“In tune with the digital transformation”, this slogan of the scheduled International Sheet Metal Working Technology Exhibition has been taken literally: Concerning the fourth industrial revolution “Industry 4.0”, the PIPE BENDING SYSTEMS (PBS) division of TRACTO-TECHNIK GmbH & Co. KG in Lennestadt (Germany) presents itself as leader of the branch. As example the global player PBS introduces system solutions in the field of pipe assembling which are based on a continuously accompanying digital data flow from the draft stage up to the shipping of the finished tube; i.e. the standard “Industry 4.0” has been implemented in an exemplary way.

Hydraulic systems as part of special machines: Almost every single tube is tailor-made – manufactured within a short processing time at a high quality level, similar to series production  Photo: PIPE BENDING SYSTEMSHydraulic systems as part of special machines: Almost every single tube is tailor-made – manufactured within a short processing time at a high quality level, similar to series production Photo: PIPE BENDING SYSTEMS

PBS had once been founded as a mechanical engineering company, but developed to offer intelligent solutions for all production steps of tube and pipe manufacturing and to get on top of the international league in terms of digital transformation. Today the modular extensible manufacturing system from PBS, composed of CAD interface and measuring technique as well as PIPEFAB software and pipe bending machines, is used around the world in many different fields of application to produce even customised pipes at a cost and quality level which otherwise can only be reached by mass production. Food, beverage or pharmaceutical industries, chemicals, bio-technique or air conditioning, at the shipyard, on a power plant construction site or if the assembly of hydraulic units has to be carried out: PBS systems stand for economical manufacturing, the perfect cooperation of the modular components offers potential savings up to 70 percent.

Directly after the transfer of the design and engineering data from the CAD system the PIPEFAB software controls the entire stages of production – from the material procurement at the very beginning to the final shipment of the finished pipes. Not only the generation of work schedules and production batches as well as the calculation of production times and production costs are based on the stored pipe geometry data; the warehouse management, withdrawal of material, pipe preparation, cutting to length, bending, deburring, welding and quality assurance operations (x-ray inspection, pressure test, etc.) are also derived from this information. No matter where around the world the measurements are taken, the design and engineering data is generated, the bending machine is situated, and whether the pipe segments are manufactured in series or individually: every single piece fits at the first attempt.

SCOPELINK and ROBOFIX: Measuring, welding, assembling – done

Another major highlight which has been developed by the PPS research engineers is the worldwide unique measuring system SCOPELINK for the frequently during pipework installation required adapter pipes. The use of SCOPELINK reduces the commonly time and cost intensive manufacturing of adapter pipes considerably: within only a few minutes the isometry data of the pipe layout can be precisely measured and stored. To save time, prefabricated pipe segments can be tailored by the software to meet the particular conditions of the installation on site. After the data transfer to the workshop or the PIPEFAB software the adapter pipe can be manufactured immediately.

Mechanical engineering “Made in Germany”: Modular structure, functional components and agronomical design. The tube working centre TUBOMAT sets its own particular standard as technological pioneer in the field of tube machining  Photo: PIPE BENDING SYSTEMSMechanical engineering “Made in Germany”: Modular structure, functional components and agronomical design. The tube working centre TUBOMAT sets its own particular standard as technological pioneer in the field of tube machining Photo: PIPE BENDING SYSTEMS

The measuring operation includes precise gathering and documentation of the adapter pipe isometry as well as the position of the flanges and their hole patterns. Based on the pipe isometry the adapter pipe is bent or assembled of segments. For exploitation in the workshop the TRACTO-TECHNIK development section has designed another advantageous tool: the automated positioning unit ROBOFIX. To ensure easy tacking and butt welding this component allows fixing two flanges with their hole patterns in exactly the same position as they will assume after their final assembly. Additionally, the data required for bending and flaring operations can be generated directly from the pipe isometry.

High-quality mechanical engineering: Know-how and expertise

Substantially revised, completely modular structured, functional and ergonomically designed – but still as rugged and reliable as appreciated by the users: As technological pioneer in the field of tube machining the latest generation of the tube working centre TUBOMAT sets its own particular standard. Independently of complex controls by digital information professional and high-quality mechanical engineering remains the key for precisely manufactured tubes of all possible dimensions.

