Challenges

At Zerbst, the most varied of assemblies run through the production in lot sizes with perfect timing. The first bending operation must be correct, as only the required quantities are produced. Joachim Gerland, CEO of EMAG Zerbst Maschinenfabrik GmbH, explains, "If a cut part is bent incorrectly in the bending machine, we have to reproduce it promptly and quickly in an additional process. It starts to cost us financially if our staff do not discover until the part reaches the subsequent welding workstation that an angle is incorrect or a part has been bent in the wrong direction, for example."

Solutions

Zerbst ordered the TruBend 5170 three times, one machine with the additional feature Part Indicator. The Part Indicator consists of a camera in front of and a camera behind the press beam. Once the operator inserts a part, the cameras record the insertion position. Both images are joined to form an overall image in real time and are displayed on an additional screen via machine control. The operator sees the actual and target insertion positions, detects any deviation and can correct it accordingly. Gerland says, "With the variety of parts that our employees manufacture every day, this is an additional check that ensures safety. The camera is also useful for differentiating between left and right. There is always the risk that staff insert parts the wrong way round when the parts are almost symmetrical. The Part Indicator detects that." The new feature has reduced the error rate significantly. Even though new employees are often put to work here.

Implementation

The company equipped all three TruBend 5170 machines with bending aids and the angle sensor ACB. That made the work much easier for the operators. The intuitive control as well as the 3D visualization of the TechZone Bend programming software are also a great support. Gerland says, "Our staff no longer have to consider how to create a 3D part out of a 2D part. They see it on the screen within just a few seconds."

Forecast

It is not easy to find good bending operators when there is such a shortage of skilled specialists. And even when you do find them, personnel still need a training period. Gerland states, "We can't change this problem in the medium term. But simplifying machine operation is a good approach, as is making the machines safer with assistance systems. The Part Indicator increases the chances significantly for us to train even beginners in a relatively complicated technology faster in future, making their work productive more quickly."