Automation IG Tube Bending Systems
As
one of the first to provide tube bending systems with reliable PLC
controls systems, Automation IG continues to redefine the standard of
quality for production tube bending systems. Using a modular system, we
provide a customized tube bender with the quality of an off-the-shelf
system. We provide fully automatic, machine loaded and unloaded
production tube bending systems to the automotive and motorcycle
manufacturing industries, as well as many others.
Full Production Tube Benders
Our
full systems are designed for high-volume production of multiple tube
designs and utilize an easy-to-learn, easy-to-use programming system
for adjustments directly from Automation IG's OI-15 HMI. Since our
systems are built on top of our modular design concept, you may choose
from single head-bending modules, dual head-bending modules, or both
with any number of forming, piercing, or press modules. Tooling can be
quickly changed using the same QuickChange technology originally
developed for robotic weld cells. Parallel transfers move tubes through
the machine as all modules work in sync. The entire system is
controlled with an industrial strength PLC controls system.
Our
full production benders are fully automatic, from loading raw tubes to
ejecting finished parts. Raw tubes are singulated and passed through an
Automation IG SeamFinder module specially designed and programmed to
locate a seam on the thickest of tubes.
Robot Tube Bender
We
leveraged our robotic expertise to develop a new modular tube bending
system. Using the same modular design as our full production bender, we
created a robust production tube bender with a smaller footprint by
utilizing the latest in robotic and controls technology.
Our
Robot Bender is the first robotically assisted tube bender that can be
operated and adjusted without ever picking up a robot teach pendant. By
eliminating the need to modify robot programs, we reduced the need for
training.
Our unique design also allows for unprecedented
freedom for configuration and options for modules. Run more varieties
of tubes, increase utilization, eliminate changeover time, and get more
from your capital investment.
Prototype Tubes
The
specialized nature of tube benders and the parts required to build them
can result in lead times that extend past your need for tubes.
Automation IG has the capability and equipment to fully process your
tubes in time to meet production deadlines.
Automation IG: One Source
Take
advantage of our capabilities and let us build the machines for your
complete process. With Automation IG building your tube bender, weld
cells, and custom equipment you can eliminate the hassle and potential
problems of coordinating multiple vendors.
Bender Modules and Components:
Seam Finder The raw tube moves from the Un-bundler to the seam finder, which locates the weld seam in the tube and orients it to the desired location using servomotors for tube rotation. If the seam is undetectable, the tube is ejected for cleaning. Once this is done, the tube is transferred and another tube is moved to the seam finder.
Single Bend Head This bender module consists of a 3-jaw chuck attached to a geared servomotor for chuck rotation, mounted to a traverse carriage and a single head bender. Both chuck and bend-dies traverse via proportional valve/hydraulic units in the Y axis. The 3-jaw chuck grips the end of the tube and moves it through programmed bends.
Dual Bend Head The dual head bender module consists of a removable center gripper/rotator unit and two bend head modules. Two proportional valve/hydraulic drives mounted to traverse carriages (Y axis) move each of the bend head modules located either side of the removable center rotator. The center rotator/gripper rotates the tube as required while the bend heads move to position in order to complete the programmed bends -- the bend heads will act simultaneously as much as possible. Optionally, the dual heads can include proportional valve/hydraulic driven X-axis offsets to accommodate offset style bends programmable from zero to 155 mm on each bend head.
Vertical Press This station performs forming and crushing operations on tubes. We utilize quick-change arrangements for the die sets, tooling, and idle stations as needed for this station.
Six Axis Handling Robot In our FlexBender system, the robot picks up the tube from the seamfinder and manipulates the tube to complete bends in bending modules. The robot can also tend multiple tubes at once in various other modules. Using a robot instead of a traditional transfer unit allows the addition of other modules, such as 4-post vertical presses.
Discharge Unit A chute and material handling system delivers completed tubes to a storage tote located outside the perimeter safety fence.
Safety Perimeter Fence, Interlock Accesses, Deadman The complete machine will be enclosed with wire-mesh style fencing with access and interlocks connected to the safety circuit. Any access door will disable the cell. Each machine will incorporate a deadman-style, operator-held panel to protect the operator when inside the perimeter fence. The operator is able to maneuver items when the perimeter fence is broken only when holding the deadman switch on this panel. This panel over-rides the operator control HMI when the perimeter fence is accessed.
Main PLC Control Unit Allen Bradley ControlLogix platform with AB servo-drives, Rexroth/Parker hydraulic drives and Automation IG's OI-15 Operator Interface Touchscreen (HMI). Communication to all of the modules is via this control unit by EtherNet or DeviceNet networks.
