Bending Fully automatic bending center increases productivity fivefold

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In the heart of Ireland, Fireblock, a visionary manufacturer of fire and explosion-proof doors and windows, has achieved a breakthrough in metal manufacturing. By implementing advanced technologies, the company has succeeded in increasing productivity fivefold while simultaneously establishing new quality standards.

Fireblocks' commitment to innovation and quality is highlighted by the statements of General Manager Pat Collins. "Our mission was not only to increase efficiency but also to improve the precision and ergonomic efficiency of the process," he explains. For this purpose, Fireblock has integrated a fully automatic bending center, the Multibend-Center from RAS, into its production line for bending its door panels. The machine has a bending length of 2560 millimeters and is completed with a 2-position portal loading system, which alternately supplies a sheet metal cut for the cover and the box of the door panel to the bending cell. The second RAS machine is a Profile-Center and automatically bends the elements of the door frames.

The machines impress with their speed, precision, and repeatability. "Every element we produce exactly meets the specified specifications. For fire protection products, this level of accuracy is indispensable," Collins emphasizes. This precision has enabled Fireblock to virtually eliminate scrap parts and rework and achieve a significant quality improvement.

Automation as the key to success

The automatic 2-position portal loading has revolutionized Fireblock's production processes. By automating the entire loading process of the heavy and cumbersome sheet metal plates, the Multibend-Center has elevated the throughput speed and repeatability in the manufacture of door elements to a whole new level. A laser scanner in the suction frame of the portal loading reads all manufacturing information via a QR code affixed to the raw sheet. The Multibend-Center then automatically loads the appropriate bending program and feeds the sheet cut to the bending center. The exact position of the cut is measured on the material transfer table and then handed over to a highly precise manipulator. This manipulator guides the bending part through the bending process. If a sheet cut needs to be manually added to the process at short notice, the operator can do this at any time by handover to the transfer table. This provides maximum flexibility without sacrificing speed.

The RAS Multibend-Center is characterized by its high speed and efficiency. Not only do the pure bending operations occur in record time, but the tool change also functions lightning-fast and automatically. This task is handled by the tool changer, which positions tool segments with the highest precision. Due to the complex bending geometries, it is even often the case that a tool change occurs within the bending process of a door element. Without automatic tool changing, many bending geometries would be unthinkable. This allows Fireblock to produce sheet metal components in record time without having to compromise on quality. Previously, manufacturing a door panel on press brakes required two employees and at least ten minutes. The machine operators had to be well-coordinated and lift and guide the large and heavy sheet with each bend. Today, a single machine operator oversees the bending center without actively intervening in the bending process. Thus, a bending cycle is completed precisely and repeatably in just two minutes without physically strenuous work. This brings not only significant cost advantages but also helps preserve the health of employees. This ergonomic improvement has significantly enhanced working conditions at Fireblock.

Leverage synergies

Through the combined use of the Profile-Center, Fireblock achieves significant improvements in precision and speed in the production of door frames. Where previously several employees required 15 minutes to produce a metal door frame, it is now accomplished in four minutes with just one employee. In addition to the efficiency increase, automatic bending of the frames has also brought a quality leap, especially in the further processing of frame elements. The side parts are placed together with the top in pre-made templates and can be welded into a door frame without preparatory work. The Multibend-Center is not only used for bending door panels; it also bends sheet metal parts for the fireplaces of the sister company Firebird. This production synergy has not only further increased the utilization of the bending center. With its unbeatable flexibility and highest precision from the first manufactured part, the Multibend-Center fits ideally with the requirements profile for fireplace components.

With automatic loading over two loading stations, the production process has already reached a high level. Further productivity increases could be achieved with automation on the discharge side of the finished bent parts. RAS offers various solutions for parts output at the Multibend-Center and advises Fireblock on which system is the most efficient. The use of an unloading robot and a pallet station promises even higher efficiency. The RAS bending experts look forward to soon being able to install the robot and pallet station in Ireland.

Competitiveness strengthened

The implementation of RAS technologies has catapulted Fireblock to the forefront of the metal manufacturing industry. The combination of increased productivity, improved quality, and ergonomic working conditions has not only strengthened Fireblock's competitiveness but also solidified the company's role as a pioneer in the industry. The investment in advanced technologies of the Multibend-Center and the Profile-Center has paid off in many ways, making partner companies Fireblock and Firebird leading manufacturers worldwide in their segment.