Types of robotic bending cells
ROBOTIC BENDING
The SafanDarley MultiCell. Bystronic’ s ByBend Star 40 and Mobile Bending Robot.
Vacuum or magnetic grippers ensure secure handling, while the system automatically checks for double-sheet picking.
■ Positioning and alignment: The workpiece is precisely positioned in the press brake working area using mechanical stops, vision systems or automatic adjustment of the back gauge. Accurate calibration between the robot and machine coordinate systems is critical.
■ Feeding into the press brake: The robot feeds the sheet along a predefined path between the upper and lower tools. Before the upper beam descends, the robot stabilises the part and reduces grip pressure. Communication between the robot and the machine takes place in realtime via industrial protocols.
■ Bending: The press brake performs the bending according to the programmed parameters. The robot maintains workpiece stability and retracts after the operation. Advanced sensors and feedback loops maintain bending accuracy within ± 0.2 ° to ± 0.5 °.
■ Repositioning and rotation: For multistep bending, the robot adjusts the sheet orientation— rotating, tilting or flipping it— and repeats the cycle. Smart pathplanning algorithms prevent collisions.
■ Unloading and palletising: After bending is complete, the robot places the finished part in a designated area or palletising station. Some systems also include inline quality inspection and automatic sorting.
Benefits of robotic bending
Robotic bending systems integrate seamlessly into smart factory environments. Data on bending angles, force, cycle time
Types of robotic bending cells
There are various types of robotic bending cells. Choosing the right configuration depends upon available floor space, production volumes and workflow requirements.
■ Floor-mounted robot( fixed or rail)
■ Gantry robot
■ Rail robot( seven-axis)
and efficiency are collected in real time and transmitted to MES and ERP systems for monitoring and traceability. This enables precise tracking.
There are numerous benefits to the process, some of which are outlined below.
■ Speed and throughput: Delivers consistent, predictable cycle times and enables true 24 / 7“ lights-out” operation, maximising asset utilisation( OEE).
■ Consistency and quality: The repeatability of the robotic movement guarantees a precise and uniform bend in each piece, eliminating defects and production waste. Precision is essential for components that require tight dimensional tolerances.
■ Flexibility and agility: The robots can be programmed to perform different types of bending, adapting to any geometry of the piece and specific production needs. A wide range of products can be processed with rapid changeovers via Offline Programming( OLP) and automated tool / gripper systems. Suitable for high-mix, low-volume( HMLV) production.
■ Enhanced safety: Robots eliminate the need for manual intervention in bending operations, reducing the risk of workplace injuries. Robotisation helps to create a safer working environment for operators.
■ Optimised productivity: The speed and efficiency of robots enable increased production and reduced cycle times, maximising hourly output. Robotisation allows for increased productivity without sacrificing quality.
■ Waste reduction: The precision of the robotic process minimises human errors and material waste, contributing to the sustainability of production. Waste reduction translates into a lower environmental impact and cost savings.
AI in robotics
“ Artificial intelligence( AI) is increasingly transforming automatic bending machines by increasing productivity and flexibility in production. AI-driven systems are capable of real-time production data analysis, automatic bending parameter adjustment and error detection. This aids producers in minimising downtime, cutting down on material waste and preserving constant product quality. Predictive maintenance and process optimisation are made possible by the integration of AI with sophisticated sensors and smart manufacturing platforms,” outlined analyst, Precedence Research.
Instead of teaching a robot every single move by hand, AI algorithms create programs in seconds, control the machine in real-time and automatically adjust for material flaws such as metal thickness or hardness. Adaptive learning systems collect data during every machine cycle. Over time, the AI learns from this data, continually refining its performance to work faster while limiting waste. AI vision systems monitor bend accuracy, stacking, workpiece handling, sorting and quality control
According to the International Federation of Robotics( IFR), robots that use artificial intelligence to work independently are becoming more common. The main benefit of AI in this context is the increased autonomy of robots empowered by AI. Different types of AI drive this trend. n
ISMR July / August 2026 | ismr. net | 39