Processing of tubes starting from coil offers important advantages: lower cost of raw material, less space to store it, simplified logistic management of semi-finished products and remarkable reduction of material scraps due to machining mode. For these reasons, processing from coil has become the standard in many sectors and BLM GROUP offers various solutions able to meet specific needs.

It is always about automatic systems able to carry out complete production processes that include straightening, facing, end-forming of the free end, bending and final cutting. Systems that neatly unload the finished part and that can therefore be easily integrated with other systems downstream for subsequent machining, typically end-forming of the unmachined end from previous processes, performed with an E-SHAPE or E-FORM system.

The distinguishing feature of these processes is the type of bend to be carried out, with or without mandrel. Bending without mandrel is carried out by the compact systems of the 4-RUNNER family that gather all the operations in a single machine tool, from straightening to bending. Bending with mandrel starting from coil, is not an easy subject to face. BLM GROUP proposes an integrated solution that joins the two systems in an automatic production cell able to carry out all machining operations, high quality bending with mandrel included. 3-RUNNER feeds the tube from coil, carries out straightening and end-forming at one end and cuts the tube, then the semi-finished part is neatly deposited on the automatic loader of the SMART that carries out bending with mandrel.

4-RUNNER

Straightening, end-forming, bending and cutting, four operations in a single machine tool. 4-RUNNER is a system for bending and end-forming from coil, all electric, with end-forming module up to six passes, right-hand and left-hand bending in-process, including the possibility to have a variable radius and an orbital outer cut module, managed by controlled axes or by disc.

To fully meet all needs there are two different versions available: 4-RUNNER H1 and 4-RUNNER H3.

4-RUNNER H1 works with tubes of diameter up to 12.7 mm. In-process right-hand/left-hand bending, flexion, multi-radius or variable radius. Bending head dimensions are extremely reduced and make this system particularly suitable for producing complex components such as flat and 3D serpentines used in the automotive, cooling, air conditioning and heating sectors.

4-RUNNER H3 can machine tubes up to 22 mm diameter and it is particularly fit to produce components for fluid transport systems. Thanks to the possibility to carry out flexion or stretch bending, bending speed can be combined with the possibility to create very short sections and this makes the system very flexible and highly productive.

3-RUNNER + SMART

The bending process from coil with mandrel requires the integration of two different systems: 3-RUNNER that feeds the tube from coil, then carries out straightening, end-forming and cutting; SMART that carries out quality bending with mandrel. The automatic loader of the SMART allows to fully automatize the process that generates a part bent and formed at one end.

At Tube & Wire 2018 it will be possible to see another end-forming pass of the unmachined end by means of an E-SHAPE system.

3-RUNNER is the multi-function machining center that uses a tube from coil up to 28.7 mm diameter, carries out straightening, end-forming and cutting at length. 3-Runner implements the concepts already tried out on the 4-Runner system: coil straightening and managing system, end-forming unit with up to six passes, all-electric orbital cutting unit. At the end of machining, 3-RUNNER deposits the semi-finished part on the automatic loader of the SMART tube bending machine that carries out quality bending with mandrel and neatly unloads the finished part.

SMART is a bending system for tubes up to 28.6 mm, specifically suitable for integration into an automatized cell, thanks to the patented head swinging system that facilitates automatic loading and unloading operations. For the rest, it is a complete bending system, all-electric, able to carry out right-hand and left-hand bending in-process, multi-radius, with fixed or variable radius.

BendingStudio with Absolute Arm Brings the Speed of 3D Laser Scanning to the World of Tubes and
Wires.

A new approach to tube and wire measurement was today announced by leading metrology and manufacturing solution specialist Hexagon Manufacturing Intelligence. 

An updated version of the popular AICON BendingStudio software platform now allows for the integration of a ROMER Absolute Arm with Integrated Scanner that can quickly determine complex tube and wire geometries using 3D laser scanning technology at almost any point in the production process.

From tube and wire inspection to manufacturing and reverse engineering applications, BendingStudio with Absolute Arm is a full-featured solution built on well-established technologies. The system will benefit from the ability to connect directly to a CNC bending machine, allowing for the simple and immediate correction of production errors.

“Speed and portability are both important to our customers in the tube and wire manufacturing industries,” says Stephan Amann, Business Director for Portable Measuring Arms at Hexagon Manufacturing Intelligence. “While our previous tube and wire solutions focused on delivering one or the other, BendingStudio with Absolute Arm combines two established products into a new solution that is greater than the sum of its parts. We have in this new system the portability to measure geometries right on the shop floor in a quickly and easily repositionable and reproducible way, alongside the speed of being able to determine a tube’s exact geometry with just a few fast sweeps of a 3D laser scanner.”

