From a coil of tubing to a finished tube connector automatically in 6 seconds

The manufacturing system from transfluid creates extremely short straight lengths after bending and forming

Is speed all that matters when it comes to production? Of course not! Especially for connections which must stand up to highly dynamic loads, quality has an important role to play. Tube connections used in automobile manufacturing must be robust, durable, clean, and demonstrate longterm leak-tightness. transfluid Maschinenbau GmbH has now developed an automation system for the t motion part of its portfolio which ensures the rapid and highly precise manufacturing of short elbow tubing sections. These special connections are used in car radiators and air conditioning.

Chipless cutting and precise rolling

The special transfluid manufacturing cell enables the coil to be handled directly. In the first manufacturing stage, the tubing (in a diameter range from 8 to 22 millimetres) is unwound, aligned, and cut. The orbital chipless cutting of the tubes can be performed up to a minimum length of 34 millimetres. Cleaning cutting is the key for enabling the subsequent processing steps to proceed immediately, as it excludes the possibility of contamination, which could endanger subsequent system use.

After the cutting process, the tube ends - where the hose is connected - are compressed in a transfer line. Then a subsequent component of the line rolls and polishes the surface. This rolling technology from transfluid allows for short clamping lengths and the forming of practically any geometry.

Reliable bending after tube forming

After the axial and rotary end forming process, the t motion manufacturing cell automatically bends 80% of the parts by 40 to 120 degrees. The particular benefit of the process as a whole is primarily that the extremely short parts must be formed and then bent on both sides, which means there are practically no straight sections. "The challenge during development was quite clearly combining the high quality requirements with a time-efficient manufacturing process", says Stefanie Flaeper, Managing Director of transfluid. "In realising this system, our team has ensured that deformations of the tubes is ruled out throughout the process, and that the surface and any previous tube forming operations are preserved throughout the entire process." A cycle time of 6 seconds makes this high-quality production method an economical solution, especially for short parts.



Stefan Köhler