Why are so many companies turning to automated production now? The answer is straightforward. For most businesses, the renminbi has been steadily depreciating, labor costs have been rising year after year, while product prices haven't kept up—instead, they've been declining. It's becoming harder to find and retain workers, managing them is more challenging, and workplace accidents are on the rise. All these factors have pushed business owners to cut direct labor and management expenses. As a result, adopting automation has become the smartest choice for companies in labor-intensive industries.
Any task that is repetitive and simple can be replaced by automated equipment, reducing the number of workers needed, lowering accident rates, and improving product consistency. In the pipe processing industry, from cutting and deburring (chamfering) to forming, bending, punching, and welding, each step typically requires a lot of manual work. Today, we’ll explore how automation can be integrated into the pipe bending process.
First, let’s look at the automatic loading and unloading system for pipe benders. A pipe bender equipped with an automatic loading and unloading machine can eliminate one worker per machine. For example, if a workshop has nine benders, adding an automatic loader/unloader to each can save eight workers. This setup allows for batch processing, and once the silo is full, the system can continue working for several hours. Meanwhile, human workers can focus on quality inspections. This automation not only boosts efficiency but also reduces labor costs and creates new profit opportunities. With low investment, quick returns, and easy maintenance, this is an attractive option for many manufacturers.
Here’s a video showing how an elbow link integrates an automation system for efficient production. The automatic loading and unloading machine in the video handles pipe fittings smoothly, with a cycle time close to manual operations but higher overall efficiency. Even with low conditions, weld seams can be detected. For instance, the cost of one year’s salary (8 hours per day) could buy a specialized plane, effectively transferring wages to automation without additional investment. If the automatic system runs two or three shifts daily, the initial cost can be recovered within six months. Over time, companies can reduce labor costs, increase profits, and minimize operational risks through low-maintenance automation.
The pipe fitting range includes diameters from 12 to 38+ and pipes from 150 to 1000 mm, with adjustable opening sizes.
Next, let’s consider the automatic loading and unloading system using industrial robots. An industrial robot can serve a pipe bender by feeding and unloading materials. The loading area must include a material sorting mechanism, and if needed, it can also inspect the weld seam. The configuration includes a robot, a pipe bender, and a sorting system.
In a typical case, one robot can operate two pipe benders. To enhance system speed, the loading mechanism is directly connected to each bender. Weld seam inspection can be done during the process, and both benders can handle the same or different pipe fittings. The robot cuts and feeds the tubes according to pre-set codes. This setup is shown in the image below.
This kind of automation not only improves productivity but also ensures consistent quality and safer working conditions. As more companies recognize the benefits of automation, integrating such systems is becoming a strategic move to stay competitive in today’s market.
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Shenzhen Jiesaiyuan Electricity Co., Ltd. , https://www.gootuenergy.com