WAFIOS presents this new development in Düsseldorf together with the machine's bigger brother, the RBV 60 R, which was presented in 2013.

The series couples power with innovative technology and new ergonomic design.

The RBV machines are new, extremely versatile and profitable tube bending machines for the production of 2D and 3D parts with more flexibility in the production of parts and higher repeat accuracy. Thanks to the new, more robust design of the machine, significant process improvements could be achieved. More performance, despite increased energy efficiency, is guaranteed due to the use of the most modern control and drive technology from the robot industry. High service and operating convenience increase the machines’ availability.

Wafios-RBV60R-002-1 opt 700

WAFIOS CNC Tube bending machine RBV 60 R

Thus the RBV series becomes a long-lasting solution for the effective production of a large spectrum of parts also in small batch sizes.

The exhibition program will be completed by the successful BMU 50 R bending machine which will be exhibited for the first time as a machine for bending tube from the coil. Visit WAFIOS in hall 5, booth A 21 at the Tube show!

Published inMachinery

So Your Second-Hand Machine Does Not Become a “Failure”

Lower investment volume, adequate production capacity – the arguments for buying a second-hand machine are obvious. Is it that simple though? Particularly in the case of complex tube bending machines, there is a whole range of factors determining the efficiency of using a second-hand system. In the worst case, the new, second-hand machine becomes a “failure” in the production sequence because the component quality and output performance do not match.

second handWho buys a car without a test drive and without knowing its features? Yet, investment in a second-hand system resembles precisely this scenario more often than you would think. This is particularly true if complex tube bending machines from a niche area are bought without consulting the original manufacturer. Pipe bending processing on an industrial scale is a good example of this: customer-specific system solutions are used in many sectors, ensuring high-precision bending results by means of CNC control, high performance drives and bending tools with a complex structure. The sophisticated plant technology cannot be simply dismantled and reconstructed to produce new components in a different company. “Detailed questions of component geometry, material and output quantity have a decisive impact on the possible applications of the machine,” explains Hartmut Stöhr, Managing Director of bending machine specialist Schwarze-Robitec (producer of machines in the brands Schwarze-Robitec, Robitec and Schwarze-Wirtz). “In our case, the procedure itself complicates the sale of second-hand machines by third parties. If one of our tube bending machines has been designed for example to process thin-walled exhaust pipes in mass production, it might not be suitable for bending thick-walled high-pressure tubes for plant construction. Ultimately, whether the drive concept and machine design can produce perfect component quality under the new conditions can be judged only by one of our specialists.”

Exceptionally High Risks

The fact that second-hand special-purpose machines are bought time and again without consulting the manufacturer is the result of economic considerations, as Stöhr knows: “It naturally sounds attractive if a machine from a prestigious manufacturer can be offered at an apparently very reasonable price for one’s own production.” Consequently, however, buyers of bending machines frequently take excessive risks. Machines are therefore taken over with no prior testing. Initial testing takes place only on the new production site. Under these conditions, it is of course impossible to verify whether the system has the required capacity. “Before buying, it should at least be ensured that the machine actually works properly. The control must show no errors, the mechanics must not be worn and the machine must be complete in terms of its components,” Schwarze-Robitec Managing Director Bert Zorn points out perhaps the simplest basic conditions. “It must then be presented in test mode, in order to be able to clarify for example that all of the axles still work properly. However, these criteria are really the absolute minimum and they are adequate in only the rarest of cases. There is generally a lot more to be considered.”

Small Things Can Tip the Balance

Time and again, the bending specialists are confronted with enquiries from users who have already bought a second-hand machine and encounter great problems a short time after the start of production. “We are contacted when the horse has bolted and the machine does not work,” Zorn says. Even small things can tip the balance here – for example if incorrect hydraulic filters are used, resulting in problems with the hydraulic pumps after a short time.

