Electropneumatics tube benders catalogue

Tube Benders

Machine

Electropneumatics & Manufacturing Hydraulics (India) Pvt. Ltd.

Division

Electropneumatics has been designing and manufacturing the highest quality, technologically advanced metal forming machines since 1972. We have more than 5000 installations worldwide of a wide variety of machines for sheet forming, moulding, spotting and tryout, compacting, honing, assembly and testing, transmission line tower manufacturing, tube/section bending and other applications. Our indigenous capabilities in all areas (mechanical, hydraulic, electrical, electronics and pneumatics) give our products an edge over the rest.

Electropneumatics specialises in tailored solutions for diverse metal forming applications and has been a pioneer of many forming technologies in India, tube bending being one among the many.

3

Tube Benders

Electropneumatics has been designing and building tube benders for more than three decades. The wide variety of models along with tooling for different tube sizes, materials and bend requirements covers almost all tube bending applications in the automotive, furniture, boiler, railway and ship building sectors. We are continuously innovating to provide the best bending solutions to our customers- higher productivity, lower energy consumption, reduced maintenance and superior, repeatable bending quality.

Electropneumatics’ tube benders are many of India’s first.

1982

3-axes CNC tube bender

NC Tube Benders

06

1985

Tube bender, capacity OD 324 x t 17mm

CNC Wire Benders

08

1997

3-axes CNC wire bender

CNC Three-Axes Tube Benders

09

2000

Boost bender for R = 1D bends

CNC Multi-Axes Tube Benders

12

2001

Multi-radius, bi-direction CNC tube bender

CNC Boost Benders

14

2006

10-axes all-electric CNC tube bender

Special Tube Benders

16

Tube Processing Machines

18

3-axes CNC rotary-head type wire bender 2008

Complete range of multi-stack, electric tube benders

2009

Orbital electric tube bender

2010

Largest 3-axes CNC tube bender, capacity OD 419 x t 21 mm

2012

5-axes CNC multi-stack heavy duty tube bender for rectangular sections

2013

Servo electric hybrid tube bender

...... and many more

5

NC Tube Benders

These hydraulic semi-automatic NC Tube Benders can handle tubes in round, rectangular, square and other sections.

The NCX models can produce parts with multiple bends in a single plane. The additional pre-settable linear and rotary indexing arrangement in NCXR models allow multi-plane bending. With the exception of plane of bend (POB) and distance between bend (DBB) being manual against preset stops, the bending cycle is automatic.

Specifications Model

Unit

30NCX 30NCXR

65NCX 65NCXR

80NCX 80NCXR

100NCX 100NCXR

150 NCX

200NCX 219 x 13

Max. tube capacity (Dxt)*

mm

32 x 2

65 x 4

80 x 2

114 x 6

168 x 11

Min. tube capacity (D)*

mm

6

10

10

25

50

76

Max. bend radius (CLR)

mm

120

300

300

500

600

660

Min. bend radius

mm

9

15

15

38

100

150

Min. bend radius

in terms of D

1.5D

1.5D

1.5D

1.5D

2D

2D

Length over mandrel

m

2

2

2

2

6

6

deg

5 - 180

5 - 180

5 - 180

5 - 180

5 - 180

5 - 180

Max. bend speed (accuracy)

deg/s (deg)

30 (±0.2)

24 (±0.2)

18 (±0.2)

12 (±0.2)

3 (±0.25)

2 (±0.25)

DBB & POB (in NCXR models)

mm & deg

±0.2

±0.2

±0.2

±0.2

±0.25

±0.25

Bend angle range accuracy

Connected load (approx.)

Weight (approx.)

kW

3.7

7.5

7.5

15

30

37

kg

1300 1500

2300 3000

2500 3000

4500 5000

16000 19000

25000 30000

D = Tube Outside Diameter | t = Wall Thickness | CLR = Centre Line Radius | DOB = Degree Of Bend POB = Plane Of Bend | DBB = Distance Between Bends *For ferrous tubes with UTS of 45 kg/mm2. Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC.

6

30NCXR

80NCX

65NCXR

100NCX

Features

Options

¡¡ No. of multi-plane bends settable = 8 (POB & DBB) (in NCXR)

¡¡ Increased bend radius (on select models)

¡¡ Programmable bending angle (DOB) in automatic open loop control

¡¡ Extra mandrel length and extended arm for specific applications

¡¡ Pre-selectable POB (in NCXR)

¡¡ Modified versions with split tools, heated tools, etc. to suit component requirements

¡¡ Memory capacity of 50 programs with 15 bends/program

¡¡ Safety mat and safety flap on bend arm

¡¡ Electropneumatics make Micro PLC with 3” touch screen MMI

¡¡ Automatic mandrel lubrication

¡¡ Independent pressure die assist (friction boost)

¡¡ Counter-clockwise bending

¡¡ Hydraulic oil cooler

CNC Wire Benders

Electropneumatics’ CNC Wire Benders are capable of bending steel wires from OD 2 to 6 mm. They can bend wires in both clockwise and counterclockwise directions. The push, tum and bend axes are driven

by AC servo drives.

