Customer Satisfaction! Another Derateck Sheet Metal Automation Production Line Running Steadily

The automated production line solution, custom-built by Derateck for a well-known sheet metal enterprise, has now fully entered normal operation. Since its commissioning, the line has been running stably with outstanding performance, and the customer is highly satisfied with the actual results.

 

This production line integrates high efficiency, high precision, and intelligent automation. It consists of four core units: the unloading unit, punching unit, transfer unit, and bending unit. Through Derateck’s self-developed central control software, production tasks are centrally managed, broken down, and dispatched, connecting all units via unified communication and scheduling to achieve unmanned production. This effectively addresses the pain points of traditional production models, significantly improving production efficiency, processing quality, and equipment utilization.

 

Four Core Units Working in Synergy

 

1. Unloading Unit

Centered around an FA3015/6000W fiber laser cutting machine, equipped with a DRW3015-7 seven-layer vertical storage tower and a DLF3015-Sort automatic loading/unloading device. The laser cutting machine features an integrated welded frame structure, and the exchange table adopts a parallel pull-to-pair working mode, resulting in shorter exchange times and higher production efficiency. It is powered by a Precitec auto-focus cutting head, a FSCUT4000E system, and Inovance servo motors. The DRW3015-7 vertical storage tower has a load capacity of 3 tons per layer, is equipped with plate separation and double-plate detection functions, and runs on a self-developed operating system with a clean and user-friendly interface. This unit is designed with full consideration for stability and efficiency in high-frequency production environments, achieving automated, continuous, and precise cutting operations.

 

2. Punching Unit

Centered around a DAS3.1550 servo CNC turret punching machine, featuring a closed-frame wide-body structure that enhances resistance to horizontal torsional forces and improves overall machine stability. Equipped with a DWP3015-7 seven-layer vertical storage tower and a DPE3015-Sort loading/unloading and sorting system, powered by the Fanuc Oi-PF control system, with Metalix CNCKAD software for programming. This unit delivers outstanding performance in punching accuracy, production cycle time, and intelligent control, reliably handling multi-batch, multi-variety production demands.

 

3. Transfer Unit

Comprising five high-low exchange trolleys and two sets of DLG200-3015 gantry-type handling and palletizing robots. Through task distribution by the central control system, materials are picked up from the laser and punch unloading roller tables and placed onto the corresponding transfer palletizing high-low exchange trolleys, greatly improving inter-process衔接 efficiency and ensuring smooth material flow.

 

4. Automatic Bending Unit

Composed of two TAM-80/2500S CNC press brakes and two FANUC R-2000ic/210F robots with movable axes. The press brakes feature mechanical deflection compensation and are equipped with the Italian ESA S640 system (6+1 axes). The robots work in tandem with the press brakes to enable continuous operation, significantly reducing manual labor while ensuring bending accuracy and consistency.

 

Since the production line entered daily operation, customer feedback has been overwhelmingly positive. The customer reports a marked improvement in overall efficiency, excellent consistency in cutting, punching, and bending accuracy, and stable, reliable equipment operation. Processes that previously required multiple skilled workers to coordinate — such as loading/unloading, material handling, and bending — are now seamlessly completed by the automated line. This not only substantially reduces labor costs but also eliminates quality fluctuations caused by human error at the source. The customer is highly satisfied with the line’s actual performance and believes this solution has effectively resolved their long-standing production pain points.

 

Leveraging its extensive and diverse sheet metal equipment product line, combined with its self-developed central control system, Derateck continues to deliver more efficient and intelligent production solutions to its customers. The successful implementation and stable operation of this production line once again confirm Derateck’s technical strength and delivery capability in the field of sheet metal automation. Looking ahead, Derateck will continue to deepen its efforts in the intelligent upgrade of sheet metal processing, helping more manufacturing enterprises advance toward new heights of smart manufacturing.