Robotic press tending cell
Our customer: Isola Powertekk s.r.o.
Isola Powertekk s.r.o. operates manufacturing facilities in Olomouc and Velké Losiny, Czech Republic. The company, part of the Norwegian Isola Group, specializes in the production and supply of gutters, lightweight roofing systems, insulation materials for pitched, flat, and green roofs, as well as floor insulation solutions. In addition, it operates in the field of deep foundation engineering, manufacturing components and accessories used in foundation construction and tunnel engineering.
Automation of press operations
The objective of the project was to automate the loading of metal blanks into the presses and the unloading of finished stamped parts.
The first workstation is equipped with two KUKA industrial robots that handle both the loading of metal blanks into the press and the unloading of finished stamped parts. The workstation operates with a cycle time of 8.5 seconds per part, while the robotic system itself is designed to achieve cycle times of up to 6.5 seconds per part.
The final cycle time is determined by the technological capabilities of the press.
The second workstation is equipped with a single KUKA robot that provides complete press tending, including loading semi-finished parts into the press and unloading finished components. This workstation operates with a cycle time of 18 seconds per part.
Project description
For reliable material feeding, both workstations are equipped with a sheet separator that uses a magnetic field to separate individual sheets. This ensures that the robot always handles only a single sheet at a time, minimizing the risk of loading errors and contributing to a stable and reliable press operation.
When a new pallet is introduced, the system uses laser-based sheet detection to accurately determine the position of the top sheet and establish a reference point for subsequent handling. Material picking as well as finished part unloading are performed by vacuum grippers featuring an air-saving function, enabling fast, gentle, and energy-efficient manipulation throughout the process.
The robotic cell includes:
- Automatic loading of metal blanks into mechanical presses
- Automatic unloading of finished stamped parts
- Robotic material handling using vacuum grippers with compressed air saving technology
- A magnetic sheet separator for reliable separation of individual metal blanks
- Laser-based sheet detection when a new pallet is introduced
- Integration of KUKA industrial robots into the production process
- Safe and fully automated operation of the robotic cell
Benefits of the Solution
The implementation of the robotic press tending system has eliminated repetitive manual handling of metal blanks, resulting in a smoother and more stable production process. The robots take over physically demanding loading and unloading operations, significantly reducing the workload of operators and allowing them to focus on higher-value tasks.
The automation also delivers higher productivity, improved utilization of production equipment, and consistent process quality. Precise material feeding and repeatable robotic handling minimize downtime and reduce the risk of production errors.
The result is a reliable and efficient robotic cell that increases production performance, improves working conditions, and supports the long-term stability of the manufacturing process.
Our customer says:
»There are many suppliers of robotic workstations on the market today and it is not easy to choose a reliable partner able to come up with the right solution, able to deliver the equipment on time and provide long-term reliable service.
I am glad that we have chosen Blumenbecker Prag for our projects.«