Automated Tool Changing Just One of the Enhancements
To Amada's Astro 100NT Robotic Bending System

Building on a twenty-year bending robot history and an installed base of 900+ units worldwide, Amada has introduced automation products to improve the performance of its ASTRO 100NT robotic bending system. The goal of these improvements is to extend the system's lights-out capabilities by enhancing the automation of its tool-changing, gripper-changing and hand-changing functions.

The ASTRO 100NT robotic bending system is capable of totally unmanned operation, capabilities that have made it especially attractive in terms of productivity and profitability. According to Amada's Leo Wegner, ASTRO product manager, "This capacity for lights-out operation pays off for companies in several ways. It can cut labor costs, but it can also allow a company to better utilize key operators in functions where their skills can be put to optimum use. In addition, the precision and reliability of the automated system, make it the ideal solution for just about any bending task, in lots of 10 to 10,000.

The ASTRO 100NT cell configuration includes the bending robot, a loading robot and an unloading robot, plus Amada's latest HDS NT press brake, which is integrated with two CNC-controlled robots. One robot replaces the human operator by automatically handling part bending at the brake. The second robot loads material in and out of the cell from a storage or transport device and hands off material and parts to and from the bending robot.

The advanced design of the HDS NT press brake employs a hybrid drive system that achieves high speeds by the combined response of a hydraulic pressure unit and a servo motor drive system. To reduce electrical consumption and heat, hydraulic operation is suspended when the ram reaches the top of its stroke. Ram positioning to one micron makes it possible to maintain high accuracy levels, even over a continuous working period.

An enhanced and more robust automation-software package, ASTRO CAMII, makes it possible for programs to be generated automatically, including tool selection and layout, robot gripper selection, bending sequence, plus data for robot motion and bending. In addition, network functions within the AMNC-PC control have been upgraded, so that now operators can call up complete sets of data from the network server.

For precise bending control at any position, a 5-axis backgauge provides continuously updated feedback to the CNC. The backgauges follow the robot's movement along the "X" axis to maintain accurate sensing feedback for multi-staged bending. To provide maximum flexibility, the ASTRO 100NT can operate in a fully robotic mode as a bending cell or as a conventional press brake, using offline programming. Its ease of operation enables a single operator to attend up to two ASTRO cells and a stand alone press brake for maximum manpower economy.

Amada's Wegner notes that, "We've further improved the Astro 100NT system with three automation tools that will exceed an 80% green-light-on time in most installations."

Tool / Gripper / Hand Changing

A key to productivity enhancement is the Automatic Tool Changer (ATC) which can automatically load and unload tools based on the program specification, eliminating operator intervention. Scheduling capabilities and all operations are fully automated under PC and CNC control. Designed to increase productivity and shorten delivery time, the ASTRO cell delivers consistent, repeatable accuracy over a complete product schedule run, regardless of bending complexity.

The Automatic work-piece Gripper Changer (AGC) and Automatic Hand Changer (AHC) can be exchanged automatically, depending on the needs of a product run, and both features simplify work scheduling, even on jobs with small lot sizes.

Productivity Proven

Looking back on Amada's experience with robotic bending, Leo Wegner reflects: "We have witnessed an overwhelming number of cases where just one robotic bending system quickly equaled the output of 3 or 4 conventional press brakes. When you think about just the cost-cutting implications there-work hours saved, elimination of manual tool setup, floor space reduced, maintenance costs cut, and the personnel that can be allocated to more important tasks, such as secondary operations—you begin to understand the exciting possibilities posed by robotic bending."