Press Brake Reconfiguration Concepts Based on Part Features

Press Brake Reconfiguration Concepts Based on Part Features of Box-type Bent Sheet Metal Components. Norman Gwangwava Doctorate in Technology: Engineering: Industrial Supervisor: Dr Khumbulani Mpofu (TUT) Co-Supervisors: Dr Nkgatho Tlale Dr Yan Yu (NCUT) Date: 07 September 2012

PRESENTATION OUTLINE • Research Motivation • RMT: RMS’ Crucial Element + Ways of Reconfiguration • Sheet Metal Bending • Press Brake Reconfiguration Concepts • Concluding Remarks 2

RESEARCH MOTIVATION Product demand is unstable and rapidly changes Variety of products increase Short window opportunities for new products Short time to market TURBULENT MARKET Short product life-cycle Highly educated customers , who are more demanding Rapidly changing customer needs World –wide competition 3

Reconfigurable Manufacturing System- RMS • RMS is designed at the outset for rapid change in structure, as well as in hardware and software components, in order to quickly adjust production capacity and functionality within a part family in response to sudden changes in market or in regulatory requirements, (Koren et al. 1999). • RMS is a system capable of tailoring the configuration of a manufacturing system to meet the production demands placed on it dynamically, (Liles and Huff, 1990). – RMS Rationale • RMS concept has been proposed to meet the changes and uncertainties of manufacturing environment, and this objective would be achieved by reconfiguring hardware and/or software resources. 4

Reconfigurable Machine Tool. RMT • RMT is a modular machine that can be morphed to minimally fulfil the assigned machining tasks. It offers the pros of both ‘flexible’ and ‘dedicated’ machine tools, (Gupta. A, 2003). – An RMT is the most essential element of RMS, (Koren et al, 1999 and Stoian. C, et al, 2007). 5

Ways of Reconfiguring RMTs • There are two ways to reconfigure machine tools: replacing machine tools and integrated reconfiguration function. Reconfigurable Machine by Replacing Machine Modules. 6

Ways of Reconfiguring RMTs. . Cnt • Reconfigurable Machine Using Integrated Reconfiguration Functions. 7

Reconfigurable Bending Press Tools (RBPTs) 8

Conventional Press Brake • A press brakes is a machine used to bend sheet metal. To do so, a bottom tool is mounted on a lower, stationary beam and a top tool is mounted on a moving upper beam, (Simons, 2006). Source- Wila B. V, 2007 -2008 9

Bent Sheet Metal Products and part features • Household goods made from bent sheet metal comprise of cutlery, sink basins, cooking stoves, panels for fridges and kitchen cabinets. • Industrial goods include electrical meter boxes, automotive parts and body panels. • Other applications are in communication equipment and medical instruments Research Focuses on box-type bent sheet metal parts/products 10

Bent Sheet Metal Products and part features. . Cntd…. 11

Parts’ Localized Formed Features • Manufacturing features are broadly classified into four major classes— cut, stretched, drawn and bent 12

S H E E T M E T A L F E A T U R E S Source: Kannan and Shunmugam, 2009 13

PRESS BRAKE RECONFIGURATION CONCEPTS The following parameters for press brakes were identified as the basis for reconfiguration with the main objective of process plan optimization; Press brake length- determines setup length available and shared setup Bending force – optimum capacity utilization Setup time and ramp-up time Number of strokes Number of axes Bending technology – for application of reconfigurable multi-modular machine tools (RMMT) • Sheet stock feeding and handling • • • 14

Press Tool Reconfiguration Concepts. • Reconfiguring Press Brake Length – scissor concept for extending the press frames. – A sliding door mechanism to provide machine guarding and also supporting the ram and bed against deflection. – The ram and beam modules can either be provided as standard single sizes to be changed according to the new extended press size – or they can be in sections which will joined together. One end will always be fixed. – Slide Rail, Fixturing and Anti-vibration modules on movable ends are also suggested as means to ensure rigidity of the reconfigured press brake structure. 15

Concept Sketches. . Supporting Frame Hydraulic Cylinder x 2 Bed Joined to extend press length Movable End Slide Panels Top View 16

SCISSOR FOR EXTENSION Extension RACK AND PINION - is a type of linear actuator that comprises a pair of gears which convert rotational motion into linear motion. 17

OPEN GAP RECONFIGURATION Hydraulic cylinder Sliding Rail Open Gap Reconfiguration Press brake table 18

CONCLUDING REMARKS • RBPTs will form a new era in advanced research on sheet metal bending machinery. • RBPTs will cater for the dynamic needs of the modern day, highly educated and more demanding customers. 19

? THANK YOU! KIITOS!!! eng. normie@gmail. com 20