TRACTO-TECHNIK | PIPE BENDING SYSTEMS

Since more than 50 years we develop and manufacture sustainable and innovative machines, precise measuring systems and intelligent software solutions for the manufacturing of tubes and pipes. Thus, in the course of time a unique system for efficient tube production has been created. PIPE BENDING SYSTEMS offers the best solution if it comes to individual parts and small series production with high product variance. Here you can also figure out our core competence: Thinking about solutions in the area of tube manufacturing.

Published inProcessing

The first pipe must be suitable

Perfect cooperation: Bending, measuring, software

Independently of food, beverage or pharmaceutical industries, chemicals, bio-technique or air conditioning, at the shipyard or on a power plant construction site: for many applications tubes and pipes – at a high standard of quality, exactly formed and machined – are key products for successful market presence. Manufacturing of sophisticated customer-specific pipework in large quantities at competitive prizes on the quality level of standard products represents a serious challenge. Thus, for a superior and economic fabrication of complex tube and pipe geometries intelligent manufacturing solutions are required: the modular extensible manufacturing system from the PIPE BENDING SYSTEMS (PBS) division TRACTO-TECHNIK supports the workflow of tubes and pipes in an efficient and flexible manner. The modules of the system – bending machine, measuring technique and software – cooperate in a unique way.

Sophisticated economic production: One-of-a-kind parts for special machines assembly – the first tube segment must be suitable. Photo: PIPE BENDING SYSTEMSSophisticated economic production: One-of-a-kind parts for special machines assembly – the first tube segment must be suitable. Photo: PIPE BENDING SYSTEMS

Dr. Christan Gerlach, head of business area of PBS, explains: „Numerous excellent examples of the implantation of our efficient system can be seen in the field of high-prized, high quality tube production for machines for special applications. Rarely a tube geometry appears twice, most of them are unique – finally one-of-a-kind products. Today one of the most important manufacturers of food processing lines worldwide produces the tubes for the daily assembly of his apparatuses nearly just in time (during the year, in one single plant several hundred kilometres of tubes are installed). Of course each bend or elbow must be suitable.”

The workflow of the system is managed by a software module named PIPEFAB: beginning at the supply of the pipe from the high-rack, followed by the machining operations – marking, sawing, bending, deburring, welding – up to the finished part. „If the customer owns several plants, PIPEFAB is able to propose the actually most efficient site for the production of each part on the whole globe. Already now we of TRACTO-TECHNIK create the basis for global applications of digital engineering and manufacturing of piping network within the meaning of Industry 4.0. Our system applies independently of installing connecting pipes or manufacturing manually or automatically in the workshop” resumes Dr. Gerlach.

Dr.-Ing. Christian Gerlach, Head of business area TRACTO-TECHNIK GmbH & Co. KG, PIPE BENDING SYSTEMS: „Our system modules assist the workflow in a unique way.” Photo: PIPE BENDING SYSTEMSDr.-Ing. Christian Gerlach, Head of business area TRACTO-TECHNIK GmbH & Co. KG, PIPE BENDING SYSTEMS: „Our system modules assist the workflow in a unique way.” Photo: PIPE BENDING SYSTEMS

TRACTO-TECHNIK | PIPE BENDING SYSTEMS

Since more than 50 years we develop and manufacture sustainable and innovative machines, precise measuring systems and intelligent software solutions for the manufacturing of tubes and pipes. Thus, in the course of time a unique system for efficient tube production has been created. PIPE BENDING SYSTEMS offers the best solution if it comes to individual parts and small series production with high product variance. Here you can also figure out our core competence: Thinking about solutions in the area of tube manufacturing.

Contact:

TRACTO-TECHNIK GmbH & Co. KG

PIPE BENDING SYSTEMS

Hunold-Rump-Str. 76-80

D-57368 Lennestadt

Phone: +49 (0) 2725 / 9540-0

Website: http://pipe-bending-systems.de

E-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

PIPE BENDING SYSTEMS (PBS) - More than just the pipe bending machine

As an expert in integrated customized piping and pipe prefabrication TRACTO-TECHNIK attracted attention already last year with the presentation of its PIPE BENDING SYSTEMS strategy. At the same time the company introduced the fundamentally revised, completely modular designed and functionally optimized TUBOMAT pipe fabrication machine as the perfect solution for hydraulic piping.

