Ambitious robotic automation at I. Bergmann A/S
Listen to CEO Magnus Bergmann tell how robotic automation has made a difference for the company from the first to the latest robotic cell in the video here.
The first robot cell - a 16 kg KUKA robot with part table and templates operating a Biglia 465 D15 lathe - was installed in. Bergmann in 2015. As with most new projects, it took some work to get employees on board with the idea of automation and to get the complex parts running as desired. However, the collaboration ensured both good training for the employees and that all requests for the robot cell were met - including running raw parts in layers. The benefits soon became clear, and so I expanded. Bergmann also expanded production with their second robotic cell in 2018.
The level of ambition was raised with the next robot cell, consisting of a 120 kg KUKA robot with three different gripper types, changer station, clamping station for vice, cube with 8 zero point units and infeed and outfeed conveyors for workpieces. It operates a Mazak HCN-4000 milling machine and can run many different workpiece types of varying shape and size with automatic change of grippers and fixtures. It also turns the workpiece in the vice to machine all sides and runs unmanned virtually around the clock.
With the latest solution, you had . Bergmann needed a robotic cell for two of their CNC machines that could handle different part types with the shortest possible changeover time. In addition, raw material and finished parts needed to be handled in multiple ways in and out of the cell to ensure flexibility.
In cooperation with I. Bergmann, the solution was a 70-kg KUKA robot with three different gripper types, two workpiece trolleys with a selection of templates, raw material magazine, set-up station, turning station, conveyor with mobile unloading conveyor system and safety guarding with door access.
The possibilities of robotic automation
With the experience of the two previous automation solutions, we installed the latest cell in 2022 - I. Bergmann's most flexible and complex robotic cell to date. The reliable 70 kg KUKA robot operates both a Mazak CV5-500 on one side and a Mazak VCN-430A on the other. It can handle a wide range of workpiece types, including blocks, rounds and sheets, and can switch between them quickly. This ensures enormous flexibility and optimised production in terms of chip times for the different workpiece types in the two machines.
The set-up is also flexible in terms of workpiece handling - in addition to the two workpiece trolleys that are driven in from the front, there is also a raw material magazine in the middle of the cell where plates and blocks can be set up. The finished parts can also be delivered either on the trolleys or via a mobile conveyor system behind the machine, where they can be packed.
The good cooperation
Magnus Bergmann and QRS have been working together since 2015, when their first cell was installed. The cooperation is characterised by high expertise and mutual trust, where good, innovative solutions are created through joint efforts. This ensures reliable production that is competitive in a globalised market. Therefore, it is no wonder that I. Bergmann is already planning the purchase of their 4th robotic cell.
"There are a lot of people selling robots in Denmark, but none of them finish projects like QRS. They don't leave the project until it's running and you, the customer, are happy."
- Magnus Bergmann, Director.
About I. Bergmann A/S
Bergmann is a family-owned manufacturing company in Copenhagen. The company was founded in 1982 by Ib Bergmann at Borups Alle, Frederiksberg, but was moved in 1990 to Vanløse, where it is still located today. His son Magnus Bergmann took over the business from his father in 2016 and has been running the business ever since. The company has 12 employees, producing a wide range of components for various industries, including the medical industry, ships, boat engines, railways, etc. Robotic automation has played a key role in the company's growth and competitiveness in the Danish and international markets.