Plate Handling Automation for Sheet Bending Line

Industry:
Construction and Heavy Equipment Manufacturing

About the Customer:
A leading global manufacturer of construction equipment, this company entered the Indian market in 1979, originally through a joint venture. Over the decades, it established a strong presence, becoming a leader in backhoe loaders and other heavy machinery in India. The company now operates three manufacturing facilities across India, including a state-of-the-art plant in Talegaon, Pune, which serves both domestic and international markets with advanced production capabilities.

The Backdrop:
The Talegaon facility, one of the company’s most advanced plants, required an efficient plate-handling automation system to support its sheet-bending line. In 2014, the company identified the need for a vacuum gripper and gantry system to handle sheets for bending operations—technology already in place at its UK facility. However, importing the UK system for use in India proved prohibitively expensive. To address this challenge, the company sought a local partner with the expertise to replicate and enhance the existing system while providing long-term support.

Sparkline, although new to this type of automation solution, was selected based on its design and project management capabilities. To ensure a seamless implementation, the company sponsored a Sparkline team visit to its UK facility to observe the system in action, analyze the UK setup, and align it with the specific requirements of the Pune plant’s operations.

The Challenge:
The customer’s challenge was twofold: first, to avoid the high costs associated with importing the plate-handling automation system from the UK; and second, to find a local supplier who could design, manufacture, and commission a similar system that would seamlessly integrate with existing operations.

The Requirements Included:

  • Seamless Integration: The new system had to integrate efficiently with the existing bending line and meet the production requirements.
  • Automated Operation: While initially semi-automated, the system would eventually need modifications to reduce cycle time and support increased demand.
  • Cost-Efficiency: The system had to be designed locally to meet budgetary goals and eliminate the need for costly imports.
  • Enhanced Safety: The setup had to reduce manual intervention, minimize human error, and maintain a high safety standard.

The Solution:
After studying the UK system and assessing the Pune plant’s operations, Sparkline developed a customized solution that met the customer’s specifications. The initial system was manufactured and commissioned within four months, at a significantly reduced cost compared to importing the equipment from the UK.

Key components of the solution included:

  1. Semi-Automated Plate Handling System: The initial system was semi-automated, with four vacuum cups for gripping sheets and manual solenoid valves operated by the machine’s operator. This setup provided a 10-minute cycle time to load, bend, and transfer the sheets for further processing.
  2. Modifications for Enhanced Automation**: As production demand grew, the customer sought a cycle time reduction of 40%, prompting Sparkline to modify the system and enhance its automation:
    • Additional Vacuum Gripper: Sparkline added a fifth vacuum cup to accommodate various sheet sizes, from 1400mm to 6000mm in length and up to 2000mm in width.
    • Electromagnetic Valves: The manual solenoid valves were replaced with electromagnetic valves to improve precision and eliminate manual intervention.
    • Servo Motors for Swiveling Motion: To achieve precise motion control, Sparkline replaced induction motors with servo motors, enhancing efficiency and reducing handling time.
    • Hydraulic System for Vertical Motion: A hydraulic system with distance sensors was installed to control the up-and-down movement, while barcode-enabled LT and CT gantry movement ensured precise gripper positioning.
  3. Advanced Programmable Logic Control (PLC): Sparkline developed 35 unique programs for handling various bend shapes, enabling operators to select specific programs based on component numbers. This reduced setup time, optimized handling, and facilitated the removal of complex bent parts from the press bed.
  4. Automated Conveyor System: An automated roller conveyor, equipped with sensors, was installed to transport parts to the next station. This conveyor moved only when parts were detected, ensuring streamlined and efficient flow between workstations.
  5. Comprehensive Safety Barricades: The entire system was barricaded to prevent any human entry, ensuring zero accidents and eliminating the risk of human error in operations.

Sparkline’s modifications were completed within six months, achieving the target cycle time of six minutes per sheet and significantly increasing productivity.

A Statement of Overall Benefit:
Sparkline’s custom-built automated plate handling system enabled the customer to achieve a 40% reduction in cycle time, enhancing productivity and safety while eliminating downtime and breakdowns. This innovative approach not only met production demands but also optimized costs by leveraging local manufacturing and minimizing import expenses.

Benefits:

  • Increased Productivity: The system reduced cycle time from 10 minutes to 6 minutes, meeting the increased production demands and optimizing the sheet-bending process.
  • Enhanced Safety: Comprehensive automation and safety barricades led to zero accidents and eliminated human errors, ensuring a safer working environment.
  • Zero Downtime: The system has operated seamlessly without any breakdowns for four years, supporting uninterrupted production and enhancing overall line efficiency.
  • Cost Savings on Capital Expenditure: By modifying and automating the existing semi-automated system, the customer achieved cost efficiencies and avoided the need for a costly, imported setup.
  • Streamlined Operations: The automated conveyor and programmable logic reduced manual intervention, providing a smooth and efficient material flow between stations.

Sparkline’s solution allowed the customer to meet its productivity goals with a fully automated, cost-effective, and highly reliable system that has continued to perform optimally in a high-demand manufacturing environment.