Tube Bending Machines

Transcription

1 Tube Bending Machines

2 Electropneumatics has been a leading manufacturer of tube and pipe bending equipment for over Twenty-Five years. These years of experience in designing and manufacturing tube benders has enabled Electropneumatics to enjoy undisputed leadership in this market. Users bank on our machines for their technological maturity, unmatched quality, highest reliability and long useful life. Electropneumatics draw-type tube benders can meet a wide variety of customer requirements from the small production or prototype job shop to the high end user. In this context, our tube benders have fully proved their worth in various industries/segments. At Electropneumatics, we stress on constant and intensive product research and development and dedicate considerable human and financial resources to continually strengthen our technological force, at the same time satisfy customer requirements.our continued interaction with our customers and our desire to produce the best has lead to a progressive spirit of innovation, evidenced by the incorporation of new developments and ideas in our machines over the years. Electropneumatics can offer the right machine for the right application. We have an exhaustive range of machines, right from semi-automatic to the more sophisticated, automatic, highly productive, precision benders. Our machines can be complemented with complete tooling for accurate repeatability from part to part. Electropneumatics also makes tube end forming machines for flaring, cold heading, beading, swaging and such applications. Tooling to suit your every application-tight radius bending, different tube sections, thin-walled tubes, multi-radius bending, tube-in tubes, hot bending of special metals/alloys etc. are offered. Electropneumatics takes special care to design safety and reliability into each tube bender. The Electropneumatics user-friendly programmable digital controllers are specially designed for bending and are logically laid out for proper machine sequencing. The controller and machine together synchronise and interlock the push, turn and bend functions to guarantee easy repeatability, precision and scrap-free production. Our dedicated customer service ensures trouble-free production for you.

3 Whether a standard task or a highly complex bending problem, the wide range of Electropneumatics machines assures optimum and economic solutions. Close Customer Relations and service along with superior quality. Up-to-date design and latest manufacturing facilities.

4 NCX / NCXR : Semi-automatic Single Axis NC Tube Bending machines Our NCX / NCXR Series of tube bending machines are specially designed with economy in mind, without compromising on production and accuracy. They cater to the automobile and automotive component supplier industries, chemical and boiler plants, furniture industry and moulded luggage manufacturers. These hydraulic, semi-automatic machines can handle tubes from 6 mm to 325 mm outside diameter. It is possible to bend tubes of variety of materials with round, square or rectangular sections and different profiles. The NCX tube bending machines have a clamping die, pressure die, mandrel and bend head, which are all hydraulically operated. These machines can be used for production of components with multiple bends in a single plane. To enhance the usefulness of these NCX machines, Electropneumatics has developed the NCXR Series. These tube bending machines have a pre-settable linear and rotary indexing facility for multiplane bends, in addition to the clamp, pressure die, mandrel and bend arm. This eliminates the need for locating fixtures on the machine. A carriage with a manual/hydraulic chucking arrangement that is capable of traversing the length of the machine is provided. With these machines, all operations of bending process are done automatically, while rotation and linear orientation of the component between two bends is done manually by the operator against pre-settable stops. Electropneumatics user-friendly programmable microprocessor based numerical SMARTBEND 410 series controllers are specially designed for these machines. Features Minimum 1.5D/2D bending, based on model Bend angle range = 5 to 180 degrees (DOB) Programmable DOB in automatic open loop control. Pre-selectable POB [in NCXR series] No. of multi-plane bends settable = 8 (POB & DBB) [in NCXR series] User-friendly microprocessor based numerical controller SMARTBEND 410 with colour LCD monitor and keyboard access, advanced on-line diagnostics, display of on-going process, status of input/outputs and error messages. Memory capacity of 1000 programs with 15 bends per program. Perfect quality bends by programmable bending angle and preset bending sequence. Precision bending tooling to suit your component. Manifold style hydraulics. Note : D = tube outside diameter T = tube wall thickness CLR = centre line radius DOB = degree of bend POB = plane of bend DBB = distance between bends. 65NCXR

5 Options Increased bend radius (on select models) Independent pressure die assist control and booster units for tight bending with CLR < 1.5 D. Extra mandrel length to suit component requirements. Automatic mandrel and machine lubrication. Hydraulic oil cooler Safety features such as safety mat and safety flap on bend arm. Extended arm and reduced spindle height for specific applications. Special tooling such as split tools, heated tools, etc. Hydraulic actuator for split tooling to bend rectangular / square and other shapes. Counter-clockwise bending. Linear and Rotary Indexing facility. Specifications MODEL Tube OD Capacity (D)* mm Max. tube thickness (t)* mm Max. bend radius mm Min. bend radius mm 30 NCX 30 NCXR 65 NCX 65 NCXR 100 NCX 100 NCXR 150 NCX 200 NCX 325 NCX 6 to to to to to to