Information in the Manufacturer’s Database

On the other side, rogue sellers sometimes exploit the ignorance of buyers: old plants are repainted then even given false type references and accordingly sold more expensively. It is also a problem if original components have been replaced or improper repairs or alterations carried out on the machine. Customers are additionally left in the dark about possible difficulties with obtaining spares for very old parts. In the event of production problems, even the original manufacturer’s fitters are sometimes baffled, as they cannot repair the foreign parts and the result may then be expensive downgrading to original condition. Ultimately, Schwarze-Robitec therefore recommends asking at some point before any investment decision. “There are various options if you contact us,” explains Jürgen Korte, Authorised Representative at Schwarze-Robitec. “We can look at our records to see exactly which machine is being offered. In addition to the delivery condition and the exact age of the machine, we can then also provide statements about whether the machine has undergone regular maintenance by the manufacturer. This is at least an initial indication of the current condition of the plant. Moreover, we can assess whether the machine type offered is an option at all for the application area.”

Focus on Safety Technology in the Case of Second-Hand Machines

Of course, these indicators also provide no absolute guarantee. The ideal way when buying second-hand machines is therefore to buy from the original manufacturer. As well as factory-tested second-hand machines, Schwarze-Robitec also supplies reconditioned machines. In the case of the bending specialist, reconditioned means: the manufacturer restores the machine to mint condition by complete dismantling and reconstruction from scratch – naturally including the latest control, electrical installation, hydraulics etc. Furthermore, the reconditioned system is also always compliant with the current safety regulations and therefore has CE marking. This is a very important topic, particularly when buying a second-hand machine. If machines display no CE marking and their safety technology is incomplete, they must not be placed in operation. In some cases, even the lack of operating instructions – with directions on the correct procedure in case of damage – might be enough for a second-hand machine to not comply with the safety regulations. “For an original manufacturer, such things naturally go without saying. The customer also receives a full guarantee on our reconditioned machines,” Authorised Representative Korte explains the advantages of buying from the manufacturer.

If There are No Spares

The issue of spares is of similar importance when buying a second-hand machine. Here, of course, the older the machine, the less reliable our stock. Generally, only the machine manufacturer is able to say whether it is still possible to obtain vital components in case of damage. Here again, the database provides information on the components used in a machine. However, from this perspective, a reconditioned machine is always the first choice. In this case, all obsolete components are replaced – from the control to the smallest sealing ring. Moreover, the manufacturers guarantee lasting operation of the system through an extensive service provision. The question of spares is then resolved from the outset.

Better Brand New?

In which case should a second-hand machine be avoided and a completely new system chosen? In the view of the specialists, the product range and daily use of the machine are critical. “If no series parts are to be produced and enough time is scheduled for maintenance and repair, a second-hand machine is certainly an option that can be considered,” Managing Director Bert Zorn states. “However, if production is dependent on a high level of availability of the plant and you want to benefit from the advantages of the latest control generation then the company is better advised to have a new machine or a reconditioned plant. A new machine can then also be completely customised to the requirements of the customer. We recommend that any company interested in a tube bending machine or wanting to pass on their old machine first contact us, the manufacturer.”

Published inMachinery

According to a recent academic paper, titled “The China Toll”, the United States lost more than 2.7 million jobs to China in the years between 2001 and 2011. Haven Manufacturing, the well-known Georgia based manufacturer of machinery and equipment for tube and bar processing, is doing their part to fight the trend of continued American job and manufacturing loss to Asia.

dual blade cutting

Last year Oddello Industries, a Tennessee based manufacturer of high quality metal, tube, pipe, composite, and MDF components for OEMs in a variety of industries, purchased a dual-blade cutoff machine from Haven as part of the development of a process to manufacture several individual parts from 1” square tube to be packaged, along with a variety of sheet-metal stampings, into high quality adjustable mattress foundations. The state of Tennessee alone has lost well over 56,000 manufacturing jobs, more than 2% of the state’s total employment, to China based companies in the past decade. Oddello, by partnering with proven America based equipment suppliers like Haven Manufacturing, has shown itself to be able to compete for, and win, business back from China based manufacturing concerns. Oddello’s capable engineering staff partnered with Haven’s engineers to develop a fully programmable process which couples a piercer, designed and manufactured by Criterion Machinery, with a Haven Servo Dual-Blade Shear Cutoff machine. The resulting process has proven able to process nearly 15 miles of tube per day into 38 unique parts (SKUs) within length tolerances that never exceed 0.0015 inch.

