« BACK  

Integrated all-electric tube bender and cutter delivers competitive advantage to volume tubular part manufacturers

Unison has engineered a combined tube bender and cutter with a precision, programmable all-electric architecture
Unison has engineered a combined tube bender and cutter with a precision, programmable all-electric architecture

Unison has launched an all-electric tube bender with an integrated cutter, providing automated single-step manufacturing of volume parts such as exhausts and tubing or piping shapes. The new machine is believed to be an industry first - bringing the programmability and precision advantages of all-servo-control to the tubular parts manufacturing market.

The machine's all electric, servomotor-controlled architecture gives comprehensive programmability throughout the entire part fabrication cycle. The position and forces of the tube bending dies can be precisely controlled, as can the movement profile and torque applied during the 'nick and shear' cutting cycle - delivering the highest accuracy and quality of shape fabrication and end finish. Servomotor control also ensures that cutting positions are extremely accurate and repeatable from batch to batch - to within +/- 0.1 mm (0.004 inch) - as tubing remains under control of a high-resolution digital motion architecture throughout the operation. These benefits are in addition to the well-known returns of low energy consumption and quiet operation of all-electric motion control architectures, compared with traditional hydraulically actuated machinery.

After a bending operation, moving the tube to the shear tool position and making the cut takes typically 12-15 seconds. This compares with perhaps 60 seconds - plus the need for skilled labour - that would be required for handling, loading, set-up and cut-off when the same task is performed at a separate station. In addition to these fundamental throughput gains, Unison's new integrated machine means that many manufacturers will also be able to produce multiple parts from each length of tubing, providing another major boost to productivity.

"Integrated bend-and-shear answers the needs of manufacturers of volume parts such as automobile exhausts and tube and pipe component shapes," commented Unison's Alan Pickering. "Compared with production processes based on separate bend and cut stages, we believe the time and labour savings will start delivering a payback on an investment after only a very short timescale - down to as little as a few weeks for multi-shift manufacturing companies."

The new machine is called the Breeze-Blade, and is capable of bending and cutting tubing with outside diameters of up to 76 mm (3 inches). It comes with a multistack (multiple on-machine tooling) facility for software-controlled changeover between parts batches, with the nick and shear tooling loaded into one of the tool positions.

Cut-off is performed in two steps. The bent tube shape is positioned automatically by the machine's servomotor-driven carriage, and a circular clamp grips the tube directly adjacent to the cutting position. The first tool strikes the tube to create a nick that penetrates around two thirds of the way through the tubing wall. The shear blade then drives through the tubing - with control over aspects such as acceleration, speed, deceleration and torque to suit the material and the tubing shape. This highly-controlled action ensures a high quality dimple-free cut with minimal burring. The clamp has been specially designed to ensure that cuts can be made close to a bend - to within approximately 6 cm (2.4 inches).

PUBLISHED: 02 Nov 10 Bookmark and Share
Company:
Unison
Country:
UK
Tel:
+44 1723 582868
Fax:
+44 1723 582379
Email:
alanp@unisonltd.com
Website:
www.unisonltd.com
Other News from Unison:

