NEW TAURING BENDERS ALPHA SERIES

NEW TAURING BENDERS ALPHA SERIES Today, a company specialised in section bar bending has to have reliable machines and fixtures manufactured with skil...
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NEW TAURING BENDERS ALPHA SERIES Today, a company specialised in section bar bending has to have reliable machines and fixtures manufactured with skill and capability. In every application field, from vast infrastructures to simple aluminium door/window frames, the bending of the section bars takes on an ever-increasing importance, regardless of whether these are in iron, aluminium, stainless steel, copper or other metals. Tauring, for more than half a century, has been offering a secure and efficient response to the many diversified market demands, that over the past few years have seen us leaders with an innovative building philosophy applied to benders. Although new manufacturers continually appear on the international scenario of machine tools, the solutions that are usually offered are now obsolete, certainly not able to face the challenges that a modern company has to cope with. The new products are dynamic, precise, reliable, strong, versatile and economic to run – these are the Tauring benchmarks.

CONSTRUCTION PRINCIPLES The construction principle applied by the major part of manufacturers consists of two rolls, mounted on levers pivoted on a central pin, following an orbital path. These two rolls are opposed by a third fixed roll, in central position to the fist two. Fig.: b) shows the system described in detail:

Independent supports

fixed upper roll central pin (fulcrum)

adjustable lower rolls Fig.: a

Fig.: b

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This machine geometry (fig.: b) is very widespread, because of the low production costs. However, due to its composition, this system has some equally evident disadvantages because of the forces involved, that submit the structure to considerable stress concentrated in a single point : the central pin. The latter is the weak point of the entire system, since, even if largely over-dimensioned, it never has the stiffness required to guarantee an even distribution of the stress it is submitted to. Tauring has built and patented an innovative drive and support system of the roll-carrier shafts on straight-line slides (fig.: a), much more precise and stiffer than the previously described system. Added to this important development there is the possibility to apply independent supports (s.i.), that restrain the ends of the shafts strongly limiting deflection. The straight-line slides act as the base for the assembly of the supports, so that even during the adjustment of the slides, the shafts are always rigidly restrained on three points. The following diagram shows this in detail :

independent supports

independent supports

upper roll

adjustable lower rolls

Fig.: c – Functional diagram of straight-line slides and independent supports

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The big advantage of this configuration is the net improvement in the stiffness of the entire bending system. In fact, a shaft rigidly restrained at both ends, with the same diameter can bend section bars with a bending strength module (Wf) that is twice more than the standard configuration with overhanging shafts. Obviously this is possible due to an advanced design, that also includes the simulation of finished parts of the bending, as well as the correct dimensioning of all the components.

The concept set out above can be easily seen in the following examples :

independent support

Type of geometry: Shaft rigidly restrained to the independent support , diameter 80mm, useful length 220mm. Bending coefficient: 0.085 

Type of geometry: Overhanging shaft , diameter 80mm, useful length 220mm. Bending coefficient: : 0.8 

Type of geometry: Overhanging shaft, diameter 120mm, useful length 220mm. Bending coefficient: 0.25 

The comparisons shown mainly highlight the bending coefficient variations in the different configurations. . In the first case, the shaft with 80mm diameter is supported at the end by the independent support. The shaft, like the bearings works in the ideal manner, because the bending stress is discharged on the support, that works almost exclusively in 3

compression, transmitting the reaction on the slide, and as a consequence on the machine body. In the second case the same shaft is shown, but with an overhang (as a classic shelf could be loaded). The part near the bearing undergoes heavy stress whereas the opposite end is free from any stress. In this case also the support bearing works in an inconsistent manner. In the third case, a shaft has been inserted that has the same useful length as the previous examples, but the diameter is increased by 50%, restrained only by a bank of long bearings. It can be clearly seen that the bending coefficient is about 3 times more than in the first case, although the shaft diameter has been increased considerably.