The Oddello-Haven collaboration has proven so successful that Oddello’s management recently decided to expand the tube stamping and cutting operation. Not only is this great news for the company and its employees, but it is great news for the people and community of Morristown. The additional jobs and income provided by the expansion will undoubtedly improve the quality of life for many people in the region. The original Haven cut-off machine has proven so reliable and efficient that the company has ordered an additional Haven Model 873 Servo Dual-Blade Shear Tube Recut Machine to handle increased demand from both new customers and the customer for which this process was originally designed. The Haven 873 is capable of cutting tube from square or round stock, in lengths from 2” up to 120” and employs a programmable closed-loop servo drive to assure accuracy.

Published inMachinery
Tuesday, 14 May 2013 13:00

New mill for Bolivia

New mill for Bolivia

OTO just completed the production of a 1 ½” high productivity tube mill for delivery to Ferrotodo, a leading tube manufacturer located in Santa Cruz, Bolivia.

This is the third tube mill that OTO havesupplied to this customer in ten years of extremely fruitful collaboration. With this mill in place Ferrotodo will increase their share in the export market, and in particular, the automotive industry.

The tube mill has been installed with the aim of entering in the automotive industry, and will principally be used for the production of headrests, and the main frame for the seats for two top car manufacturers.

The machine is capable of manufacturing tubes in the range from 10mm up to 38mm, with  thicknesses up to 2mm, and the capability to process special high resistance steel, the mill is also able to produce stainless steel tubes.

Among the various features, the mill will be capable to produce tube having very robust tolerance in diameter in order to satisfy the extremely stringent requirements of the automotive industry. This is the fourth mill of this specific size that OTO has manufactured so far, and one more is on order for  delivery to South America next year.

Published inMachinery
Trilogy Takes Over Representation of Schwarze-Robitec in North America

Trilogy Machinery, Inc. becomes the exclusive North American distributor for Schwarze-Robitec tube bending machines.

Schwarze-Robitec is one of the world’s leading manufacturers of tube cold bending machines. The traditional company from Germany, which was founded in 1903, develops and produces tube and pipe bending systems for the automotive, shipbuilding and offshore industries, power plant construction and the chemical industry as well as special bending solutions for many other sectors of industry.

The bespoke quality products will now be sold throughout North America exclusively by prestigious partner agency Trilogy Machinery, Inc. “For our customers in the USA, Canada and Mexico, we have gained the ideal partner in Trilogy, which will now continue the successful work of Charles Russell Jr. and Tony Granelli,” Schwarze-Robitec Managing Director Bert Zorn reports. “Agency president Allan Flamholz has worked in the area of metal processing machines for over 33 year and has exact knowledge of the latest market requirements.

With his trained team, he offers the best possible advice for our entire range of products and solutions.” In addition to customer advice and customer care, the new appointment of Trilogy Machinery includes the complete sale including import of bending machines and tools.

Published inMachinery
Bending, Measuring and Further Bending in One Go

To accurately bend steel or stainless steel tubes and tube systems must accept long auxiliary processing times for the generally unavoidable measuring and adjusting process. This is because the rebound behaviour of the materials can differ widely – even if the tubes come from a single batch. The production of prototypes and individual items is similarly time and labour-intensive. The Springmatic optical measuring system provides a remedy here: the new development from Schwarze-Robitec, which is integrated into the bending tool, measures the bent tubes directly whilst tensioned on the bending machine and immediately starts the required further bending process if desired or saves the required correction value for subsequent bends.

