Automated cell installed

Two components were presented to AddisonMckee to process, one required bending and drilling, but to be produced by a fully automated solution; the other component only needed forming; production was to be manually controlled (to be automated at a later date).

The bending cell incorporated a bunker system fed by pallets of cut 34mm dia tubes, which were unloaded magnetically and processed within a buffer system, to a pick-up point were the tube was seam detected and presented ready for an ABB robot to collect. The robot with a double gripper held the tube until the eB80bending machine had completed two symmetrical 1 x D bend on bend applications; it then removed the bent tube and inserted the new tube, and the bending process recommenced. The bent tube is then transferred by robot to a combined inspection gauge and drilling fixture. If the component is deemed incorrect it is transferred to a reject chute; otherwise two holes are drilled and it is transferred to a finished part stillage on a turntable. When the stillage is full the turntable presents an empty stillage ready for the process to work continuously.

AddisonMckee worked with and was assisted by Premier Automation to engineer a fully integrated robotic system that met all logistics and health and safety requirements.

The component to be formed was a straight 50mm dia tube that required three AddisonMckee machines to form both ends and trim to length. One end required a flat to be produced by a two hit 70RF machine; the other end required a 70SRF (selectable ram form). The SRF machine used three hits to produce an offset reduction to a size that allowed the 34mm bent tube to be inserted on the final welded assembly. After forming the resultant end deformation was trimmed to the correct length with an FM70TTPN (tube trim with pre-notch).