In recent years, more and more companies have started to consider adopting automated production. The reasons behind this shift are straightforward. For many businesses, the Chinese yuan has been steadily depreciating, while labor costs continue to rise each year. However, the selling prices of their products haven't increased proportionally—instead, they've been declining over time. Recruiting workers has become increasingly difficult, managing them is a challenge, and workplace accidents are on the rise. All these factors have pushed business owners to look for ways to reduce direct labor and management expenses. As a result, automation has become the preferred choice in labor-intensive industries.
Automation offers a practical solution for repetitive and simple tasks. By replacing manual labor with automated equipment, companies can reduce the number of workers, lower accident rates, and improve product consistency. This not only enhances efficiency but also boosts overall profitability.
In the pipe processing industry, numerous manual steps are involved, such as cutting, deburring, forming, bending, punching, and welding. Each of these stages traditionally requires significant human involvement. Let's take the bending process as an example and explore how automation systems can be integrated into this workflow.
First, the automatic loading and unloading system for pipe benders:
A pipe bender equipped with an automatic loading and unloading system can eliminate one worker per machine. For instance, if a workshop has nine pipe benders, each fitted with an automatic loader/unloader, it could save up to eight workers. Additionally, the system allows for batch processing, and once the silo is full, the equipment can operate continuously for several hours. During this time, workers can perform quality checks on the produced items. This setup not only achieves full automation but also helps the company save on labor costs and create new profit opportunities. The investment is relatively low, the results are quick to see, and maintenance is straightforward.
A typical case video demonstrates this system. In the video, the automatic loading and unloading system of the pipe bender can handle fittings automatically, with a cycle time close to that of manual operations. Overall efficiency is even higher than manual work. Even under low conditions, the weld seam can be detected. If you consider the cost of a single year’s salary (8 hours), it could be used to purchase a specialized plane (effectively transferring wages to an automatic system without extra costs). If the automatic plane operates two or three shifts daily, the investment can be recouped within six months. Over time, the company can save on labor, increase profits, and reduce operational risks by maintaining low maintenance costs.
Pipe fitting range: Diameter 12–38+, pipe length 150–1000 mm, adjustable opening size.
Second, the automatic loading and unloading mode using industrial robots:
An industrial robot can be used to feed and unload a pipe bender. In this configuration, the robot works alongside the pipe bender, handling material feeding and unloading. A sorting mechanism is required at the loading stage (and may include weld seam inspection if needed). The specific setup includes:
[Image: An industrial robot serving a pipe bender]
A typical case video shows an industrial robot working with two pipe benders. In this setup, one robot coordinates with two bending machines. To enhance the system’s speed, the loading mechanism is directly connected to the bending machine. Material inspection (including weld seam detection) can be performed efficiently. Both bending machines can process the same or different pipe fittings, depending on the program. The robot handles the blanking and cutting, ensuring precise operation according to the set code. The detailed configuration is shown below.
[Image: An industrial robot working with two pipe benders]
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Shenzhen Jiesaiyuan Electricity Co., Ltd. , https://www.gootuenergy.com