The 6CNC3W model is a compression bend type wire bender ideal for automotive remote rods for door locks, hood support, actuator levers and also for consumer and decorative items. The electric drives consume less power, reduce noise levels drastically and provide a clean machine and working environment.

6CNC3W

Specifications Model

Unit

6CNC3W

Max. wire capacity (D)

mm

6.0 (UTS 65 kg/mm2) 5.0 (UTS 110 kg/mm2)

Max. bend radius (CLR)

mm

25

Min. bend radius

mm

0.5

Min. distance between successive bends Max. range

mm

7.5

Push (Y)

mm

1000

Turn (B)

deg

0 - 360

Bend (C)

deg

0 - 110

Push (Y)

mm/s (mm)

1200 (±0.1)

Turn (B)

deg/s (deg)

500 (±0.1)

Bend (C)

deg/s (deg)

150 (±0.1)

Connected load (approx.)

kW

5.5

Weight (approx.)

kg

1000

Max. (accuracy)

speed

Power supply: 415V, 50Hz, 3-phase AC.

8

CNC Three-Axes Tube Benders

Electropneumatics’ 3-Axes CNC Tube Benders are ideally suited for bending of automotive parts because of their high productivity. These machines have a direct-acting clamp, pressure die and pressure die assist along with a mandrel extractor, power chuck, tube support and automatic machine lubrication. They are available in all-electric or combination of electrichydraulic versions.

Specifications Model

Unit

30CNC3X

65CNC3X

100CNC3X

150CNC3X

200CNC3X

325CNC3X

400CNC3X

Max. tube capacity (Dxt)*

mm

32 x 2

65 x 3

114 x 6

168 x 11

219 x 13

324 x 17

419 x 21

Min. tube capacity (D)*

mm

6

10

25

50

76

89

114

Max. bend radius (CLR)

mm

120

250

500

600

660

1000

1260

Min. bend radius

mm

9

15

38

100

150

178

228

Min. bend radius

in terms of D

1.5D

1.5D

1.5D

2D

2D

2D

2D

Length over mandrel

m

3

3

4

6

6

6

6

deg

0 - 180

0 - 180

0 - 180

0 - 180

0 - 180

0 - 180

0 - 180

Push (Y)

mm/s (mm)

1200 (±0.1)

1000 (±0.1)

400 (±0.1)

200 (±0.2)

150 (±0.2)

100 (±0.2)

75 (±0.2)

Turn (B)

deg/s (deg)

300 (±0.1)

300 (±0.1)

120 (±0.1)

50 (±0.2)

30 (±0.2)

24 (±0.2)

15 (±0.2)

Bend (C)

deg/s (deg)

150 (±0.1)

60 (±0.1)

30 (±0.1)

15 (±0.2)

2 (±0.2)

2 (±0.2)

1 (±0.2)

Bend angle range Max. speed (accuracy)

Connected load (approx.)

kW

16

19

29

37

37

60

72

Weight (approx.)

kg

2500

3500

9000

15000

30000

62000

80000

*For ferrous tubes with UTS of 45 kg/mm2. Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC.

9

65CNC3X

18CNC3X-O 30CNC3X

Features

Options

¡¡ Electropneumatics’ make CNC system with touch screen monitor and keyboard

¡¡ Extra mandrel length and extended arm for specific applications

¡¡ CANBUS network interface with reduced wiring

¡¡ Modified versions with split tools, heated tools, etc. to suit component requirements

¡¡ Programmable axes motions in closed loop position-speed feedback mode

¡¡ Safety mat and safety flap on bend arm

¡¡ Data entry as Push-Turn-Bend (Y-B-C) values or X-Y-Z co-ordinates

¡¡ Automatic mandrel lubrication

¡¡ Capability of programming in inches or millimeters

¡¡ Hydraulic chilling unit

¡¡ Multi-sequence bend capability for up to five parts with common bend radius and diameter

¡¡ Counter-clockwise bending

¡¡ Program retrieval by alphanumeric code and password protection for data entry ¡¡ Spring back calculation and off-line compensation facility ¡¡ Comprehensive diagnostics during online and offline operation ¡¡ Independent pressure die assist (friction boost)

¡¡ Servo hydraulic pump driven energy-efficient, low maintenance tube benders also available

100CNC3X

400CNC3X

11

CNC Multi-Axes Tube Benders

Electropneumatics’ Multi- Axes CNC Tube Benders have a wide variety of features and a combination of electric and hydraulic drives for the programmable axes. They are designed to bend complex parts of different materials in high-volumes for all industries, specifically automotive.

