As system integrator Bright IA was developing an automated work cell for a metal fabrication process, they decided to partner with Valin to support the mechanical infrastructure and safety systems required for the project. The goal of the automation initiative was to improve production efficiency while addressing labor challenges in a demanding manufacturing environment. By combining flexible structural design, safety infrastructure, and hands-on installation support, Valin helped Bright IA successfully deploy a robotic work cell that significantly increased production throughput while improving safety for operators.
Manufacturing Challenges
The application centered on producing metal fenders used for trailers. In the existing process, operators manually fed metal plates into a press brake and removed them after processing. This manual workflow created two major challenges for the manufacturer. First, the plant struggled to recruit and retain operators for the physically demanding work. Second, the company wanted to increase production without increasing headcount. Automation offered a way to address both issues simultaneously.
Bright IA designed an automated system using robotics to load and unload parts from the press brake. However, implementing the system required supporting mechanical infrastructure that could integrate new automation technology with existing equipment.
Integrating Automation
The press brake being used in the project was an older machine that had not been designed with modern automation in mind. Surfaces were uneven, the surrounding floor was rough, and the physical footprint around the equipment was extremely tight. Successfully integrating the automation system required adaptable structures and the ability to make adjustments during installation.
Valin supported the project by designing and building the structural framework required for the system’s conveyors and safety guarding. Bright IA specified the use of three timing belt conveyors to move metal plates into and out of the press brake. Based on general dimensional parameters provided by Bright IA, Valin designed custom frames to support the conveyors and fit within the limited space available around the press brake. The team worked through several design revisions before fabrication and ultimately delivered the completed structures to the facility.
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