Deviation from the reference geometry is measured using laser sensors and corrected by controlled bending of the part with an electric servo press. The process is repeated several times until the error falls within the specified tolerance range.

Purpose of the machine The main purpose of the machine is to bend the part along the X axis in order to improve the casting geometry. How it works: placing the part in the lower nests of the extended moving module; starting the cycle with the START CYCLE button; clamping the part with preliminary clamps; measuring the casting accuracy against the nominal dimension; moving the part into the working section of the machine; bilateral clamping of the part with the main clamps; bending the part with the X-axis pressing unit and holding it in this position for the required time; retracting the bending mechanism; releasing the main clamps; returning to the home position; re-measuring the part geometry and comparing it with the specified tolerance.   - If the part still remains outside the tolerance range, the bending operation is repeated up to three times (if no further correction is possible, an alarm is triggered); - A part that falls within the tolerance range is marked on the right-hand side and released from the clamps (OK part).

Machine design

OPERATOR PANEL

The control elements and display allow the operator to monitor the process status, control the cycle sequence and bending process rules, as well as manage the movement of the machine’s individual drives.

PART DEVIATION MEASUREMENT SENSORS

The level of part deviation from the reference geometry is monitored by a set of Keyence IL-100 sensors. These devices enable measurements with an accuracy of 4 µm.

PRELIMINARY CLAMPING MODULE

This module is designed to immobilise the part intended for the bending process. The clamping arm is driven by an SMC CP96SDD40-80C pneumatic cylinder with a stroke of 80 mm.

SIDE CLAMPING MODULE

The side clamps are responsible for precise positioning of the part before the machining operation is carried out. Due to the irregular shape of the part, the machine has been equipped with dedicated lower and upper nests whose supporting surfaces replicate the reference geometry. After the operator initially places the part in the lower nests, the presses fitted with upper clamping nests are engaged. The drive base of the clamping module consists of SMC CP96SDD50-320C cylinders. The clamping system is based on a toggle mechanism, which multiplies the clamping force and prevents the clamp from being pushed out.

X-AXIS BENDING MODULE

The horizontal-axis bending module, equipped with a high-quality SMC EMC-080-NN-2-150 servo press, is designed to improve the casting geometry. The press movement acts perpendicular to the arc of the part deflection and, after reaching the required stroke, remains in this position for the necessary time to stabilise the correction. The pressing unit is fitted with a universal fixed nest compatible with references FM2940100008A and FM2940100300A.

Benefits for the customer/user

• improved casting quality by eliminating geometry deviation of the part in relation to the reference model;
• precise measurement of the error value;
• the machine is equipped with the necessary safety measures in accordance with PN-EN ISO 12100, such as: emergency stop, light curtain, safety switch and guards;
• quick coded nest changeover system – possibility of bending left-hand and right-hand references;
• easy service access for maintenance personnel – double rear doors;
• ergonomic design.