Single stage

Instead of removing the tube after the bending process, checking it on an external measuring system then retensioning it for subsequent bending, tube processing companies can bend, measure and adjust in a single stage with the aid of Springmatic. Immediately after the bending of a tube, the new optical measuring system that Schwarze-Robitec is integrating into its bending tools records the rebound value, from which the CNC control of the tube bending machine calculates the required subsequent bending angle. Subsequent bending is carried out immediately afterwards – either fully automatically if desired or after clearance by the machine operator. “This integrated form of dimensional stability check and tube post-processing takes only a few seconds per work piece on average. This is contrasted with around three to five minutes required for measuring and adjusting in the conventional way,” Schwarze-Robitec Plant Manager Jürgen Korte reports.

Broad range applications

When developing the measuring system, the tube bending specialists from Cologne placed particular emphasis on a very broad range of applications: Springmatic reliably checks both thick and thin-walled tubes in the broadest range of materials and diameters. The system can be integrated into almost any bending tool and combined with almost all tube bending machines from Schwarze-Robitec. “The measuring accuracy from Springmatic is naturally equivalent to the accuracy of conventional external systems,” Schwarze-Robitec Managing Director Bert Zorn adds. “Furthermore, users not only save up to nine tenths of the auxiliary processing times previously required; in individual item and prototype production, they additionally benefit from a noticeable material saving as almost every component is now also a useable bulk component. These advantages have an effect particularly in tube production for the automotive, machine and plant engineering, and shipbuilding industries.”

Published inMachinery
Siemens Subsea Products adopts all-electric tube bending for production of subsea hydraulic flying leads

Siemens Subsea Products has chosen an all-electric tube bender from Unison to improve the quality and speed the production of the small-bore hydraulic tubes it uses on subsea hydraulic flying leads with Multiple Quick Connections (MQC), Cobra Heads and associated offshore oil and gas recovery equipment. The tubes feature complex bends of extremely high accuracy, and until now the company has either fabricated them manually or bought them in as pre-formed sub-assemblies.

Siemens Subsea Products produces a wide range of subsea electric, fibre optic and hydraulic power and control systems for offshore oil and gas subsea applications. Its hydraulic workshop at Kongsberg in Norway operates world-class fabrication and assembly processes, producing systems for direct sales and third-party suppliers. As part of its strategy to expand manufacturing capabilities in this specialist field, the company recently reviewed tube bending automation, starting by comparing the performance of a number of leading hydraulic and all-electric tube bending machines.

According to Terje Barth Andersen, Technical Advisor for Subsea Products in Siemens, "It was quickly apparent that electric tube benders offer a number of advantages over hydraulic machines; including more accurate and repeatable results, lower energy consumption and lower noise. In the all-electric sector, Unison's machines stand out from the competition because they allow much faster tool changeover - which is important for us because we produce many of our tubes in very small batch sizes. Another key factor behind our choice was Unison's willingness to develop a machine configuration specifically for our needs."

The tube bender supplied to Siemens Subsea is a 25 mm model based on Unison's popular Breeze platform of all-electric machines, and incorporates a 'rise and fall' pressure die which enables it to perform right- and left-handed bending; this increases manufacturing flexibility and throughput by allowing long and complex parts to be produced from a single length of tubing in one continuous cycle. Installed at Siemens' Kongsberg facility at the end of last year, the machine is currently undergoing commissioning and due to commence operation during January 2013.

The subsea equipment produced by Siemens Subsea is designed for long term deployment - many of the systems have a design life of 30 years and are intended for operation at depths up to and beyond 3,000 metres. As a consequence, the tubes used within the equipment that convey hydraulic fluid for power and control purposes are subject to extremely high internal and external pressures and need to be manufactured to exceptionally high standards. A key requirement is to minimise stressing of the tubes at their bend points - which could lead to in-service failure - by avoiding use of small bend radii. Whereas many conventional tube bending machines are incapable of handling large bend radii, the Unison machine supplied to Siemens features 'full stroke' programmable positioning of the pressure dies and clamps, enabling it to create bends with a CLR (centre-line radius) up to five times the diameter of the tube, with fully automatic set up.