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ALPHA 200 PQ10

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CHARACTERISTICS Completely hydraulic bending machine with 3 driving rolls and separate dual adjustment. The upper roll has a fixed housing. The geometry of this machine allows the bending not only of large-sized section bars, but also small section bars with very reduced bending radii. Because of its specific characteristics, this machine is ideal for use in large and medium steel structural work. One of the more significant characteristics of this machine is the application of independent supports (s.i.) at the end of the shafts. These independent supports enable the shafts to work in a restrained manner and therefore not jerking, as in the traditional bending machines, thus discharging the deflection forces on the slides and, as a consequence, on the body of the machine. In this way the capabilities of the bending machine are considerably increased (up to three times) making it possible to carry out machining operations that are usually destined for higher level cutting machines still maintaining complete working freedom, without creating any form of obstruction for the insertion and unloading of the material between the bending rolls. Also, these rolls can be easily adjusted with no need to remove the fixture. The driving rolls are hydraulically driven. Each roll is controlled separately by an epicyclical hydraulic gear motor. The machine outfitting also includes, on both sides, lateral correctors with triple hydraulic correction. Each corrector can take all the positions necessary to give an optimal correction of the bending profile. The standard outfitting has POLYVALENT rolls, for the bending of a wide range of section bars. All rotating components are mounted on bearings with high radial load, they are made of strongly bonded steel, case hardened, tempered and ground. The machine works in horizontal position and does not require foundations. The machine body is constructed in electrowelded steel with appropriate reinforcement. Electric cabinet and hydraulic power pack are incorporated in the machine structure. A wide range of accessories is available upon request so that the machine is able to bend any type of bar section. A Joy-stick panel allows movements of the machine.

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to

control

all

On request the machine can be equipped with a wireless control console.

SOME CHARACTERISTICS Control console for the following commands : Right/left rolls rotation by joystick. Right and left rolls adjustment by means of 2 joysticks with 2 positions. Rolls position control Rotation and lifting of lateral hydraulic rectifiers by means of 2 joysticks with 4 positions (axes T and V).  Lateral rectifiers horizontal transfer by means of 2 two-direction joysticks.  Rotation speed selection by potentiometer on console.  Multi-direction safety stop pushbutton that can be activated with the knee.

   

TECHNICAL DATA Number of driving rolls Shafts diameter Shafts useful length Polyvalent rolls diameter Total power installed Thrust of each hydraulic cylinder Shafts rotation speed Connection Dimensions without packing (LxDxH) Working height in vertical position Machine approximate weight

3 150 mm 400 mm 490 mm 22 kW 450 kN 1.5 - 6 rpm 400V 50 Hz 3 phases 260x295x196 cm 130 cm 8,000 kg

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MAXIMUM BENDING CAPACITY

SI: Separate Supports are necessary. HE: Equipment for I-beams is necessary.    

In some cases optional equipment and shaft stiffening tie-rods are required. The second line indicates the maximum performance that can be obtained with several passes and separate supports. All performances refer to material S275JR ÷ Fe430B or similar Since the design of this machine is a new concept, this data could be subject to variations.

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standard EQUIPMENT Polyvalent rolls; 2 single control rectifiers with triple hydraulic adjustment ; Separate shaft supports; Lifting rings; 12” colour touch screen for the programming and controlling of the 7 axis and for the auto-diagnosis program.  Service keys;  Programming handbooks for quick consultation, use, maintenance and safety;  Electronic arc meter ARC 50/300*

    

optional ACCESSORIES         

Rolls for round pipes; Integral modular rolls for square and rectangular pipes; Rolls for special section bars; Short shafts with no front protrusion; Long shafts; Equipment for INP and HE I-beam on-edge bending; Restrained shafts stiffening tie-rods; Fourth central roll hydraulic device; Wireless control console.

* See specifications below

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ELECTRONIC ARCMETER Electronic arc meters ARC 50/130, ARC 50/300 and ARC 50/500 for direct reading of the bending radii on the LCD display. The instrument allows the measurement of internal and external radii in either millimetres or inches using a portion of only 150 mm. of the section ( ARC 50/130). The display can rotate to allow a good reading with the instrument in any position, while a specific “hold” key can be used to lock the value to read it more comfortably after the measurement. There is also a deviation measurement system to fix a master radius and measure the variations and deviations. To measure wide radii, we propose the alternative models ARC 50/300 and ARC50/500.

ARC 50/300

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