May 2023 Volume 5

AUTOMATION

What if the Press Brake Fails? This is another one of the unexpected things that can and will eventually go wrong. Of course, we all want the maintenance folks to get to the press in time to prevent a brake failure, but there is a way to protect the robot equipment in case of a catastrophic failure. The robot can monitor a transducer that is attached to the ram. A program is created which runs continuously and monitors the ram position. Limits are set on this position so that the robot cannot enter the forge until it is known the ram is out of the way. Also, while the robot is in the press, this program is monitoring the ram position. If the brake slips, the transducer will detect this and share this with the active robot program. This program then skips to an escape move and signals the robot to retract at high speed. This setup has saved many robot EOATs.

Conclusion Strategically implement sensors to monitor important data in the cell-capture history, as it will help with troubleshooting and optimization. Review your cell programming and make sure your setup covers normal operation and the “what ifs”. Control access to the cell and controls. Use specific HMI screens for job changes part selection, tooling setup, and die change. Use poke yoke sensors to verify job changes occurred correctly. Build in sensor checks. Use short robot programs that can be called up from a mainline program. Expect the unexpected and have a method to recover quickly and easily. JimMorris Executive Vice President Automation for Manufacturing, LLC Phone: 607-481-4465 Email: jmorris@auto4mfg.com

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FIA MAGAZINE | MAY 2023 47