Robotic Stamping
Stamping is a metal fabrication process that involves the shaping of sheet metal. Sheet metal is fed into a stamping press to imprint the desired design on the metal workpiece. Metal punching is another form of stamping in which sheet metal is formed into a specific shape. Stamping presses have mainly been manually tended in the past. However, worker shortages, rising production costs, high demand, and worker safety issues have many manufacturers looking to automate their metal stamping applications.
Metal stamping can be successfully automated with industrial robots. Articulated robots are the most common for stamping automation as six-axis robots provide the range of motion needed to handle a variety of workpieces. Higher payload and longer reaching articulated robots are also better equipment to maneuver large pieces of sheet metal. The FANUC R-2000ib/125L is ideal for automating stamping. Collaborative robots are also being implemented in press shops for automating stamping. While the Universal UR10 and other cobots may not be able to match articulated robots in terms of payload and reach, they can directly assist workers and provide greater manufacturing flexibility.
Industrial robots can be used to feed and position sheet metal into stamping presses. Once the metal is correctly positioned, the robotic manipulator can operate the press machine. When the stamping process is over, the industrial robot arm can remove the sheet metal and either place it on a conveyor or transfer it to the next workstation. Factory robots can also be used to perform the stamping application itself. The ABB IRB 6640-180 can take on the workload of two to three workers and tend multiple stamping presses. Productions become more streamlined and efficient with stamping robots. With robotic stamping fewer workers are needed, reducing human involvement and labor costs. For those facing worker shortages, manufacturing robot arms can fill in the labor gaps.
Stamping robot manipulators help manufacturers address the safety risks associated with press shops. Heavy workpieces, hot metal, and large machinery can all be dangerous to the health and safety of workers. Removing workers from stamping applications and automating with the Yaskawa MH180 improves the safety of your factory. Worker injuries will be eliminated with handling robots.
Stamping industrial robotic arms will increase output allowing for higher productivity. With higher productivity manufacturers will be able to meet consumer demand. Robots operate at fast speeds. They can also run all day and night. Changeover time between parts is significantly decreased. Instead of manually transferring sheet metal, robots will automate the process, reducing any idle time.
Industrial robots are also better equipped to handle varying part sizes and complex part geometries. Workers may be able to handle smaller metal workpieces, but they struggle with large sheet metal. Robots can easily adjust between small and large parts. Programming allows them to accurately execute and complete stamping processes. The integration of robotic vision systems and force sensors only enhances their accuracy.
Robotic stamping mitigates errors that cause poor quality and rework by removing the human component of metal stamping. Robots are programmed to follow a defined set of parameters, ensuring all workpiece quality is consistent and meets the highest standard. Robots integrated with vision can even inspect parts prior to further processing, significantly reducing scrap rates.