The typical robotic stamping automation production line consists of several key components, including the robot, electronic control system, demolition device, transition belt, sheet washer, sheet oiler, centering station, tail end palletizing system, safety protection system, and the robot's end effector. The layout can be customized based on the available space in the workshop. For example, the unloading method can be arranged either parallel or perpendicular to the press line, depending on the specific requirements.
First, the stamping robot. In addition to the general characteristics of handling robots—such as high load capacity, precise motion paths, and stable performance—the stamping robot must also handle frequent start-stop cycles, a large working range, and accommodate oversized workpieces with significant rotational movement. To meet these demands, manufacturers have upgraded motor power and reducer specifications, extended arm lengths, and adopted scaffolding-style mounting structures for improved flexibility and stability.
Second, the robot stamping automation line control system. This system integrates presses, robots, destackers, washers, oilers, centering stations, dual material detection devices, vision systems, conveyor belts, synchronized control units, safety mechanisms, and large display panels. It is designed to seamlessly connect with the plant’s MES system. To manage this complex integration, Ethernet and industrial fieldbus networks are commonly used, often incorporating a safety bus for enhanced reliability and control.
Third, the demolition system. There are three common types: dedicated demolition machines, robot + demolition trolley, and truss manipulator + demolition trolley. Each has its own advantages. The dedicated machine uses hydraulic lifting trolleys, photoelectric sensors, and magnetic separators to automatically separate sheets. The robot-assisted system allows for dynamic height adjustments and manual placement of magnets. The truss-based system offers similar functionality but with a more flexible structure.
Fourth, the retractable belt conveyor. This component transfers individual sheets after they have been separated. It ensures the correct speed for the washing process and is usually controlled via frequency conversion to synchronize with downstream equipment. Its adjustable length helps optimize space when the washing machine is offline.
Fifth, the sheet cleaning machine. As vehicle manufacturers demand higher surface quality, pre-stamping cleaning has become standard. Cleaning can be done online or offline, depending on production volume. Online cleaning is used in large-scale operations, while offline is suitable for smaller batches. The cleaning machine includes feed rollers, brush rollers, squeeze rollers, and a hydraulic adjustment system, all designed for efficient and consistent cleaning.
Sixth, the sheet oiling machine. Applying lubricant before stamping ensures better forming quality. The oiling machine features spray nozzles, fuel supply units, and temperature control systems to maintain optimal oil conditions. It can be moved offline when not in use, ensuring efficiency and flexibility.
Seventh, the centering station. Proper alignment of the sheet is crucial before it is picked up by the robot. Three main methods exist: gravity centering, mechanical centering, and optical centering. Gravity centering relies on sliding the sheet into a corner, while mechanical centering uses cylinders and sensors for precise positioning. Optical centering, a newer technology, uses cameras and software to adjust the robot's path, reducing the need for complex mechanical setups.
Eighth, the robot's seven-axis and end effector. While standard six-axis robots are sufficient for 8 pieces per minute, some applications require even faster speeds. Seven-axis systems have been developed to increase throughput to 12 pieces per minute, matching the performance of high-speed dedicated lines.
Ninth, the line end coding system. At high output rates, human labor becomes impractical. Therefore, the finished parts are either manually coded or placed into racks by robots, which are then transported away by forklifts. This ensures smooth and efficient operation at high speeds.
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