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The TUBOMAT is the perfect solution for customized piping in hydraulic tasks.

Now TT has also revolutionized its TUBOBEND line of semi-automatic pipe bending machines and presented two new developments during EUROBLECH fair in Hanover in last October. The new machine types are characterized by modular structure, modern industrial design and are optionally available as right-hand bender or left-hand bender. Together with the very compactly designed and exposed bending head, that allows for large bending space, the TUBOBEND machines are able to bend highly complex pipe figures.

Also the bending capabilities of the new machine types have been adapted to the market requirements. The TUBOBEND 16 is for bending steel pipes up to Ø 16.0 x 2.0 mm, while the new TUBOBEND 42 easily manages to bend pipes up to Ø 42.0 x 3.0 mm. Over the coming months one may eagerly look forward to the presentation of further TUBOBEND machine types.

Efficient production by means of process networking

While „Industry 4.0“ is on everyone’s lips and a growing number of companies dream of paperless manufacturing, TRACTO-TECHNIK has already realized broad sections hereof with its PIPE BENDING SYSTEMS strategy. Increase of efficiency is not only achieved by means of more and more automation or growing axis speeds in machine technology. It’s just as important to integrate related quality assurance measures and to ensure a smooth and continuous information flow for the whole production.

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With the TUBOBEND 42, TRACTO-TECHNIK for the first time presents a semi-automatic pipe bending machine, which is available as right-hand bender or left-hand bender.

Precisely these aspects are consequently implemented within the PBS strategy by means of an integrating software solution (PIPEFAB). The software acts as a central component of the so-called „networked pipe fabrication“, provides a seamless interplay between machinery and measuring technology and supplies all manufacture-relevant information and data properly to the individual workstations. Various combinations and expansion stages of the involved components (machinery - measuring - software) finally allow each user to find his optimum PIPE BENDING SYSTEM.

About the company

TRACTO-TECHNIK GmbH & Co. KG
PIPE BENDING SYSTEMS

TRACTO-TECHNIK PBS numbers among the world leading companies in the pipe bending sector and has positioned itself as an expert for customized piping and prefabrication of media-bearing pipes.

For more than 50 years we have been developing and producing powerful and innovative machines, high-precision measuring systems and intelligent software solutions for pipe processing. During this time we have created a unique system for efficient pipe fabrication. PIPE BENDING SYSTEMS - the best system for single-part and small-series production with great product variety. This at the same time reflects our core competence: Thinking in terms of system solutions for the processing of pipes.

The product range currently covers all-electric and electro-hydraulic CNC tube bending machines, semi-automatic tube bending machines, machines for pipe end processing and hydraulic joining technology, tube measuring systems as well as special solutions and software solutions for pipe processing. Maximum customer orientation is our top priority. Thanks to the interplay between our machines, measuring devices and software solutions in different combinations and levels of deployment a scalable system emerges that offers our partners an optimal solution for every application. PIPE BENDING SYSTEMS - more than just the pipe bending machine.

Please find further information on our website http://pipe-bending-systems.com.

Published inProcessing

Leak-proof connections are indispensable to guarantee a perfectly functioning hydraulic system. In order to connect the hydraulic pipes to other components of the hydraulic system in a reliable and permanent manner, often 24 degree cone connectors or 37 degree flared connectors are applied. Both methods are widely used and internationally standardized. For more than 40 years TRACTO-TECHNIK develops practicable assembly devices for faultless pre-assembly of cutting-rings as well as for reliable flaring of the pipe ends. Now TT has launched a brand-new and compact combined device called TUBOFORM C (= connect), that perfectly manages both connection methods.

Universal, reliable & efficient

The hydraulically driven and almost maintenance free machine is equipped with an universal seating device. According to the connection method in use, customers can choose from four different assembly heads (for cutting-ring assembly with manual pressure adjustment, cutting-ring assembly with automatic pressure adjustment, 37 degree flaring and 10 degree flaring), which are easily inserted in this seating device.

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New within the TT product range: the TUBOFORM C for faultless cutting-ring assembly and reliable flaring of pipe ends.

