Automatic tool changer reduces installation time and relieves operators

Installing the machine thus takes up to 70% of the bending process. It takes a lot of effort for the operators, because not only the metal sheets themselves, but also the tools are heavy. With the Modular Tool Changer, coupled with the ByVision Bending process software, Bystronic offers the solution to significantly speed up the installation time at the Xpert Pro bending benches while making life easier for staff.

"We know from experience that operating a bending bench is no easy task. Operators not only have to put metal sheets on the machine, but also have to take the heavy bending tools from the warehouse and hoist them onto the machine. Moreover, this not only takes strength, but also a lot of time, especially now that more and more smaller batches are being produced," says Benelux sales manager Hans van de Meerakker. "An automatic tool changer is therefore no superfluous luxury. In 2016 we already launched a first system to automate this process and with the Modular Tool Changer we are now introducing an innovative model, which can be connected to all versions of the Xpert Pro bending bench without any problems, also retrofit on existing installations."

Smart, flexible and accurate

This automatic tool changer from Bystronic has a maximum tool capacity in the magazine of 52 m and is suitable for all tools weighing up to 25 kg. Whatever tool you purchase can be integrated into the magazine: top tools with a segment length of up to 515 mm and a maximum height of 350 mm as well as bottom tools between size V6 and V120. Moreover, the maneuverable robot can rotate the top tools 180°, which only increases flexibility. "Since one has to machine more and more different parts, the range of tools is constantly being expanded. The warehouse certainly provides more than enough space. Moreover, smart sensors automatically recognize the new tools and autonomously place them in the queue," explains area sales manager Salvatore D'Angelo. "That innovative sensor technology increases accuracy. While an operator may be less precise at the end of a shift, the six-axis robot always keeps acting at the same level. It automatically retrieves the right toolset from the warehouse and places everything into the clamping system with millimeter precision. For this, the robot's jaw fits perfectly into the milled-out frame in the tool set."

Still not more complex

While the robot does its work unmanned, the operator can perform other tasks, optimizing efficiency and productivity on the shop floor. Yet the operation does not become more complex for operators. After all, the Modular Tool Changer is linked to the ByVision Bending process software. Based on the bending program, the robot automatically recognizes which tools are needed. The robot is also very careful and stores the tools carefully after each operation. This avoids scratches as well as inaccuracies. "This automatic tool changer makes the bending process for each part easier, more efficient and more accurate," conclude van de Meerakker and D'Angelo. "The reactions from the market are very positive and a first unit was also recently sold in Flanders."