Boeing Receives Second All-Electric Tube Bending Machine for Helicopter Manufacturing

Unison recently supplied a second all-electric tube bending machine to Boeing Integrated Defense Systems (Philadelphia, PA). The order for this equipment came just two years after Unison delivered the first system.

This tube bending machine is a Breeze 20 system that makes precision bends on high performance alloy and aluminum tubes with diameters of up to 3/4 in (20 mm). The bending machine uses a 'long nose' to shape tubes with complex bends, and very short distances between bends, in a single fully-automated operation. It was built at Unison?s facility in Scarborough, UK, and shipped in mid-July.

The machine was installed at Boeing Integrated Defense Systems' rotorcraft manufacturing facility in Ridley Park, on the outskirts of Philadelphia, and is being used to fabricate hydraulic and fuel line components for CH/MH-47 Chinook helicopter and the V-22 Osprey tiltrotor aircraft. These Chinooks are medium-to-heavy-lift helicopters, designed for intra-theater troop and cargo movement. They are used in a wide variety of operational roles, from combat to disaster relief, and are in service with the armed forces of nearly 20 countries worldwide.

The latest model, the CH-47F, is designed to extend the service life of the Chinook class beyond 2030. Its airframe uses larger single-piece sections than previous models, to reduce vibration and the need for fasteners, and to help reduce maintenance costs. The first production model of the CH-47F was rolled out from Ridley Park on June 15, 2006. The U.S. Army has taken delivery of 77 of these helicopters since then. In August of last year they awarded Boeing a multi-year contract for 191 more, with options on another 24. The Netherlands, Italy and Canada have also placed orders for CH-47F Chinooks.

The Breeze 20 tube bending machine uses servo motors instead of hydraulic force to control the tube bending process. All-electric actuation provides significant advantages related to manufacturing precision, repeatability and energy consumption. Each of the tools employed during bending is under software control, allowing operators to create smooth bends with optimal flow performance and strength.

Once the machine is set up, operating parameters can also be stored, allowing machines to be reconfigured for another part or batch in a few minutes, without creating any scrap. Further, as the actuation elements of the machine only need energy when a bend is being made, total power consumption is greatly reduced.

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www.unisonltd.com

Unison's tube bending machines are available in North America exclusively from Horn Machine Tools, 40473 Brickyard Drive, Madera, CA 93638, 559-431-4131, Fax: 559-431-4431; http://www.hornmachinetools.com.