Improved manufacturing of exhaust pipes with compact bending geometries
The cutting of pipes offers significant potential for improvement if scrap is avoided by cleverly coordinated operation and subsequent processing steps is made possible immediately after cutting. This efficiency is revealed for example in manifold production for the automotive sector where short pipes with multiple bends close to each other are often required. Different process sequences are possible depending on the requirement: work pieces, already cut to length can, of course, be bent. Parts must perhaps be re-cut at one or both ends and sometimes also shaped.
To meet this requirement we can assemble a suitable solution from our machine portfolio as a complete system for the specific requirement. Pipes are bent and then cut by a blade. The special feature: this process is carried out on a single platform of the pipe bending machine. This enables scrap to be completely eliminated or very significantly reduced. During the process the pipes are cut to their final dimension with a separating cut 2 to 3 mm wide - depending on pipe size. This is an exceptionally economic process, particularly for short bent components with many curves.
Clean and versatile cut with two blades
Cutting with two blades produces a particularly clean separating cut. The pipe is protected from the deformation which occurs if only one blade is used. This method ensures an absolutely sharp edged and straight separating cut. And if subsequent forming is required, this can be immediately added. The process with two blades is particularly advantageous for small tubes. The reason is that in such cases possible deformation rules out forming as if deformation occurs it is impossible to insert a tool into the inner pipe.
An automation system with robotic handling
The example of a current project illustrates how pipes up to 60 mm diameter are efficiently processed with a bending radius of up to 1D. This fully automatic pipe bending solution offers a centre-line booster and three bending levels plus the level in which the tool is used for cutting. All the handling is done by four robots. The machines are configured in an efficient interaction such that all the tools are driven in turn. The system manufactures a pipe set consisting of four different pipes without trimming. A robot moves it to the finishing process which shapes the pipes asymmetrically. The handling robots each then transfer an assembly to the next welding robot which welds the pipes firmly onto the engine flange.
Want to find out more about the automated possibilities for value-adding pipe processing? Then contact us or meet us at Tube 2018 on our transfluid® stand G34 in Hall. We look forward to welcoming you!
+49 29 72 / 97 15 0
+49 29 72 / 97 15 11