The automotive industry has always been the primary field for robot applications. With the increasing demand for automation, industrial robot applications have expanded further. In addition to traditional welding applications, robots are widely used in areas such as material handling, stacking, polishing, painting, and assembly on machine tools. Metal forming machine tools are important components of machine tools. Forming processes are often associated with high labor intensity, noise pollution, metal dust, and sometimes operate in high-temperature, high-humidity, or even contaminated environments. The work is simple and monotonous, making it difficult for companies to recruit employees. Integrating industrial robots with forming machine tools can not only solve the labor shortage but also improve processing efficiency and safety, enhance processing accuracy, and have great development potential.
Integrated Application of CNC Press Brake
There are two main ways to integrate robots with press brakes. The first is to use the press brake as the core, with the robot equipped with vacuum suction cups, magnetic sheet separators, positioning tables, unloading tables, and flipping racks to form a bending unit. The second is the integration of robots with laser equipment or CNC turret punch presses, industrial robot walking axes, sheet metal transfer lines, positioning tables, and vacuum suction cup grippers to form a flexible sheet metal processing line. Estun utilizes its technology and platform in robot control systems and CNC machine tool systems to achieve seamless connection, develop bending software packages, and implement closed-loop control of robot material handling during the bending process. The robot achieves automatic matching and complete tracking at different bending speeds, and the bending software package reduces the bending teaching time from 2-3 days in the past to 2-3 hours. It has been successfully applied in the processing of switch cabinets, filing cabinets, elevators, security doors, and other products.
Integrated Application of Press Machine Stamping
There are two main ways to integrate robots with press machine stamping. The first is single-robot loading and unloading for stamping: the robot transfers the sheet metal from the destacking station to the positioning table, then transfers it to the press machine mold for stamping. After stamping, the robot retrieves the finished part and places it on the stacking station, achieving automatic loading and unloading for a single press machine. The second is robot stamping line: multiple robots are used to establish a stamping line between multiple press machines. According to the forming process requirements of the workpiece, multiple press machines need to cooperate in processing. The entire production line consists of destacking robots, loading robots, press machines, transfer robots between press machines, and end-of-line robots. Compared to Cartesian coordinate manipulators, industrial robots offer more flexibility, have less stringent requirements for molds, and are easier to integrate. Estun seamlessly connects its independent press machine control system with the robot control system, achieving optimal coordination between the robot's actions and the press machine. By utilizing field buses, the efficiency of the entire production line is maximized, and safety is enhanced.
Integrated Application of Hot Die Forging
A hot die forging production line typically consists of two forging presses, one for stamping and the other for trimming. In the integrated application of hot die forging robots, two robots are usually configured. One is responsible for transferring the high-temperature material processed by the induction furnace to the stamping and forming die forging press, while the other is responsible for transferring the material after stamping from the stamping and forming die forging press to the trimming die forging press. To prevent the hot stamped workpiece from sticking to the mold, the mold needs to be lubricated with graphite after each stamping operation. The lubrication can be performed by robots or specialized mechanisms. Due to the harsh environment of high temperature, high humidity, and graphite lubrication in forging, special attention should be paid to the protection of robots and their resistance to heat radiation. Estun's robot 4-5-6 axis motors have a structural feature of self-distancing from heat radiation at the connection between the robot's upper arm and forearm. By installing an electronic cam control system on the die forging press, the operation of the press is coordinated with the operation of the robot, improving processing efficiency and enhancing system safety.
Welding Application
Welding is the post-processing step in sheet metal fabrication on machine tools, and robot welding can be divided into resistance welding and arc welding. Welding robot applications account for over 40% of the total robot applications. In arc welding applications, the robot serves as the core and is equipped with welding machines, wire feeders, welding guns, and fixture clamps to form a welding workstation. Estun can provide dedicated arc welding robot workstations with a payload of 6kg and arm lengths of 1400mm, 1600mm, and 2000mm. In resistance welding applications, the robot serves as the core and is equipped with spot welding guns, welding controllers, water-air units, pipework packages, and fixture clamps to form a spot welding workstation. Estun can provide dedicated resistance welding robot workstations with a payload of 220kg and an arm length of 2600mm. Additionally, Estun Automation has developed dedicated welding software packages for welding applications, integrating the welding expert's process parameter library into the robot system to meet various requirements.