“The most reliable way for assembling cutting-rings is to use the automatic pressure adjustment of the machine and the corresponding assembly head”, division head Dr. Christian Gerlach explains the functioning. “In this case the specific working pressure is automatically taken from a pressure table in the machine control by inserting the diameter-depending and accordingly coded counter support plate. This way of proceeding saves times and improves process reliability because an incorrect working pressure for assembling the cutting-rings is virtually impossible. And this is very well received by our customers.”

Each counter support plate corresponds to a specific working pressure, which is stored in the machine control. Depending on the type of cutting-ring in use also customer-specific adaptations or modifications of the working pressure can be made by reprogramming the pressure table of the machine control.

The TUBOFORM C working range comprises steel and stainless steel pipes from 6 to 42 mm outside diameter. The machine is very well suited for processing single parts as well as for small and medium-sized serial production. In this case a piece counter shows the number of the parts to be yet manufactured. The working process itself - whether cutting-ring assembly or flaring - only takes a few seconds. By adjusting the cylinder stroke limiter, the working stroke and the return stroke can be optimized, thus saving time and money, especially when producing in larger batches.

Flexible & customer-specific

The separation between the hydraulic power unit with universal seating device as the basic machine and several assembly heads with corresponding tooling as additional accessories has proven highly successful in practice. “This possibility makes the machine flexible and customer-specific at the same time, because the customer only acquires the assembly heads and tools he really needs for producing”, Dr. Gerlach points out. And also use of different connection methods, i.e. cutting-ring assembly and flaring, is no problem. All assembly heads together with the corresponding tools can be changed within only few seconds. Thus the machine is well prepared for an alternative connection method.

Published inProduction
Start of TRACTO-TECHNIK 1962 in a garage

As is often the case with highly successful companies, TRACTO-TECHNIK started its success story in a small rented garage in the village of Lennestadt-Saalhausen, Germany. That garage is still standing today.

It all began on 14th November 1962 when 5 employees started to build pulling devices. These devices were designed to pull drill rods and sheet piles out of the ground. The main customer in those days was KRUPP Bautechnik in Essen.

The stable high pressure weather conditions on foundation day turned out to be a positive sign. In conjunction with the economical development all roads seemed to be leading upwards in the years that followed. Still, it was not easy in the beginning.

Wolfgang Schmidt, the son of the company founder Paul Schmidt and a company director to this day reminisced: “My father was an optimistic person and looked at things from this angle, ‘Whoever puts his head in the sand can not discover anything new’. In other words, he grabbed hold of every problem by the scruff of the neck when he belived that he could find a useful solution. Most of his results brought us forward very quickly. Our innovative strength grew through him and this is why, even nowadays, these driving factors and incentives underpin our main innovations.”

guys 1

Pipe forming technology from TRACTO-TECHNIK offers safe solutions all around the pipe. This includes innovative machine technologies and precise measuring technologies, as well as intelligent software solutions.

Gaining recognition
founderTRACTO-TECHNIK was still in its nursery years, but started to learn very quickly to stand on its own feet. The young company gained recognition and convinced clients with its competence and innovative strengths.
The company name was ‘pre-programmed' as the first products carried the names TRACTODRILL and TRACTOMAT. TRACTOMAT won a coveted award in Brussels, ‘The Blue Band’, and is still utilized today for the pulling of guard railing rods adjacent to roads.” That was not all. A short time later, KRUPP presented a development consignment to
TRACTO-TECHNIK for a hydraulically driven ramming device. The professional knowledge in the Paul Schmidt and his colleagues at an evening school in Siegen. Afterwards they searched in vain for a machine for the handling of hydraulic tubes. This included cutting lengths, deburring, bending and the pre-assembly of cutting rings. In the end Paul Schmidt looked at this decided: “If there is no such thing, then we will invent the machine.” That was the birth of the TUBOMAT and a new string to the company’s bow. Thereafter, interest from screwing manufacturers did not take long to grow. Up until the beginning of the 1980’s the company’s distributor was the KRACHT company from Werdohl. Then TRACTO-TECHNIK took over the distribution of its products on its own account.