6 Min. bend radius (in terms of D) Length of mandrel m Bend speed (Accuracy) deg/s(deg) 1.5D 1.5D 1.5D 2D 2D 2D (±0.2) 18(±0.2) 12(±0.2) 3(±0.25) 2(±0.25) 2(±0.25) Motor power kw Weight(approx.) kgs *For ferrous tubes with UTS of 45kg/mm. Standard bend direction is clockwise. Power supply : 415V, 50 Hz, 3-phase AC ±0.2 mm accuracy on DBB [in NCXR series] ±0.2 deg accuracy on POB [in NCXR series]

7 CNC3X : Automatic Three Axes CNC Tube Bending machines Electropneumatics rugged line of automatic, high speed, three axes CNC tube bending machines incorporate the latest microprocessor technology and programming capabilities combined with advanced techniques of tube bending and machine tool design. Capable of fast, repeatable bending of tubes from 3mm OD up to 168mm OD, these CNC3X bending machines are powerful precision machines that offer quick set-up and changeover. Special attention is given to design safety and reliability into each tube bender. Once a tube length is fed and the process initiated, the machine automatically completes the entire sequence of multiple bends with intermediate tube transfer and rotary indexing. High production rates of about 700 bends/hour on smaller and 360 bends/hour on medium duty bending machines are attainable, making these machines ideal for manufacture of large batches of similar components such as two-wheeler handle bars, exhaust system parts, automobile fuel brake tubes etc. and also for producing prototype components without fixtures. b The heart of the three axes CNC tube bender is its SMARTBEND 430 TX controller. A few of its salient features are : Colour LCD touch screen monitor and keyboard access for data entry and editing. Data entry as Push-Turn-Bend (Y-B-C) values or X- Y-Z co-ordinates. Capability of programming in inches or millimeters. Memory of 32 bends per program, 1000 programs. Automatic computation of tube length based on set parameters. Spring back calculation and off-line compensation facility. Programmable tube loading position. Multi-sequence bend capability for up to five parts with common bend radius and diameter. Advanced on-line diagnostics with closed loop monitoring of servo axes, display of axes position / speed, on-going sequence and error messages. Back up retrieval by alphanumeric code, password protection for data entry tool, tool part data storage and on-screen part counter with reset facility. Port for interface with external PC and printer. The three axes, i.e. Y-Push (DBB), B-Turn (POB) and C-Bend (DOB) are completely programmable. Models 30CNC3X, 65CNC3X, 100CNC3X and 150CNC3X are hydraulically powered (electro hydraulic server), while Model 16CNC3X is an allelectric machine incorporating AC servo drives with stepless speed variation.

8 Features Minimum 1.5D/2D bending based on model. Bend angle range = 5 to180 degrees (DOB). Fully programmable individual axis movement with closed loop position and velocity feedback control. Drop away clamping system, hydraulic power chuck, pressure die assist, hydraulic mandrel extractor unit, tube/mandrel support and automatic machine lubrication. Precision bend tooling to suit component, on request User-friendly interface. High Productivity. Options Extra mandrel length to suit component. Automatic mandrel lubrication. Hydraulic oil chilling unit. Safety features such as safety mat and safety flap on bend arm. Extended arm and reduced spindle height for specific applications. Special tooling such as split tools, heated tools etc. Hydraulic actuator for split tooling to bend rectangular/square and other shapes. Counter-clockwise bending. Specifications MODEL 16 CNC3X 30 CNC3X 65 CNC3X 100 CNC3X 150 CNC3X Tube OD Capacity (D)* 3 to 16 6 to to to to 168 mm Max. tube thickness (t)* mm Max. bend radius (CLR) mm Min. bend radius mm Min. bend radius terms of D) (in 1.5D D 1.5D 2D Length of mandrel m Carriage Travel m S p e Push (mm) 1200(±0.1) 750(±0.1) 650(±0.1) 400(±0.1) 200(±0.2)

9 Turn (deg/s) 500(±0.1) 300(±0.1) 300(±0.1) 120 (±0.1) 50(±0.2) Bend (deg/s) 150(±0.1) 120 (±0.1) 60(±0.1) 30(±0.1) 15(±0.1) Motor power kw Weight(approx.) kgs * For ferrous tubes with UTS of 45 kg/mm 2. Standard bend direction is clockwise. Power Supply: 415 V, 50 Hz, 3-Phase AC.