Robots are typical representatives of advanced manufacturing technology and automation equipment. Intelligent industrial equipment has become the foundation for the upgrading and transformation of the global manufacturing industry. The integrated application of industrial robots and CNC machine tools enables intelligent manufacturing and the transition from concept to reality in digital workshops and smart factories.
Integrated Application of CNC Press Brake
There are two main ways to integrate robots with press brakes. The first is to use the press brake as the core, with the robot equipped with vacuum suction cups, magnetic sheet separators, positioning tables, unloading tables, and flipping racks to form a bending unit. The second is the integration of robots with laser equipment or CNC turret punch presses, industrial robot walking axes, sheet metal transfer lines, positioning tables, and vacuum suction cup grippers to form a flexible sheet metal processing line. Estun utilizes its technology and platform in robot control systems and CNC machine tool systems to achieve seamless connection, develop bending software packages, and implement closed-loop control of robot material handling during the bending process. The robot achieves automatic matching and complete tracking at different bending speeds, and the bending software package reduces the bending teaching time from 2-3 days in the past to 2-3 hours. It has been successfully applied in the processing of switch cabinets, filing cabinets, elevators, security doors, and other products.
Integrated Application of Press Machine Stamping
There are two main ways to integrate robots with press machine stamping. The first is single-robot loading and unloading for stamping: the robot transfers the sheet metal from the destacking station to the positioning table, then transfers it to the press machine mold for stamping. After stamping, the robot retrieves the finished part and places it on the stacking station, achieving automatic loading and unloading for a single press machine. The second is robot stamping line: multiple robots are used to establish a stamping line between multiple press machines. According to the forming process requirements of the workpiece, multiple press machines need to cooperate in processing. The entire production line consists of destacking robots, loading robots, press machines, transfer robots between press machines, and end-of-line robots. Compared to Cartesian coordinate manipulators, industrial robots offer more flexibility, have less stringent requirements for molds, and are easier to integrate. Estun seamlessly connects its independent press machine control system with the robot control system, achieving optimal coordination between the robot's actions and the press machine. By utilizing field buses, the efficiency of the entire production line is maximized, and safety is enhanced.
Integrated Application of Hot Die Forging
A hot die forging production line typically consists of two forging presses, one for stamping and the other for trimming. In the integrated application of hot die forging robots, two robots are usually configured. One is responsible for transferring the high-temperature material processed by the induction furnace to the stamping and forming die forging press, while the other is responsible for transferring the material after stamping from the stamping and forming die forging press to the trimming die forging press. To prevent the hot stamped workpiece from sticking to the mold, the mold needs to be lubricated with graphite after each stamping operation. The lubrication can be performed by robots or specialized mechanisms. Due to the harsh environment of high temperature, high humidity, and graphite lubrication in forging, special attention should be paid to the protection of robots and their resistance to heat radiation. Estun's robot 4-5-6 axis motors have a structural feature of self-distancing from heat radiation at the connection between the robot's upper arm and forearm. By installing an electronic cam control system on the die forging press, the operation of the press is coordinated with the operation of the robot, improving processing efficiency and enhancing system safety.
Welding Application
Welding is the post-processing step in sheet metal fabrication on machine tools, and robot welding can be divided into resistance welding and arc welding. Welding robot applications account for over 40% of the total robot applications. In arc welding applications, the robot serves as the core and is equipped with welding machines, wire feeders, welding guns, and fixture clamps to form a welding workstation. Estun can provide dedicated arc welding robot workstations with a payload of 6kg and arm lengths of 1400mm, 1600mm, and 2000mm. In resistance welding applications, the robot serves as the core and is equipped with spot welding guns, welding controllers, water-air units, pipework packages, and fixture clamps to form a spot welding workstation. Estun can provide dedicated resistance welding robot workstations with a payload of 220kg and an arm length of 2600mm. Additionally, Estun Automation has developed dedicated welding software packages for welding applications, integrating the welding expert's process parameter library into the robot system to meet various requirements.
Robots are typical representatives of advanced manufacturing technology and automation equipment. Intelligent industrial equipment has become the foundation for the upgrading and transformation of the global manufacturing industry. The integrated application of industrial robots and CNC machine tools enables intelligent manufacturing and the transition from concept to reality in digital workshops and smart factories.
