Cobot press brake tending means using collaborative robots to load, support, and unload parts at a press brake so every bend has consistent form and precision.
With press brake automation you move the handling work from people to a robot, while your existing press brake keeps doing the bending it was designed for.
You gain steadier speed, better quality, and lower cost per part, without rebuilding your whole sheet metal line or replacing good equipment.
At Olympus Technologies in the UK, we integrate Universal Robots and press brakes into a complete solution that is practical, cost effective, and ready for a real production environment.
What Cobot Press Brake Tending Actually Does
The Basic Handling Cycle
A press brake tending cell is an automation solution built around a cobot. The system works by looking after the whole handling cycle around the bend.
In a typical setup, the robot will:
- Pick flat components, often mild steel sheet or other sheet metal.
- Align each part to the back gauges for accurate bending.
- Support the part during the bend so the shape and form stay correct.
- Unload and stack the finished part ready for welding or the next processes.
You keep your existing press brake. The automation is built around it.
- The press brake still controls the bending program.
- The cobot handles loading and unloading.
- Both are connected through the control system so they behave as one system.
Once the programme is set, the cell behaves the same way on every cycle. That repeatability gives precision and stable quality.
Manual vs Automated at a Glance
Manual
- Operators lift and turn each part by hand.
- Position is judged by eye.
- Cycle time drifts through the shift as people tire or parts get heavier.
Automated with cobots
- The cobot follows a defined programming path.
- Position and support are controlled in software.
- People still use their judgement for setup, planning, and quality checks, but repetitive motions move to the robot.
This is the same for small parts and large sheets. The difference is in how you design the solution for each case.
Why Collaborative Robots Fit Press Brake Automation
Flexibility and Changeovers
Traditional robots suit high volume, single part automotive work behind fences. Press brake tending is different.
You need:
- Frequent changeovers.
- Good access for setters and engineers.
- The flexibility to run a range of batch sizes and material thicknesses.
Collaborative robots from Universal Robots are designed with this in mind.
Key advantages:
- Designed to work close to people when a proper risk assessment allows it.
- Mounted on a compact fixed base or mobile stand beside the press brake.
- Easier programming tools than many legacy robots.
- One Universal Robots platform, multiple models for different payloads and reaches.
This means you can:
- Match the robot to your part weight and size.
- Adjust or extend jobs without calling a specialist every time.
- Use the same platform across many different applications such as machine tending, dispensing, case packing, and palletising.
For many companies, a single robot platform with a full range of applications is ideal for long term investment and skills development.
Shared Training and Software
Universal Robots backs the hardware with UR Academy training.
- Short online classes help your team discover how the system is designed to work.
- Clear, readable software tools make it easy to see what the cell is doing.
This makes it simpler to grow from one cell to several and to create new programmes as your business grows.
Strategy 1: Small Parts and Brackets
Small parts need a different approach to large sheets.
Typical Small Part Scenario
You may be bending:
- Small brackets, gussets, cleats, and fixtures.
- Parts in mild steel sheet, stainless, or aluminium.
- High part count, low individual weight.
Pain points:
- Repetitive handling all day.
- High speed expectations.
- Many small variations in shape and bend sequence.
Grippers and Part Presentation
For small parts, the focus is on precision and cycle time.
Good strategies:
- Use finger grippers or compact vacuum tools sized to your components.
- Present parts in simple nests on pallets, trolleys, or stackers.
- Keep the line of movement short between infeed, press brake, and outfeed.
The goal is a cost effective layout with short moves and minimal clutter. This keeps speed up and robot motions easy to follow and maintain.
Programming and Batching
For small parts, programming choices matter.
- Group parts into class families with similar bends and form.
- Reuse a base program and tweak pick positions and angles.
- Keep naming and numbering in the robot clear so operators can select the right job quickly.
Because parts are light, the robot can usually move faster, so most of the gain comes from consistent handling, not raw acceleration.
Safety and Ergonomics
Small parts can still cause problems. Stacks can be sharp, and constant twisting leads to strain.
With cobot tending:
- Operators move into setup, inspection, and cell supervision.
- Manual handling drops, which lowers risk over the long term.
- Jobs that were hard to staff become more attractive.
For many shops, this is the first step into press brake automation because it tackles a visible pain point with a relatively low cost and affordability friendly project.
Strategy 2: Large Sheets and Heavy Panels
Large sheets and heavy panels need a different strategy and system design.
Typical Large Sheet Scenario
You may be bending:
- Door skins and cabinet fronts.
- Large construction panels and frames.
- Long parts that are difficult to support manually.
Pain points:
- High weight at arm's length.
- Hard to hold the shape during bending.
- More risk if a part slips or drops.
Support, Balance, and Safety
For large sheets, the cobot must do more than just pick and place.
Good strategies:
- Use larger vacuum tools or multi point grippers that support the material evenly.
- Add simple mechanical supports or tables under the part to share the weight.
- Use the robot to follow and support the form through the bend, not just stand still.
Safety is critical. You need to ensure:
- Guards, light curtains, and scanners match the reach envelope.
- Stopping distances are measured and recorded.