All critical movement axes on the Unison tube bender are controlled by precision servomotors, enabling fast and repeatable fabrication of parts with accuracies to within fractions of a millimetre. The machine is also capable of generating the high torque needed for bending tubes fabricated from exotic alloys such as Inconel, Duplex and Super Duplex, which are used extensively for subsea applications to improve corrosion resistance.

Siemens Subsea's first project involving the Unison machine will be the South Belut Project production of 800 tubes, all made from 316 and requiring complex bends and orbital welding in both ends, for use on umbilical termination units known as MQCs. These are used on various subsea structures, including Christmas trees, and Siemens' versions can accommodate up to 13 hydraulic lines, demanding extremely tight manufacturing tolerances. Each tube is designed on a Inventor 3D CAD system, and the company generally then produces a prototype to verify its accuracy and feed any necessary corrections back into the production process to ensure the quality of subsequent parts. Automating the tube bending process is set to accelerate this procedure - the CAD system and bending machine are linked by a production computer network - and will help Siemens Subsea Products maintain the fully traceable manufacturing records needed for this industry.

Terje Barth Andersen points out that the accuracy and throughput capabilities of Unison's tube bender offer major economic benefits to companies working with expensive materials. "We calculate that the machine will pay for itself in less than two years, based solely on the number of tubes that we can now process in-house instead of purchasing as ready-made parts. Furthermore, the machine's automated set-up capabilities and control software flexibility will help us significantly reduce scrap material by 'right first time' manufacturing. We also envisage selling excess tube bending capacity to the market, making this an even more cost-effective investment."

Steve Haddrell of Unison adds, "This order from Siemens Subsea Products demonstrates a growing awareness of the benefits of all-electric tube bending. The traditional market for high-performance machines of this type is in the aerospace industry, where precision bending of exotic alloy materials is a common requirement. But companies serving the offshore oil and gas industries also face similar demands, as their products are used in ever more hostile environments."

Published inMachinery
Nanshan Aluminum is the only listed company focusing on aluminum products in China

According to relevant industry analysis, in China, production lines for aluminum plate processing has been developing toward wide plates, and as the most typical representative, the 2800mm single stand 6 rolling mill project of Nanshan Aluminum is being currently implemented as scheduled (Nanshan Aluminum is the only listed company focusing on aluminum products in China, and the Company has been topping other large aluminum enterprises in terms of corporate size and production output) and is expected to put into operation by the end of 2014. This project was undertaken by ABB China and SMS, which may mill aluminum products with a maximum width of 2650 mm, reaching a record in width of cold rolling mills for aluminum plates in China.

ABB has cooperated with Nanshan Aluminum for a long time. Early in 2003, ABB built two 2300mm wide single stand production lines for Nanshan Aluminum, which set a benchmark for the construction of the same type roller mills, and construction of the same type of roller mills had become all the rage across China and ABB had also undertaken more than 10 high-end aluminum rolling mill projects in China afterwards. In 2012, ABB built a three stands continuous cold rolling mill production lines for Nanshan Aluminum, which was the first in Asia and the second in the world. This time, Nanshan Aluminum builds this 2800 mm single stand rolling mill project, aiming at the global high-end market, and the fact that it cooperates with ABB again demonstrates its recognition of ABB’s comprehensive strengths.

ABB is responsible for the design, debugging of the electrical and automation systems for the project as well as the follow-up services. ABB mainly supplies equipment and systems, including distribution systems, MCC, primary and secondary automatic control systems, motors and transmission systems, special instruments, operating floors and cases, and fields sensors.

This project has many features in electrical systems and automation systems and we would like to introduce as below:

Feature 1: All final transmission systems for the rolling line utilize imported ABB motors

Rolling mill stands imported from ABB Finland are equipped with main motors with a power up to 6,500 kW and a voltage grade of 3,150 V, and are also equipped with ABB ACS6000 medium voltage drive transmission systems. Most motors equipped for other parts are also imported ABB products.