Servo hydraulic pump driven, energy-efficient, low maintenance tube benders also available.

Specifications Model

Unit

10CNC5X3

19CNC5X3

38CNC5X3

65CNC5X3

90CNC5X3

Max. tube capacity (Dxt)*

mm

10 x 2

19 x 2

38 x 2

65 x 3

90 x 3

Min. tube capacity (D)*

mm

3

3

6

10

25

Max. bend radius (CLR)

mm

30

80

180

250

300

Min. bend radius

mm

12

24

20

15

38

Min. bend radius

in terms of D

1.5D

1.5D

1.5D

1.5D

1.5D

Max. radius difference (max.-min.)

mm

15

35

50

90

90

Tooling stack

nos.

3

3

3

3

3

m

2

2

3

5

5

deg

0 - 180

0 - 180

0 - 180

0 - 180

0 - 180

Length over mandrel Bend angle range Axes drives Max. speed (accuracy)

—

Electric

Electric

Electric

Electric

Electric

Push (Y)

mm/s (mm)

1200 (±0.1)

1200 (±0.1)

1200 (±0.1)

1000 (±0.1)

850 (±0.1)

Turn (B)

deg/s (deg)

360 (±0.1)

360 (±0.1)

300 (±0.1)

300 (±0.1)

180 (±0.1)

Bend (C)

deg/s (deg)

300 (±0.1)

180 (±0.1)

150 (±0.1)

90 (±0.1)

50 (±0.1)

Radius (X)

mm/s (mm)

180 (±0.1)

180 (±0.1)

150 (±0.1)

100 (±0.1)

100 (±0.1)

Stack (Z)

mm/s (mm)

100 (±0.1)

100 (±0.1)

100 (±0.1)

100 (±0.1)

50 (±0.1)

kW

12

12

22

45

48

Connected load (approx.)

*For ferrous tubes with UTS of 45 kg/mm2. Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC.

12

19CNC5X3

65CNC5X3

38CNC5X3

90CNC5X3

Features ¡¡ 3-radii bending capability by 3-stack tooling in single set up ¡¡ Push, turn, bend, lateral and vertical axes powered by AC servo motors ¡¡ Programmable closed loop position-speed control with optimized parallel axes motions ¡¡ Independent pressure die assist (friction boost) ¡¡ Servo hydraulic pump driven auxiliary functions for energy efficiency available as added feature

CNC Boost Benders

Electropneumatics’ CNC Boost Benders meet the stringent ovality/thinning requirements of bending thick-walled,tightradius tubes required in the boiler, chemical and process industries. Synchronisation and programmability of speed and position through servo controls results in excellent control on the bend quality.

Specifications Model

Unit

Max. tube capacity (Dxt)*

mm

63.5 x 7.1

114 x 6

mm

50.8 x 5.6

63.5 x 7.1

mm mm

300 120

500 150

Capacity in boost mode (mandrel-less) Max.

bend

radius

(CLR) : Normal Boost mode

mode

Min. bend radius (mandrel-less) Min. bend radius

speed

(accuracy) : Normal Boost mode

DBB and POB accuracy (in CNC2XR-B models)

mode

100CNC2XR-B

24

38

1D (on D/t < 9)

1D (on D/t < 9)

m

Bend angle range

100CNC2X-B

mm

Serpentine bends (max. 120 CLR)

Length of mandrel bend

65CNC2XR-B

in terms of D

Speciality/Suitability

Max.

65CNC2X-B

2

Serpentine bends (max. 150 CLR)

6

2

6

deg

5 - 180

5 - 180

deg/s (deg) deg/s (deg)

18 (±0.2) 10 (±0.2)

12 (±0.2) 6 (±0.2)

±0.2

±0.2

mm & deg

Hydraulic clamp &. boost unit for axial compression with programmable controls for synchronised bend-boost speed relation

Booster unit Connected load (approx.)

kW

Weight (approx.)

kg

11 5000

18.5 6000

8000

9500

*For ferrous tubes with UTS of 45 kg/mm . Standard bending direction is clockwise. Power supply: 415V, 50Hz, 3-phase AC. 2

14

100CNC2X-B

65CNC2X-B 100CNC4X-B

Features

Options

¡¡ Minimum R = 1D bending on tubes with D/t ratio < 9

¡¡ Provision of carriage with manually presettable linear and rotary indexing facility for multi-plane bends (in CNC2XR-B models)

¡¡ Achievable parameters on R = 1D in ‘boost’ mode Ovality: 8 - 10%, Thinning: 12 - 13% ¡¡ Capability of serpentine bends (with suitable tooling) ¡¡ Fully programmable closed loop (servo) ‘bend-boost’ speed and position control ¡¡ Unlimited tube length and capability of serpentine bends ¡¡ Mandrel-less and tie rod-less operation in ‘boost’ mode ¡¡ Suitable for both boost and normal (higher capacity) bending

¡¡ Extra mandrel length ¡¡ Split tool arrangement for R > 57 mm

Special Tube Benders

Section Benders These machines bend non-round sections like square or rectangular tubes for chassis long members of jeeps, trucks and commercial vehicles, and sections used in luggage frames, furniture frames, automobile accessories, etc.