»
New head of sales & support appointed to meet Unison growth
»
Unison Ltd is increasing its manufacturing capacity and opening a new factory in Virginia, USA
»
All-electric tube bender multiplies productivity for cleaning trolley maker
»
Ultibend improves productivity with new all-electric tube benders
»
Precision tube bending takes next step in evolution
»
Innovative automated tube bending cell allows wheelbarrow manufacturer to almost double manufacturing output
»
World's most powerful all-electric pipe bending machine swings into action at Norwegian shipyard
»
Custom all-electric tube bender will accelerate right-first-time production for precision metal fabricator
»
Custom tube bender eliminates cut-off waste of tubular parts for exercise machines
»
Unison opens its own service and sales office in North Carolina
»
Accurate and cost effective tube bending - a new machine concept from Unison
»
Unison receives its Queen's Award
»
Tube bending pioneer wins Queen's Award
»
Ultra-powerful all-electric pipe bender starts operations at US shipbuilder
»
Second Unison all-electric bending machine for fast-growing tube fabrication specialist
»
Precision aerospace engineers choose Unison tube bending technology
»
Tube manipulation specialist embraces all-electric technology and enjoys fast return on investment
»
All-electric tube bending machine innovator appoints new American support partner
»
UK tube manipulation sector "in robust health" says Unison after open house event
»
Size matters: all-electric tube benders take a MASSIVE step forwards
»
Tube bending CAD/CAM software also accommodates laser tube cutting
»
Faster and smarter tubular parts production
»
Scarborough could be the UK's next 'engineering hotspot' thanks to the new University Technical College
»
Powerful all-electric pipe bending machine boosts manufacturing throughput and accuracy of large-bore hydraulic parts
»
Tube bending specialist accelerates throughput and implements right-first-time manufacturing with the help of all-electric machine
»
Advanced tube bending technology helps British Airways maintain latest-generation aircraft
»
New all-electric tube bender extends shape-forming capabilities of aerospace manufacturer
»
Tube bending leader adds new low-cost entry-point machine to its range
»
Higher-productivity tube bending to be highlighted at Tube 2014
»
Innovative tube bending CADCAM solution
»
Advanced tube benders speed construction of subsea wellhead trees
»
Proof that engineering careers still appeal to UK youngsters!
»
Novel tube bender boosts productivity by 500% for leading American tubular part fabricator
»
Higher-productivity tube bending to be demonstrated at Fabtech
»
Lord Green opens design and manufacturing facility for tube bending innovator
»
More production capacity fuels international expansion of tube bending innovator
»
World's largest all-electric pipe bender ordered by US shipbuilder
»
Record sales for tube bending machine builder Unison
»
Siemens Subsea Products adopts all-electric tube bending for production of subsea hydraulic flying leads
»
Unique robotic tube bending system can dramatically speed production
»
Clean, green production efficiency underpins tube bending machinery upgrades at leading truck parts manufacturer
»
Yorkshire's centre of engineering excellence continues investing for its future
»
Right-first-time tube bending technology to be highlighted at Farnborough
»
Business Secretary Vince Cable visits fast-growing UK machine builder
»
Novel twin-head tube/bar bender provides platform for high throughput automated production
»
Fully-automated production cell increases wheelbarrow frame manufacturing efficiency
»
Architectural metalworker achieves right-first-time output using unique bend correction system
»
Right-first-time tube bending technology to make European premiere at Tube 2012
»
All-electric tube bender provides production versatility for submarine builder
»
Scarborough plays host to hundreds of budding designers and engineers
»
Unison supports World Motorcycle Land Speed Record Attempt
»
Rotating-head tube bender produces ultra-complex part shapes in one fast automatic cycle
»
Unison to support VTube software in the UK
»
First all-electric tube bender for leading European tube bending specialist
»
Record sales for tube bending machine builder Unison
»
Precision aerospace tubular parts fabricator chooses all-electric CNC tube bender to combat emerging challenges
»
Tube bending excellence 2011
»
Integrated all-electric tube bender and cutter delivers competitive advantage to volume tubular part manufacturers
»
Architectural metalwork leader chooses right-first-time tube bender
»
Advanced tube bender will boost flexibility of performance exhaust manufacturing
»
Scarborough continues investing in the UK's engineering future
»
Metalworking machinery leader opened its doors at Scarborough engineering week
»
Boeing Integrated Defense Systems orders bending machine
»
End-former accelerates refurbishment process for automotive parts specialist
»
Advanced tooling added to tube bending portfolio


Industry News:
The PurgEye® 300 Nano
Low cost 1 PPM Weld Purge Monitor®
Huntingdon Fusion Techniques Limited, UK
Roll-Kraft Seminar Session
Outstanding attendance once again at Roll-Kraft's annual regional seminars
Roll-Kraft, USA
Brazing corrugated tubing to stainless steel pipe and cap using UltraFlex Induction Heating
Brazing corrugated tubing to stainless steel pipe and cap using UltraFlex Induction Heating
Ultraflex Power Technologies, USA
Alfa Laval rotary jet head GJ PF FT
Easy as this: Reduce cleaning time by 70% and operating cost by up to 80%!
Alfa Laval Kolding A/S, Denmark
The new Mosweld (SiC) system is equipped with highly-­ reliable (SiC) Silicon Carbide transistors
EMMEDI presents a new evolution of HFI Welder
Ajax Tocco Magnethermic Corporation, USA
Qwik-Freezer™ is the industry standard portable CO2 Pipe Freezing System, in use around the World
Double Freezing technique for large diameter valve replacement
Huntingdon Fusion Techniques Limited, UK
The versatile Inflatable Stoppers are used to service a wide variety of industrial applications
Inflatable Stoppers for petrochemical applications
Huntingdon Fusion Techniques Limited, UK
UKF Stainless Ltd offering the best in productivity and performance for efficient handling of tubes to the industry worldwide
UKF Stainless celebrates 25 years of offering the best in productivity and performance for efficient handling of tubes to the industry worldwide
Ultimaster, Germany
DN710 mm TOM® Pipe, PN12.5, PN16, PN20 & PN25 bar
Molecor launches into the market the new DN710 mm Oriented PVC Pipe
Molecor Tecnologia SL, Spain
The PurgEye® 300 Plus
Highest quality welds made with lower costs
Huntingdon Fusion Techniques Limited, UK
» VIEW ALL NEWS «