3 phase ABB Robotic Stamping High Tonnage Tandem Press Line Smart Factory Solutions
Price:
Negotiable
MOQ:
1
Delivery Time:
60 days
Brand:
Qicheng
Product Description
Smart Factory Solutions: ABB Robotic Stamping & High Tonnage Press Lines
In the era of Industry 4.0, Zhejiang Qicheng Intelligent Technology provides specialized Smart Factory Solutions for High Tonnage Press Lines (1200T - 2500T+). By seamlessly integrating world-class ABB 6-axis and 7-axis robotics with our proprietary SAS Intelligent Control System, we transform traditional tandem stamping lines into high-velocity, data-driven production engines, empowering global automotive and heavy industrial sectors to achieve breakthroughs in both capacity and precision.
High-Tonnage Stamping Performance Matrix
For heavy-duty metal forming, we utilize high-inertia management and microsecond-level synchronization to ensure superior system stability under extreme loads.
| Performance Metric | Manual / Legacy Mechanical Line | Qicheng ABB Robotic Stamping Line |
|---|---|---|
| Compatible Tonnage | 600T - 1000T | 1200T - 2500T+ (Ultra-Heavy Duty) |
| Robotic Hardware | Standard Units | ABB IRB 7600 / IRB 8700 (High-Payload) |
| Throughput (SPM) | 6 - 8 SPM | 12 - 15+ SPM (High-Speed Sync) |
| Payload Capacity | < 150 kg | Up to 800 kg (Reinforced Wrist) |
| Changeover Time | 45 - 90 Minutes | < 3 Minutes (Integrated QDC) |
Technical Pillars of Smart Factory Systems
To ensure efficient production of large-scale components (e.g., chassis rails, side panels, and heavy enclosures), we build technical barriers across three dimensions: motion control, structural rigidity, and material handling.
- Dynamic "Fly-Through" Synchronization: Utilizing ABB StampWare and real-time crank-angle tracking, the robot does not wait for the press to reach Top Dead Center (TDC). By calculating a "Safe-Entry Vector," the robot initiates movement while the ram is still ascending. This logic increases the effective output by over 20%.
- Seismic-Isolated Foundation Engineering: High-tonnage strikes generate massive ground-borne harmonics. We employ polymer-filled damping pedestals to decouple the robot's high-resolution encoders from press impact forces, ensuring a repeatability of ±0.05mm throughout a 15-year lifecycle.
- 7th-Axis Servo Linear Transfer Rails: For lines with large press spacing (6-10 meters), robots are mounted on servo linear tracks. With travel speeds up to 5m/s and integrated control as a 7th axis, these rails eliminate intermediate stage tables and significantly reduce the factory footprint.
- SAS Intelligent Cloud Monitoring: The system integrates 24/7 Predictive Maintenance (PdM). By monitoring motor thermals and gearbox vibration frequencies, the system flags alerts if data deviates by 5% from its "healthy signature," preventing unplanned downtime and maintaining high OEE.
Flexibility & Material Handling Capabilities
Modern smart factories must possess the ability to rapidly switch between various materials, such as High-Strength Steel (HSS) and Aluminum alloys.
- Hybrid De-stacking Stations: Features magnetic fanners (for steel) and air-knife separation with eddy current double-sheet detection (for aluminum), switchable via a one-touch software recipe.
- Class-A Surface Protection: Utilizing truss-reinforced Carbon Fiber EOAT (End-of-Arm Tooling) with non-marking vacuum cups, we ensure that exterior body panels remain free of scratches or pressure marks during high-speed operation.
- Virtual Commissioning (Digital Twin): Before hardware installation, a 100% accurate Digital Twin is built using ABB RobotStudio®. We simulate all die and pillar interferences to achieve "out-of-the-box" onsite commissioning efficiency.
Smart Factory Strategic Q&A
How does the system mitigate vibration for workpieces exceeding 4 meters in length?
We implement Active Deflection Compensation. The ABB robot's 6th axis (wrist) is programmed to apply a real-time counter-tilt during the transfer path to offset the physical deflection of ultra-long EOAT, ensuring the part is placed into the next die with absolute precision.
How do you handle the aggressive oil mist and high-temperature environments of stamping shops?
All ABB robots provided by Qicheng are equipped with Foundry Plus 2 protection. The chassis features IP67-rated sealing and internal pressurization to prevent drawing oil mist from corroding internal electronics, making them ideal for both Hot Stamping and high-intensity cold stamping environments.
How does this Smart Factory solution accelerate the Return on Investment (ROI)?
By boosting throughput by 3-5 SPM, reallocating 4-6 high-risk manual positions, and reducing die wear through precision placement, the ROI is typically achieved within 14 - 18 months. Furthermore, it eliminates production quality fluctuations caused by human fatigue.
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Get in Touch
Have questions about our products or want to discuss a custom order? Our team is ready to help you.
Company
Zhejiang SAS Intelligent Technology Co.,Ltd.
Location
No. 1668, Yedao Road, Haiyan Economic Development Zone, Jiaxing City, Zhejiang Province, China
Contact Person
Mike