Industry yardstick
The item TRACTO-TECHNIK are happy about is the multiple thousand-fold proven TUBOMAT which, with small technical improvements to its original form, is still being used as the yardstick with regards to hydraulic tubing and therefore still retains its degree of esteem. 40 years after the arrival of the first TUBOMAT the business area concerned with pipe forming  technology now develops and produces safe solutions all around the tube package. This includes innovative machines and precise measuring technologies, as well as intelligent software solutions. The latest highlight is an all-electric right-and-left hand pipe bending machine fitted with 15 servo-axes, which can produce highly complex pipe figures within seconds. Only 5 years after founding the company it was time to move into a newly built factory. It was decided to stay in Saalhausen, due to the low cost property available and also because the personnel lived there. The main factor was ‘feeling at home there’. A small incident, in 1970, lead to a radical upheaval in the company’s product politics. A fresh tarmac road in front of the Schmidt’s house had to be disrupted once again after only a few days in order to install a water pipeline. This gave  Paul Schmidt another clever idea. The GRUNDOMAT soil  displacement hammer was born and this was the start of many innovative developments for the trenchless pipe installation sector. This was just the start of a triumphant succession of innovation from the company.

The mole
thumb moleAs a world market leader, GRUNDOMAT soil displacement hammers are now ‘Global Players‘, as they are applied on a daily basis all around the world. For trenchless installation technology, the ‘mole’ has become a strong symbol. It has become the marketing sign of an industry that has won the trust and regards of the company’s customers.
Currently, more than 350 patents secure the company’s research and product developments. This has turned TRACTO-TECHNIK into a pacemaker and pioneer. TIMI (TRACTO IDEAS MAKE INNOVATIONS) makes sure that the innovation processes at TRACTOTECHNIK have a true structure. The Avia Award given to the company by the economical examining engineers at DELOITTE had lots of praise for this ethos.
The broad-mindedness and enthusiasm at TRACTO-TECHNIK for technology has provided numerous new developments. These have also brought a large number of awards and tributes. TRACTO-TECHNIK has over 500 employees world-wide. They are down to earth and reliable people. TRACTO-TECHNIK knows that only satisfied and competent employees are also able to keep the customers satisfied. There is a very strong bond between the employees and the company. Some 85 employees have been at TRACTO-TECHNIK since the beginning of their apprenticeships with some of them having spent all their working years with the company. The company’s steered bore technology (e.g. the GRUNDODRILL machines) has been especially fascinating. The tasks and requirements were diverse and led the way to the level of technology available today. They were true pioneering achievements. New ideas have always been taken on the board – arising particularly from daily practical experiences - which were converted into this relatively young technology under the motto: ‘The Best is the Enemy of the Good’.

               drilling             head

                       The new GRUNDODRILL 18 ACS                                           GRUNDOMAT soil displacement in the target
                          for rock drilling and standard bore                                          area after a successful bore

 

Accelerating growth
In the 1980’s the company’s growth started to accelerate and it started to spread out all over the globe, first of all in the UK, then in France, USA and Australia. The TT export department and the sister companies take care of and support more than 60 partners all over the world.
In Germany the service in all regions is covered by the homebased plants and many subsidiaries. At the turn of the century the internet started to gain more acceptance and became a powerful instrument for increasing publicity and the development of national and international networks.

guys 2

The management team at TRACTO-TECHNIK: Meinolf Rameil, Wolfgang Schmidt and Timotheus Hofmeister


TRACTO-TECHNIK has got clear eco-political targets, which are thoroughly and constantly encouraged, as well as an environmentally-friendly machine technology and also numerous ecological projects. In the meantime the Germany’s nature protection board (NABU) has implemented trenchless pipe installation methods into its general directives.
In 2007, GRD bore technology was developed for an efficient exploitation of geothermal energy. Bores are carried out from a plastic manhole in all directions (360°) and inclinations (30° - 65°). The compact bore rig is applicable to site even on the tightest of premises and hardly causes any surface damage. TRACTO-TECHNIK leads by example and successfully applies geothermal heat at its operating plants. Continuity and stability have always been benchmarks in the company’s policy. Company directors Timotheus Hofmeister and Meinolf
Rameil like to state this more precisely: “Our aim is for endurable and profitable growth. To do this we need products in line with the market and a powerful distribution force with a clear strategic alignment. We can only achieve this as a team.” The challenges of the future are seen by TRACTO-TECHNIK as a need for modern and safe supply and disposal in the energy and communications field, where technologies and methods of trenchless pipe installation can contribute substantially.

Published inMachinery