In the process of deep integration of information technology and industrialization, new technologies, new models and new ideas are emerging. Industrial enterprises are accelerating the process of digital transformation under the direction of "Made in China 2025". Digitalization has brought many changes and impacts to the industrial manufacturing industry, from production efficiency, innovation and development, supply chain management, customer experience to sustainable development and other aspects. Digitalization is an important way of transformation and upgrading of the manufacturing industry, and is also the trend and direction of the future development of the manufacturing industry.

ESTUN's intelligent sheet metal bending workstation realizes work order management, production execution, equipment management and program management online. The edge computing module collaborates with the E-Noesis industrial digitalization platform to bring accurate and intuitive equipment management, lean and intelligent production process management, and fast and convenient after-sales service.

ESTUN E-Noesis Industrial Digital Platform

Focus on industrial production, insight into the value of data

Realize quality improvement, cost reduction and efficiency of enterprise operation

01 Status of equipment, keep track of it at hand: Localization/Cloud deployment, equipped with 4G high-speed IoT card, data collection frequency as low as 200ms, mobile phones and computers can check the equipment operation status and production progress information anytime, anywhere.

02 Equipment performance, calculate in real time: uptime rate, operation efficiency, value-added operation efficiency;

03 Fault alarm, health monitoring: Equipment maintenance prediction and reminder function, 100% recognition of robot failure and precise positioning, the alarm description is more specific. When equipment fails, it can alarm in real time and push messages to remind mobile phones.

04 Data report, one-click view: Automatic generation of reports, downloadable PDF files; Hierarchical management of permissions (base, workshop, equipment).

Customer Pain Points & Solutions of Bending industry

Q1 Data Silos, Lack of Interoperability

Solution

Ø Integrate the factory MES with workstation equipment, enabling bidirectional data exchange and digitizing the bending workstation;

Ø  Automatically synchronize work orders without manual intervention;

Q2 Manual Recording, Time-Consuming, Prone to Errors

Solution

Ø  Initiate, pause, time, and piece count for work orders;

Ø  Upon completion of work orders, automatically report to the factory MES system;

Q3 Lack of Monitoring, Low Efficiency

Solution

Ø  Monitor/collect status parameters, and report to the factory MES;

Ø  Monitor/collect fault alarms and report to the factory MES;

ESTUN Digital Bending Workstation

1.Work Order Management

Automatic Work Order Synchronization:

Ø The system periodically requests data from the factory MES interface to obtain work order information;

Ø  The frequency of interface calls can be customized, for example, once every 6 hours;

Ø  In case of special circumstances, work order data can also be manually obtained immediately by clicking the 'Sync Work Order' button;

Manual Work Order Creation:

Ø  Click the 'Create Work Order' button, and the system will automatically generate a work order number following the format: YYYYMMDD + serial number. Alternatively, the user can manually input a work order number;

Ø Manually input information such as product materials, model, quantity, bending program number, planned time, etc., and save the work order data;

Work Order Query List:

Ø  The system provides multidimensional query functions, allowing searches based on product materials, work order number, drawing number, product model, planned time, work order status, and other criteria.

2.Production Execution

Work Order Start：

ü  When starting the production of a work order, the staff selects one work order and clicks the 'Start Work Order' button;

ü  The system automatically records the start time of the work order, updates the status to 'In Production,' and issues the work order;

ü At the same time, only one work order can be in the 'In Production' status.

ü  Information such as factory, process, equipment number, operator, and start time can be transmitted to the factory MES to indicate the start of the process.

Work Order Interruption：

ü  In case of urgent rush orders or other special situations, it is necessary to pause the current production work order and start a new one. The staff clicks the 'Interrupt Work Order' button, and the system automatically records the interruption time, updating the status to 'Interrupted.'

ü  Multiple work orders can be in the 'Interrupted' status at the same time;

ü  When resuming production for the interrupted work order, the staff clicks the 'Start Work Order' button to restore the work order to the production status and continue production.

Work Order Reporting：

ü  After completing the production of one product, the work order completion count increases by 1. When the completion quantity reaches the target quantity of the work order, the staff clicks the 'Report Work Order' button to confirm the completion of the work order;

ü  Information such as factory, process, equipment number, operator, quantity, completion time, etc., can be transmitted to the factory MES to indicate the end of the process。

3.  Device Management

Equipment Status Collection：

ü  Real-time collection of robot operation status, such as: working, idle, standby, alarm, downtime, etc.;

ü  Summarize and calculate robot operating time, including: startup time, working time, value-added time, total working hours, etc；

Equipment Parameter Collection：

ü  Real-time collection of robot operating parameters, such as: torque, load on each axis, current, voltage, etc.;

ü  Drawing of operating parameter curves, such as torque trends, load trends, etc.；

Equipment Alarm Monitoring：

ü  Real-time collection of robot fault alarms, with the ability to integrate with instant communication tools like enterprise WeChat for immediate notification;

ü  Various fault alarm statistical analysis, including: Top fault alarm statistics, alarm frequency ranking, alarm duration statistics；

Equipment Data Reporting：

ü  According to the needs of internal systems such as the factory MES or QMS quality management system, categorically summarize and report data on equipment status, operating parameters, and equipment alarm

4. Bending Program Management

Program and Product Matching Table:

Ø  Establish and maintain a 'Bending Program and Product Matching Table' in the system;

Ø  Assign a corresponding bending program to each product material;

Ø  Bending programs need to be edited and debugged in advance;

Ø When a new bending program is edited and debugged, manually add a new record to document the relationship between the new bending program and the new product;

Automatic Bending Program Deployment:

Ø  When a work order starts, the system automatically matches the bending program that should be executed for the current work order based on the 'Bending Program and Product Matching Table' and automatically deploys the bending program number to the robot. The robot automatically switches to the corresponding program based on the program number.

Ø  Automatic program deployment improves efficiency;

Ø  Reduces human errors in operations and enhances accuracy.

Digital Bending Workstation - Digital Twin Dashboard

• Millisecond-level data acquisition;

• Data-driven models;

• Real-time dynamic 3D modeling and simulation,  clear and intuitive;

• Provides a visual representation of equipment operation, including operational posture and internal parameters;

• Reproduces issues, restores scenes, aids in better analysis and problem-solving;

• Data collection from the outside in,comprehensive analysis, and visual presentation.

The application scenario of sheet metal bending

ESTUN Digital Bending Workstation, by bridging the MES of the factory and the equipment of the workstation, carries out intelligent data statistical analysis to achieve digital visualization operation and intelligent decision-making, bringing bidirectional data interconnection, and helping sheet metal manufacturing to develop towards digitalization, integration and intelligent informationization.