The Challenge
Handling Multi-Bend, 500+ lb Parts with Minimal Labor
The customer needed a flexible robotic solution to replace multiple manual operators and improve consistency. Their goals included:
- Automating bending for high-mix parts, some exceeding 500 lbs
- Performing multiple bends per part with precise repositioning
- Supporting automatic tool changes between bends
- Minimizing labor and operator fatigue while maintaining throughput
MWES was selected to design and deliver a scalable machine-tending cell tailored for bending complex, heavy metal components.
The Solution
Track‑Mounted ABB Robot with Multi‑Tool Changer & BendWare Integration
MWES delivered a turnkey robotic cell featuring:
- ABB robot on a floor track servicing a Bystronic press brake
- Three tool-changing EOATs for varied part geometries
- Part squaring table and re‑grip station between multiple bends
- BendWare robot programming and Xpert 250 brake interface
- Automated infeed/outfeed station and full ANSI/RIA safety systems
This automation streamlines multi-bend sequences and reduces operator intervention, delivering flexibility and reliability in high-volume bending.
The Results
24/7 Operation with Increased Throughput, Safety & Quality
The completed system unlocked productivity gains and labor reductions:
- Enabled continuous bending with minimal staffing
- Improved part consistency across varied geometries
- Removed heavy lifting from operators and reduced injuries
- Simplified tool changes and program control for flexible production By automating complex bending processes, MWES helped the fabricator enhance throughput, reduce labor dependency, and avoid quality variation.