Feature 2: DTC core technology provides the transmission systems unbeatable excellent dynamic properties

Medium- and low-voltage motor driving systems utilize ABB’s traditional DTC technology. Compared with PWM and other control modes, DTC has a significant advantage in response time: at a frequency of less than 40 Hz, the typical torque response time may reach a super level of 1-2 ms, 10 times faster than that of traditional control modes. DTC technology may easily achieve high precision control on motor speed and torque without speed encoders.

The nature of DTC technology determines its high energy conservation. When the system works, the adaptive motor model-based high-speed digital microprocessors might capture actual flux and torque from motors at a speed of 40,000 computations per second and compare the captured values with settings, and the system may only make adjustments when there is any difference between the settings and readings. As a result, in terms of the principle of operation, DTC technology provides theoretical basis for energy saving.

Feature 3: This is the first time for EDT milling mode to be used in aluminum mills in China, which ensures features of ordinary rolling and roughen rolling

In order to better meet the market demands, Nanshan Aluminum demanded that this rolling mill shall provide roughen rolling features, and some final products require surface texturing by EDT rolling. . In consideration of this, ABB designed EDT rolling mode for this rolling mill, in other words, use the upper intermediate roll extended bending system instead of the hydraulic screw down cylinder for rolling, so as to achieve roughen rolling with low rolling force. In addition to special electric spark roughen rollers for working rolls and special roller types for intermediate rollers, for EDT rolling, it is even more important to achieve stable rolling with small rolling reductions (rolling force ≤200t, far below the normal rolling force level). However, when the rolling reduction is less than 10%, if we continue to use normal hydraulic pressure cylinders (which provide a maximum rolling force of 30MN), we cannot meet requirements on rolling stability and control precision for roughen finishing.

As a result, for ABB, the key point is how to integrate the existing general rolling strategies and roughen finishing, and based on the mathematical model rolling mill and secondary process control, the system may switch rolling modes safely and reliably optimize rolling process control.

Feature 4: Achieve highest standard in the industry for all indicators

Nanshan Aluminum has always been strict with precisions of systems and equipment. The reason why it has long been cooperating with ABB is that, ABB may provide a wide range of mature technologies and products across electrical and automation entire industry chains, covering motors, transmission systems, instruments and meters as well as control systems, so that Nanshan Aluminum may achieve the highest indicators in the industry and lead the development of the industry. For example, for this Project, thin aluminum plate may achieve 8I-Units, and the thickness control may achieve a precision of 2 um, static tension may achieve a control precision of 1.5%, and the speed control precision may achieve 0.01%.

Mr. Sun Yongming, Head of Paper, Metals & Cement in China said, “ABB will continue to serve global high-end metallurgy projects, and provide total solutions for upgrade and renovation of electrical and automation systems to both new and existing customers.

With advantages in excellent technology, product, service and project management in electrical and automatic systems and its great success in localization and a strong service capability, and based on win-win cooperation with international mechanical equipment suppliers, ABB has dominated most of high-end aluminum rolling mill projects market in China.

In face of the current downturn in Chinese metallurgy, Sun from ABB said honestly that, “ABB will strongly support steel, nonferrous metal enterprises to upgrade and renovate their plants, including both process upgrading or periodic equipment replacement, ABB will provide personalized and marketed-oriented total solutions in solution design, equipment selection and control strategy as well as other steps in consideration of corporate situation and latest technology development trend. ABB has also obtained good practical experiences in Panzhihua Steel, Ningbo Baoxin Steel and many other enterprises.”

 

Published inMachinery
Revolutionary, rotating in-line dimension measurement

Zumbach Electronics, the Swiss manufacturer of inline measuring and monitoring systems, has developed a rotation-based laser scanning process that maps round and polygonal shapes up to 6000 times per second - a first for the industry.

