As system integrator Bright IA was developing an automated work cell for a metal fabrication process, they decided to partner with Valin to support the mechanical infrastructure and safety systems required for the project. The goal of the automation initiative was to improve production efficiency while addressing labor challenges in a demanding manufacturing environment. By combining flexible structural design, safety infrastructure, and hands-on installation support, Valin helped Bright IA successfully deploy a robotic work cell that significantly increased production throughput while improving safety for operators.

Manufacturing Challenges

The application centered on producing metal fenders used for trailers. In the existing process, operators manually fed metal plates into a press brake and removed them after processing. This manual workflow created two major challenges for the manufacturer. First, the plant struggled to recruit and retain operators for the physically demanding work. Second, the company wanted to increase production without increasing headcount. Automation offered a way to address both issues simultaneously.

Bright IA designed an automated system using robotics to load and unload parts from the press brake. However, implementing the system required supporting mechanical infrastructure that could integrate new automation technology with existing equipment.

Integrating Automation

The press brake being used in the project was an older machine that had not been designed with modern automation in mind. Surfaces were uneven, the surrounding floor was rough, and the physical footprint around the equipment was extremely tight. Successfully integrating the automation system required adaptable structures and the ability to make adjustments during installation.

Valin supported the project by designing and building the structural framework required for the system’s conveyors and safety guarding. Bright IA specified the use of three timing belt conveyors to move metal plates into and out of the press brake. Based on general dimensional parameters provided by Bright IA, Valin designed custom frames to support the conveyors and fit within the limited space available around the press brake. The team worked through several design revisions before fabrication and ultimately delivered the completed structures to the facility.

Designing the Conveyor 

The conveyor support frames were designed to fit around the press brake and integrate within the tight layout of the work area. By handling the design of the frames, Valin helped remove a significant engineering task from Bright IA’s workload, allowing them to focus on the broader automation system.

The modular framework allowed the conveyors to be mounted securely while still providing the flexibility needed to adjust alignment and positioning during installation.

Safety Fencing and Interlocks

In addition to the conveyor frames, Valin designed and supplied perimeter safety fencing for the automated work cell. The fencing was based on a general layout provided by Bright IA but required detailed design work to fit within the tight workspace and accommodate door access points.

Valin also installed safety door interlock switches on the fencing to help ensure operators could not enter hazardous areas while the equipment was operating. The system was designed with OSHA compliance considerations in mind, including requirements related to fencing layout and safe access.

On-Site Installation and Troubleshooting

The installation phase revealed additional challenges common to retrofitting automation into legacy equipment. Because the press brake and surrounding environment were not perfectly aligned or square, the structures required a high level of adjustability.

Valin’s modular aluminum extrusion framework allowed the team to make these adjustments during installation. When the system began running, the teams identified additional areas that required reinforcement or modification. Valin personnel visited the facility multiple times to help resolve these issues, adjusting the conveyor structure, reinforcing sections of the fencing, and recommending additional hardware needed to complete the installation.

This hands-on collaboration was critical during commissioning. In several cases, Valin helped Bright IA select and install additional components that were not originally specified but became necessary during implementation. The modular nature of the structural system made these changes possible without major redesign.

Flexible Design

The flexibility of the structural system was an important advantage for the project. The aluminum extrusion framework uses T-slot channels that allow components to slide and reposition along the structure. This makes it possible to adjust equipment placement, add new devices, or expand the system if production requirements change.

Maintenance teams can also modify the framework themselves by adding additional structural pieces and fastening them directly into the existing slots. This adaptability ensures the system can evolve as the manufacturer continues to automate more processes.

Results

Once operational, the automated work cell delivered a substantial improvement in production throughput. Although the original goal was to achieve a 20-second cycle time, the legacy press brake was unable to reliably operate at that speed due to mechanical limitations. After testing, the team adjusted the system to run slightly slower to prevent the machine from locking up.

Even with this limitation, performance improved dramatically. The process went from approximately 85% efficiency in the manual operation to 138% efficiency with the robotic system, resulting in a significant overall increase in throughput.

Automation also significantly improved operator safety. In the previous manual process, workers had to feed metal plates directly into the press brake. The new system allows operators to remain outside the work cell, with parts loaded and unloaded using forklifts rather than manual handling near the press. Combined with the safety fencing and interlocks installed around the cell, the automation system also greatly reduces the risk of injury and removes operators from potentially hazardous areas.

The project demonstrated the value of close collaboration between integrators and local suppliers. Valin supported the project not only through design and fabrication, but also through availability during installation.

Team members delivered materials directly to the site and assisted with adjustments as issues arose during commissioning. This level of support allowed Bright IA to resolve problems quickly and keep the project moving forward.

Looking Forward

Following the success of the project, Bright IA and manufacturer have already begun discussing additional automation initiatives. Additional safety fencing is being quoted for the existing installation, and similar structural solutions are being considered for future automation projects.

The manufacturer has expressed strong satisfaction with the system and is evaluating how similar approaches could be implemented on additional equipment across its facilities.

By combining product expertise, flexible structural design, and hands-on support during installation, Valin helped enable the successful deployment of a complex automation project in a challenging manufacturing environment. The result was a safer, more productive process and the foundation for continued automation expansion.

Need Help Automating Your Manual Process?

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