10 Multi-axes Versions Electropneumatics as a part of its continuous efforts to introduce innovative products to cater to newer applications and to find cost effective solutions for bending problems has developed a new range of Multi-radius, Multi-axes Tube Bending Machines in two versions The Multi radius CNC Tube Bending Machine and The Multi radius Bi directional CNC Tube Bending Machine. CNC4X : Multi radius CNC Tube Bending Machine In addition to the three basic programmable axes for push (DBB), turn (POB) and bend (DOB) functions, this model incorporates two additional axes for lateral (programmable Z-axis) and vertical movement of the carriage. The lateral movement is to accommodate radius changeover. The vertical travel is for raising / lowering of the chuck and the mandrel to align with the different radius stacks. This makes the machine versatile for uninterrupted bending of a component with a combination of multiple radii and multiple planes the same set-up without tool change. The design guarantees optimum bending freedom. Changeover and set-up times are drastically reduced. These machines can be used for components in the automotive and aircraft industry, as well as for prebending of parts for hydroforming.

11 CNC4X-LR : Multi radius, Bi-directional CNC Tube Bending Machine Certain intricate components with complex bends requiring counter clockwise bending and with multiple bend radii cannot be easily bent on a conventional machine in a single setting, as the component will interfere with the machine elements or the floor. Such tubular components, like those in auto fuel and brake systems, call for multiple operations on separate machines involving part loading/unloading, handling, etc., resulting in lower production rates and inconsistency. Taking this into consideration, Electropneumatics has developed a new range of bi-directional tube bending machines wherein both clockwise and counter-clockwise bending are possible in the same machine with automatic, in-process changeover from one bend radius to another. The machine is capable of continuously producing multiple radii/bend combination tubes of practically any shape in a single set-up with no intervention by the operator. 16CNC4X2-LR

12 Special Purpose Bending Machines To supplement our standard range of tube bending machines. Electropneumatics also offers customised solutions to suit your needs. Come to us with your bending requirement and we will engineer an optimum and economic solution for you. Our special purpose benders are designed to handle just about any application in the industry. These special purpose machines are meticulously designed to cater to your specific component requirements, taking into consideration the complexity of bending. Special tooled-up machines to bend profiles/sections and a variety of tube materials have been developed based on the specific job requirement and bending constraints. Wiper die and flexible/articulated ball mandrels for thinwalled tubes (tube-in-tube), compound tools/clamps, independently powered pressure die assist for tight bends, heated tooling for hot bending of special materials and alloys, split tooling for complex section bending and U-bends or bend 180 degrees, etc. are some of the special features that can be provided on our tube benders. Section Benders For luggage frames, furniture frames automobile accessories etc. Some machines are specially designed with an extended bend arm and reduced bend spindle height to accommodate complicated bend configurations. Chassis Benders For square, rectangular or tubular chassis long member of trucks and commercial vehicles.

13 Serpentine Benders For boiler/economiser tubes and refrigeration applications.

14 Section Coilers These machines cater to the refrigeration industry and are suitable for forming refrigeration condensor/evaporator coils etc. They can bend square, rectangular, round or any special section. Bending Modules for Multi-Plane Hot Bending For complicated bend geometries of components such as stabiliser bars, torsion bars etc.

15 Portabend This universal mobile multi-purpose tube working station is made with the hydraulic pipe fitter in mind. It has independent units for sawing, ID/OD deburring, bending and ferrule pre-setting applications. Booster Benders Booster benders find most application in bending tubing for the boiler, chemical and process industries, where struct control of wall thinning and ovality of the tube is required. The machines are provided with a clamp and boost arrangement, and are also available with digital controls on speed and pressure as an option. Automatic Three Axes CNC Wire Benders These high speed wire benders with all electric servo drives are ideal for bending wire components such as remote rods for door locks, hood support, actuator levels and also a variety of consumer product components and interior decoration items. For unmanned production, these are supplemented with optional wire decoiler, straightner, cut-off and feed units. Universal versions with rotary bending heads are also available for handling complex jobs.

16 Major Customers Alfa Laval (I) Ltd. Ashok Leyland Ltd. Bharat Earth Movers Ltd. Bharat Heavy Electricals Ltd. Bhabha Atomic Research Centre Bajaj Auto Ltd. DGP Windsor India Ltd. Featherlite Corporation Gabriel India Ltd. Garden Reach Shipbuilders & Engineers Godrej & Boyce Mfg. Co. Ltd. Greaves Ltd. Hero Honda Motors Ltd. Honda Motorcycle & Scooter Imperial Auto Industries Jamna NHK Jay Bharat Maruti Ltd. Kinetic Engg. Ltd. Kinetic Motor Company Larsen & Toubro Ltd. Naval Dockyard Omax Autos Ltd. Samsonite India Ltd. TELCO TVS Suzuki Ltd. Voltas Ltd. Yamaha Motor Escorts.