For our clients it’s not just about technically tuned presses and feeding lines, more importantly, it is long-term service and continuous communication.
An inherent part of the company is the know-how that is stored in our archives, and in the people and their approach to work, which is key to the production of quality and reliable machines. We have also used this experience with our latest client.
Meeting challenging requirements
A Slovakian customer approached us with a request to increase their competitiveness with self-sufficiency and quality in the production of their product. This company is medium sized with more than 25 years of experience specializing in the production of high-quality storage containers of various sizes. Their problem was with continuous pressing of the side and roof panels for warehouse containers.
The solution Bliss Bret designed and delivered was a production line consisting of a 2PHS250 hydraulic press with a capacity of 250 tons with ABB feeding robots and Siemens automation for continuous production. A continuous communication of technical solutions ensured that the resulting product met the clients’ requirements and criteria. The design
of the production line included a take-off and double stacking station as well as a CNC feed/extractor manipulator connected directly to the press.
The lateral semi-automatic tool changer serves to optimize tool change time, increase operator safety, and improve operator ergonomics. Placing the individual components of the line appropriately in the space enables loading and unloading tools with a forklift. There is no need of crane technology required.
Universal system also for future applications
For alternative use of the production line in the future, industrial robots are equipped with an automatic gripper exchange system. The universal output gripper system, which has been designed for current production, allows all panel sizes and shapes to be handled without the need for replacement.
Reliable removal of the incoming flat sheets from the stack is made possible by a suitable separator that separates the oiled top sheet using nozzles, suction cups, and appropriate movement so the robot removes exactly one sheet.
The total number of pressing steps in the production cycle is set by the operator on a 19” Siemens HMI touch screen. On the opposite side of the press, two extractor grippers take the formed sheet from the feed grippers and complete the production cycle by pulling the final product in incremental steps onto the support table. At the output of the production line, the ABB robot places the finished product in a stack.
For each type of product different number of pressings, different panel sizes and resulting different robot paths and pressing cycles apply. To quickly set up a new production, the individual production processes are stored in the PLC library and with a few clicks on the HMI, the operator recalls a specific production type from memory, according to which all the necessary production line parameters are set. The 2PHS250 hydraulic press itself is equipped with safety systems. Any dangerous movements on the press, such as a ram falling off, are secured by dual hydraulic and dual electrical control: sensors, dual pressure valves and switches. If necessary, the press is stopped and the operator is guided to rectify the fault by the information in the alarm messages (oil and coolant temperature monitoring, power monitoring, current monitoring, position check, heating check, hydraulic overload, limit switches on mechanical and hydraulic axes, etc.). A hole punching activator was installed in the ram of the press at the client’s request, which is fully controlled by the program and its activation can be set on the HMI.
The press also includes a service platform at the top of the press, which allows comfortable maintenance (of the press) and better access to the hydro unit.
The hydraulic press with a total capacity of 2,500 kN is equipped with CNC infeed/outfeed manipulators to ensure continuous production. When the input ABB robot places the sheet on the support table, it is grabbed by two feed grippers and pushed into the hydraulic press. Then, with each pressing, the sheet is partially formed into the desired shape.
Stacking is carried out by two cells, which allows operators to remove finished panels without stopping the production process. During stacking, the ABB robot fills cell A up to a pre-set number of pieces. When the required number of panels is reached in cell A, the mechanical door from cell B is moved to cell A, preventing the robot from entering the space of cell A. At the same time the space of cell B is freed up. The robot continues stacking into cell B. Whilst removing the finished products, the operator is protected from any injury of the robot by a mechanical barrier.
Machine delivery is just the beginning.
For us, client care continues even with the sale of the press. At Bliss- Bret, the after sales journey is important to us and we are proud of our servicing and maintenance that we continue to provide for our clients. At servicing, all equipment is maintained by our professionals from the factory. We install remote management as standard on the machines, which allows our programmers to connect remotely to diagnose faults or repair minor machine faults, significantly reducing service response time.
At Bliss-Bret we follow the motto “Without quality, no future“