To make production processes as efficient as possible, modern in-line measurement devices are required, not only to measure parameters such as diameter, ovality, width and height at very high speed, but also to instantly detect shape deviations and rolling errors.

Some suppliers claim that in steel production, mechanical solutions are more than adequate for these purposes. But, not all manufacturers in the industry agree. Zumbach Electronics has been an innovation leader in the market since 1957, and its experience has shown it pays to continually develop new technologies, and solutions that deliver more precise measurements, thus contribututing to higher productivity. The company also believes in user-friendly operation and close-to-zero maintenance.

These very standards were applied to their latest product series, the Steelmaster SMR. Steelmaster units have been used in steel production for many years, as a tried-and-tested solution to improve the monitoring of hot rolling and cold processes. Until now, dimensional measurement and error detection have always been carried out by static or oscillating devices, depending on the application. These devices can measure with great accuracy the outer dimensions and diagonals of both round and non-round products such as squares, hexagons and flat products, regardless of twist and angle of twist.  Yet until recently, the level of precision achievable in manufacturing processes involving high rolling speeds and short lengths left much to be desired. The new Steelmaster SMR product generation, comes with sophisticated technology in the shape of an innovative and much faster rotational measurement system. With its superior performance, the system opens up a whole new range of applications. The system is based on up to three fully synchronised high-tech laser measuring heads of the ODAC® series, which uses an innovative rotational principle to measure outer dimensions, diagonals, diameters and cross-sections with 3600 coverage. Each laser measuring head rotates at a speed of 100 rpm and maps the scanned products up to 2000 times per second to create a precise product profile. In this way up to 600 profiles can be generated every minute. This allows manufacturers to significantly reduce scrap while maintaining stricter tolerances of ½ and ¼ DIN. There are no longer any restrictions as to the shapes the system can cope with. These models can handle any asymmetrical, polygonal and irregular shapes made of steel and metal to a diameter of approximately 135mm and temperatures of up to 12000 C.

Enhanced Profile
Measurement The innovative rotary movement isn’t the only technical refinement, because there is also the unique, non-contact transmission of power and signals within the measurement unit. The software is very flexible, allowing data statistics, numerical and graphical displays, logs and so on, to be freely configured in line with requirements and working practice in the production environment. Zumbach developed a novel method, EPM (Enhanced Profile Measurement, pat. pend.) for geometries with irregular or asymmetric shape aberrations (e.g. asymmetric overfill or underfill). In particular it is also able to capture and calculate polygonal shapes, which can occur in certain rolling processes or after subsequent peeling / grinding operations. For any shape it will measure at high accuracy not only min., max. and mean diameters but also the true out-of-round deviation RONt as defined by ISO / TS 12181-1 as well as the inscribed circle MICI and the circumscribed circle MCCI.

An optional module named FPS, especially for 3-roll blocks, calculates accurate values corresponding to the diameter values which would be found by manual 3-point micrometer screws (if both readings are related to room temperature). This FPS module additionally calculates the “Touch” and “Gap” diameters which are essential for the initial roll setting. The dynamic regression analysis included in the software package means that twist and angle of twist no longer influence the measurement result. This results in lower scrap rates and ensures compliance with strict tolerances. The technology also performs regardless of position, vibration, material temperature and light intensity.

The measuring units have the same tried-and-tested architecture as the proven static and oscillating systems. Zumbach delivers 100% quality inspection with virtually 0% outlay for repairs and maintenance. The fully contact-free transmission of power and signals also ensures maximum operating safety. An efficient air flushing and cooling system keeps the unit functioning reliably and can be supplemented if necessary by a water circuit.  All Steelmaster systems can be extended to include up to four measuring units with a single data acquisition and processing system. Any combination of static, oscillating and rotating SMR measurement units may be used. By opting for the measuring system, manufacturers can benefit from high-precision measurements and the resulting competitive advantages, such as faster start-up, less downtime and lower personnel requirements. This results in new quality standards and opens up new, multiple applications.

Published inMachinery