Configurable robotic bending systems: flexible automation for the future of sheet metal fabrication

The configurable Robotic bending system: Transforming sheet metal fabrication

The sheet metal industry is undergoing a profound transformation thanks to robotic automation, and one of the highlights of this evolution is the Configurable Robotic Bending System (RBS) recently showcased by LVD. As reported by Canadian Metalworking, this system provides metal fabrication shops with unprecedented flexibility by allowing them to customize their robotic bending cell according to their precise needs

In this article, we will explore what the RBS is, its main benefits, technical features, typical use cases, and points of caution. We will conclude with a FAQ addressing the most common questions.

1. What is the configurable Robotic bending system?

The LVD RBS (Robotic Bending System) is a modular automation platform that combines a press brake, a robotic manipulator, software, and grippers tailored to the user’s requirements.

Unlike rigid “turnkey” cells, the RBS allows multiple parameters to be configured:

• Choice of press brake (force, length, type)

• Type of material input and output (bins, pallets, conveyors)

• Style of robotic gripper depending on the weight, material, and geometry of parts

The goal is to ensure that each cell is perfectly adapted to a shop’s production flow, maximizing productivity while optimizing return on investment.

2. The three RBS platforms

LVD offers the RBS in three platforms, depending on the size and weight of the parts to be bent:

• RBS 4: for light parts up to 4 kg, maximum dimensions approximately 600 × 400 mm. Compatible with 40–50 ton presses.

• RBS 40: capacity up to 40 kg, larger parts (1600 × 1200 mm), profiles up to 2000 mm. Presses from 80 to 220 tons.

• RBS 80: for very large parts, up to 80 kg, profiles up to 3000 mm, and high-force presses (135–220 tons).

This modularity allows companies to select the platform that matches their production needs without paying for features they won’t use.

3. Technical features and innovations

Key highlights of the RBS include:

• Offline programming software
  LVD’s CADMAN-SIM software automatically generates robot trajectories and bending sequences without requiring on-machine training.

• Intuitive interface
  The system is controlled via a “Touch-B” touchscreen that manages both the press and the robot, simplifying operations.

• Adaptive bending (optional)
  With the Easy-Form® Laser system, the RBS can measure bending angles in real time and automatically adjust to compensate for thickness variations, work hardening, or grain direction.

• Manual operation possible
  The press can be used in manual mode if needed, useful for small batches or one-off parts.

• Variety of grippers
  Users can choose from different types of grippers: universal, magnetic, heavy-duty, etc., depending on the nature of the parts.

• Configurable material flow
  Input/output options include feed bins, pallets, and conveyors, allowing optimization of production flow.

4. Benefits of flexible automation

The RBS system offers several major advantages:

• Production flexibility: By configuring the cell to their needs, shops can handle varied batches, from small runs to medium volumes, without unnecessary costs.

• Reduced cycle time: Automatic programming and tight robot-press coordination minimize downtime.

• Improved quality: Adaptive bending ensures precise angles from the first bend, reducing scrap.

• Rapid return on investment: Precisely adapting the cell avoids overspending, accelerating ROI.

• Scalability: The system can evolve with future needs (changing press, gripper, or flow) thanks to its modularity.

5. Typical applications

The LVD RBS is particularly useful in:

• Metal fabrication shops with a wide range of parts from small, lightweight components to larger, heavier pieces.

• Companies aiming to automate while retaining production flexibility, especially when alternating between manual and robotic production.

• Manufacturers seeking consistent quality and minimizing manual adjustments.

• Firms looking to industrialize without overinvesting, building a tailored cell rather than an oversized “just-in-case” system.

6. Points of caution

Although the RBS is very powerful, certain aspects should be considered before adoption:

• Initial cost – Even configurable, a robotic system requires a significant investment (robot, press, software, integration).

• Training & maintenance – Operators need training on the press, robot, and simulation software.

• Floor space – Depending on the chosen configuration (input, output, press type), the cell can occupy significant workshop space.

• Advanced customization – Excessive customization can complicate maintenance if specific parts (grippers, stations) are used.

• Robotic safety – Like any robotic system, safety measures (sensors, barriers if needed) are required to protect operators.

FAQ – The Configurable Robotic Bending System

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