Section Coilers These machines can form coils of condensers and evaporators used in refrigeration products. They can bend square, rectangular, round or any other section. They are usually provided with a decoiler, straightner, D-proflle former and cut-off unit.

Robotic Bending Cells Our bending cells are used for unmanned, consistent and high speed bending of tubes in high volumes. A robot can be integrated with 2 or 3 tube benders for loading and unloading of tubes or can be used to do the bending itself.

16

Electropneumaticsâ&#x20AC;&#x2122; has indigenous expertise in developing customised solutions for the most demanding bending requirements. We work with our customers to offer the right equipment and automation, either as a single product or a production line, that can give the best productivity and quality

using the latest techniques. These custom-designed machines can bend sectional profiles, tight-radii, different tube materials, thin-walled and thick-walled tubes, solid rods in cold or hot condition.

Stretch Benders This CNC Hydraulic Stretch Bending machine has 8 nos. hydraulic servo controlled axis. The speeds of all these axes are synchronized with respect to each other in a programmed manner.

The machine produces complex multiplane bend shapes of rolled sections used in automobile windows, door frames etc.

Portabend This universal mobile multi-purpose tube working station has a sawing, ID/OD deburring, bending and ferrule pre-setting unit. They are most suitable for hydraulic piping work in hydraulic shops, hydraulic machine tool factories and also for on-board and off-shore tasks.

CNC U-Bender for long Copper tubes This is a special purpose 2 Axes CNC bending machine for U-bending of smaller diameter, long copper tubes used in HVAC industries. The machine is featured with automatic feeding from the coil, straightening, cutting as per the programmed length and suitable for making tight bends (upto 1D) used in shell and tube type heat exchangers.

Tube Processing Machines

Features ¡¡ Machines available for end forming, cutting and punching of tubular parts ¡¡ Compact and modular, yet robust designs ¡¡ Can process tubes from OD16 up to OD114 mm in carbon steel, stainless steel, alloy steel, aluminium, copper, brass and other materials

2-Stage, Linear Indexing Light Duty Tube End Former

¡¡ Special purpose machines available to suit specific needs ¡¡ Custom-designed tools offered for all operations ¡¡ High productivity machines ¡¡ User friendly Electropneumatics’ NC/CNC controls with intelligent operator interface

End Forming Machines ¡¡ Cold forming of intricate shapes and profiles- heading, flaring, swaging (expanding/reducing), beading and others are possible ¡¡ Available in one, two or multiple stages with linear or rotary indexing facility

2-Stage, Linear Indexing Medium Duty Tube End Former

¡¡ Can form one or both ends of the tube simultaneously

End Cutting Machines ¡¡ Square end trim cuts, angle, radius and scallop cuts ¡¡ Incorporates dual blade shear and supported shear technologies ¡¡ End cutting systems can be incorporated on tube benders

Punching Machines ¡¡ Hole punching in tubular (round, square, rectangular, oval) and other sections

2-Stage, Linear Indexing Heavy Duty Tube End Former

¡¡ CNC programmable hole pattern 18

Electropneumatics offers total solutions in tube processing including tube bending, end forming and cutting. The end forming and cutting machines cover a wide range of diameters and applications in the automotive, air conditioning and ventilation, HVAC, furniture, boiler, shipbuilding, piping, construction and such industries.

The end forming machines are meticulously designed, proven and reliable. The end formed parts produced by this chipless process have increased strength, good surface finish and tight tolerances. Special multi-section punching machines for programmable punching of holes in round, square, rectangular, oval and other sections are also available.

2-Station, Special Tube End Former

5-Stage, Rotary Indexing Tube End Former

2-Way, 2-Stage Special Tube End Former Dual Shear Tube cut-Off Machine

Multi-Section Punching Machine

Electropneumatics & Hydraulics (India) Pvt. Ltd. Gat No. 254/255, Kharabe Wadi, Chakan-Talegaon Road, Chakan, Pune 410501, India.

Tel. : +91 2135 667500 Fax. : +91 2135 667502 www.electropneumatics.com

To find out how we can help you, email us at epcsales@electropneumatics.com