool stations since the entire length of the press beam can be populated with tools. The bending robot picks up the workpieces from the HP-20 loading and unloading robot with a mechanical gripper that works just like a hand and is therefore predestined for small complex workpieces. The hypersensitive back stop sensors are a special feature of the system that enables extremely accurate production. It is mounted on the backstop of the press brake and measures the position of the workpiece each time it is placed into the press brake. The sensor system actively detects whether the sheet is correctly positioned. In the event of deviation from the programmed specified value, the position of the bending robot is automatically corrected. This active process enables folding results of the highest quality. Handling of small, complex workpieces Highest production accuracy Unlimited station bending Low reject rate, even with complex components Constant calculable production times Low setup times for repeated production batch sizes HP-20 loading and unloading robot Continual production without non-productive times The HP-20 loading and unloading robot picks up the rough blanks by vacuum cups and transfers them after successful double sheet detection to the ASTRO-100 bending robot. Following the bending process, the HP-20 picks up the finished workpieces on the transfer table and specifically sets them down. Due to the perfect interaction of the robotics, the bending cell has practically no non-productive times because the bending robot can produce continuously. In order to maintain an enlarged working area, the loading and unloading robot in the ASTRO-100 II NT PLUS is now not mounted statically but is movable along a 5,000 mm long floor tracks. The ideal requirement for loading and unloading parallel to the primary processing time. Because of the possibility of vertical loading, there are practically no limits to the loading possibilities. 6

7 ASTRO-CAM Software Programming made easy! The ASTRO-100 II NT bending cell is programmed with the external ASTRO-CAM software. The programmes for the press brake itself and the entire motion sequences of both robots are created on an external PC. The low programming effort enables economic production of even small batch sizes with the ASTRO-100 II NT bending cell. Programming can take place both manually and automatically in a 3-dimensional demonstration. The software automatically determines gripper selection, chooses the tool type as well as the tool layout and calculates the bending sequence. The result can then be subsequently verified in a three-dimensional simulation. Easy programming Reduced downtimes by external programming Automatic generation of processes Optimum programme control by threedimensional simulation of the production process HP-20 loading and unloading robot 3D simulation of the bending process 7

8 H L T Amada GmbH Amada Allee Haan Germany Tel Fax info@amada.de Technical data Press force Drive Deflection compensation Bending length Distance between side frames Throat depth Stroke Open height Backstop adjustable range Table width HDS-1030 NT 1000 kn servo-hydraulic active hydraulic cylinder 3000 mm 2700 mm 415 mm 200 mm 620 mm 600 mm 60 mm Number of controlled axes 7 Speed approach/return stroke 200 mm/s max. bending 20 mm/s Connected load Oil volume Weight Controller Loading and unloading robotics Controller Max. capacity (incl. gripper) 15 kva 57 l 8700 kg AMADA AMNC HP-20 AMADA AMNC II - AS100CE 20 kg Number of controlled axes 6 Max. workpiece dimension Raw material stacking height Drive as ASTRO-100 NT 500 mm AC servo motor Folding robotics ASTRO-100 NT Controller AMADA AMNC II Max. capacity (incl. gripper) 20 kg Number of controlled axes 5 Length of linear axis 3080 mm Max. material thickness mm Max. sheet size 800 x 1000 mm 300 x 1800 mm Drive AC servo motor Weight 560 kg Further equipment Loading table with sheet metal separation and thickness detector Repositioning gripper on the upper press beam with pneumatic support Basic configuration of gripper for ASTRO-100 II NT and HP-20 Safety devices according to CE-standards External CAM software ASTRO-CAM Status indicator light In the interest of technological progress, we reserve the right to make any changes to technical dimensions, construction and equipment as well as illustrations. Specifications on accuracy in accordance with VDI/DGQ *Workpiece precision and material thickness to be processed are also dependent on production conditions, material, type of workpiece, its pretreatment, size of the table as well as the location in the work area. Amada GmbH ASTRO-100 II_500-Pr_EN / /1