With this new version, BendingStudio will retain all its previous capabilities, allowing users to combine use of the ROMER Absolute Arm with Integrated Scanner with a complementary AICON TubeInspect. With these two measurement hardware endpoints operating on the same software platform, users will benefit from increased efficiency within a toolkit covering every need in tube and wire design and manufacturing.

As a pioneer of on-line measurement committed to extensive research and development activities, ZUMBACH Electronics has continuously grown as one of the world-wide leading manufacturers of in-line measuring and control systems. Top priority at ZUMBACH Electronics remains to be customer relationships through local presence combined with proven high-quality products, services, personal consulting and support. ZUMBACH’s PROFILEMASTER® systems are developed from a core set of proprietary mega pixel camera/laser modules and software technologies. The application of these technologies has been adapted to serve specific measurement, monitoring and surface flaw detection needs for; extruded plastic and rubber tubes, hoses, profiles, wire and cable, wood, plastic composites, steel rod, bar, profiles and much more.

Depending on the customer application and product dimension, ZUMBACH offers a full range of PROFILEMASTER® gauges, including models for small precision profiles starting from a dimension of 0.5 mm (.02 in.), cold formed tubes and profiles as well as medium size products, hot or cold, up to dimensions of 600 mm (23.6 in.)

Switch on your connections today and build your path to Industry 4.0 with ease.

When searching the component parts for your implementation of IO-4.0, connectivity is key to your success, whether it is email related, performance measurement, machine availability, cost of manufacture, resourcing, communication, supply chain, delivery, stock control or whatever concerns your specific needs in business.

Wireless communication, USB, Ethernet TCP/IP, Profibus DP, Distributed IO, Profinet, Ethernet IP, Canbus, SMS, Can Open, MRP, MES, ERP, OPC UA, Web Interfaces, VPN, Virtual Network Computing, Power distribution, etc. are all key phrases in the connectivity area to consider in implementing any business strategy for optimization and efficiency. 

ZUMBACH equips its powerful instruments with the globally recognized OPC UA standard platform. With this key technology, measurement solutions provide an easy and secure information exchange with differing systems, whether they be in the production line – business Platform system or anywhere else.

When looking to really understand your business and its inherent process’s, only through connectivity solutions can you hope to learn the truths behind how you operate and perform and onwardly apply any adaptations needed to improve. 

Connectivity, unlocking the black arts to release your creativity and possibilities to set new standards.

Auto parts supplier Martinrea equips large-scale press line in Mexico with blank loaders and Crossbar Robots 4.0

Martinrea set a clear goal for itself: to be the world’s best auto parts supplier. To achieve its objective, the global company and employer of roughly 15 000 people decided to equip its first large-scale press line in Mexico (at its facility in Silao) with a blank loader and multiple Crossbar Robot 4.0 units, thereby gaining the ability to provide its customers with maximum flexibility.

The blank loader is ideal for outer skin parts, as state-of-the-art cleaning and oiling systems ensure outstanding component quality. The new optical line scanner from Schuler detects the precise position of the blanks before they are loaded into the first press. A Crossbar Robot then corrects the position as needed.

The Crossbar Robots 4.0 are the centerpiece of Martinrea’s press line in Silao. They transport the parts directly from one press station to the next, and can accurately position these parts for any die. Especially where multi-part components are produced, this flexibility delivers an unbeatable advantage. 

Since the Crossbar Robot is hung on a track, it can cover distances of up to twelve meters between press stations. Distances this large are mainly found on older lines, where space was provided for an unloading or turning station. This means that the new Crossbar Robot can replace loading feeders, unloading feeders and part orientation stations in the gap between presses. This frees up more space for maintenance and reduces the number of toolings per gap from three to one. At the same time, it also provides a significant boost in output.

Crossbar Robot 4.0 increases flexibility and output

The Crossbar Robot is based on a six-axis industrial robot that was expanded by Schuler engineers to include two additional axes: one for the hand of the robot arm and one for the horizontal drive. This enhancement significantly increases the robot’s range of motion, flexibility and output. The maximum load capacity, including the tooling, is 90 kilograms. Thanks to an innovative energy management system with integrated energy recovery, the new robot is 50% more energy-efficient than its predecessor, the 3.0 model. For blank loaders and Crossbar Robots, Schuler provides a wide range of solutions for an automated tooling change that can be performed fully automatically in just two minutes.

With its process data interface, the new Crossbar Robot comes perfectly pre-equipped for Industry 4.0. Thanks to its intelligent networkability, this robot functions as an analysis tool that monitors processes and provides information about any errors that may occur.