TPT July 2018

T E CHNOLOG Y

T E CHNOLOG Y

Automation system for pipe machining engine manifolds

tubes are initially bent and then cut with blades. The special feature in this case is that this process is completed on the level of the bending machine and therefore enables scrap to be eliminated completely or extremely reduced.” The tubes are therefore able to be cut to their final length. Depending on the pipe size, the separating cut runs from 2 to 3mm. “In terms of

A PROCESS is particularly valuable if it avoids scrap and makes the immediately following process possible. For example, in exhaust technology in the automotive industry (at least when engine manifolds are involved), short tubes that feature numerous bends in short sequence are frequently required. While there is the option to bend previously cut parts, it is often the case that workpieces are cut on one or both sides and, under some circumstances, also need to be shaped. transfluid provides a solution for this, as general manager Stefanie Flaeper explained: “Depending on the requirements, our portfolio combines machines to create systems that are able to be loaded with tube lengths. The A system developed by transfluid enables the processing of tubes of up to 60mm with a bending radius of 1D

Two blades ensure a clean cut

Photo credit: © transfluid

bend; no additional follow-up cuts are required. The bending machine for this solution features a centre-line booster and three bending planes, plus the plane where the cutting tool is used. An additional system, which only recently left the company’s workshop, can process tubes up to a diameter of 60mm in practical applications. The features of the machine are similar to those mentioned above, but the handling is executed in full by four robots. The machines are designed so that all of the tools are interchangeable and shared. This system is able to produce a set of tubes for an engine manifold, consisting of four different tubes, without the need for follow-up cutting. A robot supplies the tubes immediately to the final processing step. This system component shapes the tubes asymmetrically to that they can be welded to the motor flange compactly in a separate work process. Finally, the handling robots take over again, and provide one kit each to the following welding robot. Both systems complete the cutting process with two cuts, as a good cut is required for the best possible resulting product. transfluid Maschinenbau GmbH – Germany Fax: +49 2972 9715 11

commercial efficiency, this is a value- creating alternative production option, especially in case of bending parts with relatively numerous bends,” continued Ms Flaeper. Depending on the application, the different ways of cutting ensure that optimised results can be achieved. Especially in the case of larger tubes in the exhaust area of a lorry, eg with 127mm diameter, it may be sensible to use only one blade to cut, even if this results in a small deformation in the outer diameter. This does not play any role if shaping or calibration is still required on this tube end. “A significantly cleaner cut results if two blades are used for cutting,” said Ms Flaeper. “This has the advantage that no deformation occurs on the pipe. This produces an absolutely straight separating cut.” Shaping can also be applied directly. In the case of smaller tubes, this approach is usually better, since possible deformation towards the inside does not enable corresponding shaping tools to be used. The diameter is usually too small. A system developed by transfluid for a current project enables the processing of tubes of up to 60mm with a bending radius of 1D. Most of the tubes produced in this case feature two or three bends, with the cut made straight after the last

Photo credit: © transfluid Photo credit: © transfluid

The tubes are initially bent in sequence and then cut with blades

Email: sales@transfluid.de Website: www.transfluid.net

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JULY 2018