- Operators have clear sightlines and simple controls.
This approach suits industries such as construction, HVAC, enclosures, and other world markets where large panels are common but the production is still mixed.
Buffering and Flow
Large sheets often benefit from simple buffering.
- Infeed stillages or A frames near the brake.
- Outfeed stillages or roller tables for finished parts.
- Clear processes for moving work to welding or assembly.
Olympus can integrate the cobot cell with upstream or downstream steps, for example welding cells, laser welding, or palletising, using a plug and play style approach where it makes sense.
Shared Building Blocks of a Cobot Press Brake Cell
Small parts and large sheets use many of the same building blocks.
Hardware Building Blocks
A typical press brake tending cell from Olympus Technologies includes:
- A Universal Robots cobot sized to your part weight and reach.
- A fixed base or mobile stand beside the brake.
- Grippers tailored to your material and range of parts.
- Part presentation hardware such as stackers, tables, or conveyors.
- Guarding and safe access to match your site rules.
This is delivered as a complete solution, not a set of loose components.
Software, UR Academy, and Operators
On the software side, the cell uses the Universal Robots environment plus Olympus base programmes.
Programmes define:
- Where to pick from.
- How to move into the press brake.
- How to automate support through the bend.
- Where to place finished components after unloading.
Your team then builds on this.
- UR Academy supports new users with structured lessons.
- Simple, visual programming makes edits easy.
This approach helps ensure the system works for your people, not just in a demo.
Optional Sensing and Vision
Some applications benefit from extra sensing.
You can add:
- Edge detection for accurate bend line location.
- Simple inspection checks.
- Presence sensors to confirm every pick and place.
The aim is always to match automation level to real need, not to add technology for its own sake. That keeps both cost and complexity under control.
Integrating Cobots With an Existing Press Brake
Step 1: Assess the Press Brake
Olympus engineers start by understanding your machine and production environment.
We look at:
- Press brake model, tonnage, and age.
- Control type and existing interfaces.
- Available signals and safety hardware.
- Infeed and outfeed space around the line.
This shows what is already compatible and what we need to install.
Step 2: Mechanical and Electrical Design
Mechanical work may include:
- Designing and mounting the robot base or mobile stand.
- Gripper design for your full range of parts.
- Racks, stackers, or tables for infeed and outfeed.
Electrical and control work includes:
- Power and control wiring.
- I O, fieldbus, or Ethernet links between cobot and brake.
- Safety devices such as scanners and light curtains.
We ensure all parts of the system are correctly connected and work as a class leading, safe cell.
Step 3: Software, Testing, and Handover
We then:
- Build and test base programmes off line where possible.
- Run trials in your shop on real parts.
- Tune paths, speed, and timings for both small and large parts.
Handover includes:
- Training for operators and setters.
- Clear documentation, including CE and your VAT number on commercial paperwork where relevant.
- A support path if you want to extend the cell later or invest in more units.
The goal is a system that fits your real production and is simple enough that your own people prefer to use it.
Cost, ROI, and Affordability
Key Cost Elements
Typical cost elements include:
- Robot, base, and grippers.
- Part presentation hardware.
- Guarding and safety devices.
- Software, integration, and testing.
- On site installation and commissioning.
- Training and documentation.
Quotes from Olympus Technologies break these out so you can see how the investment is built up.
Where the Return Comes From
Returns usually come from:
- Fewer manual hours at the press brake.
- Less scrap and rework from handling errors.
- Higher throughput on the same machine.
- More stable delivery performance to customers.
For busy brakes, especially in construction, general fabrication, and other industries, payback often fits normal capex expectations. The affordability often improves further when you repeat a proven design on more than one brake.
Low Cost Ways to Get Started
You can make the step easier by:
- Starting with one focused cell as a pilot.
- Reusing the same design on other brakes after success.
- Reusing programmes, safety concepts, and working methods.
Olympus can help you discover a sensible starting scope and avoid over committing too early.
Getting Started: Quick Checklist
To explore press brake automation with cobots, start with a simple list.
1. Identify Priority Jobs
Look for jobs that:
- Cause overtime or bottlenecks.
- Have high handling effort.
- Generate quality issues due to inconsistent handling.
2. Capture Simple Data
Note:
- Material type and thickness.
- Typical batch size.
- Part weight, size, and shape.
- Current cycle time and any rework rate.
3. Take Photos of the Area
Capture:
- Around the press brake.
- Infeed and outfeed space.
- Any space or access constraints on the line.
4. Share With Olympus Technologies
With this, Olympus Technologies can:
- Suggest a compatible, cost effective cell concept.
- Explain how the system will integrate with your existing press brake and wider automation.
- Outline cost, payback, and next steps so you can decide how far to invest.
We also supply related cells for machine tending, dispensing, case packing, palletising, welding, and laser welding, so you can build a joined up automation strategy over time rather than isolated projects.
If you want a clear next step, you can use this page as a checklist, then speak to the Olympus integration team about a cobot press brake tending cell for your own shop.
It is an ideal way to automate one of the hardest manual tasks, improve quality, and give your people a safer, more sustainable role in a modern world class fabrication business.
