All-Electric Tube Bending of Multiple Radii in a Single Setup

In Booth C-10874, BLM Group USA (Novi, MI) will demonstrate their Elect series of all-electric tube benders suited for tube diameters from 42 mm to 150 mm (1.5 in to 6.0 in). With multiple tool stack capability, it can produce fixed and variable radii in a single setup. The all electric operation of the Elect provides energy efficient production and eliminates the need for hose and piping associated with hydraulic systems. This helps to simplify maintenance and improve reliability for more consistent bending. These 9-axis systems are well-suited for tube production in a variety of industries including HVAC, furniture, automotive and aerospace. The Elect multiple tool stack capability can accommodate up to eight tools of variable radius at the same time. Both automatic or manual loading is available with the ability to position the automatic loader to the left or right of the machine. Additionally, a special loading cycle is available for heavy tube or multi-ball mandrels. Elect tube benders can incorporate automatic tube bundle loading and a handling robot for a complete turnkey system that manages the entire tube loading and unloading sequence.

A key differentiator for the Elect series is its proprietary VGP3D three-dimensional programming software that manages the entire system from a single point. Using part geometry data or 3D CAD data, VGP3D creates a part program, checks for part feasibility and calculates the real cycle time. By simulating the machine, tooling and the part bending sequence, it eliminates the risk of collisions, which typically occur during a first test run. Additionally, the machine automatically considers material composition and calculates the behavior of the part to minimize waste and guarantee part repeatability, process control, and accuracy even for complex parts. Part marring that can be caused by slippage at the end of a bend or wear tool is also reduced. All part bend positions, tooling information and power parameters are saved within the part program, providing easy recall of the recipe when a job is repeated. This guarantees quick setup and changeover and provides lot to lot repeatability.

Also on display will be demonstrations of their next generation LT7 Lasertube machine that is capable of 3D cutting and can improve productivity and accuracy through innovations in tube management and handling. This machine features a 3 kW fiber laser that provides a broad working range and allows for easily cutting round, square or rectangular sections up to 6 in diameter. Special sections and open profiles can also be processed. Loading chains can be extracted from the rear standard bundle loader within seconds, providing the flexibility to load a single bar or open section quickly and simply. The loading and unloading systems also adapt to accommodate short and long parts with innovative tube supports throughout the process. At the end of each production batch the LT7 automatically configures itself for the next batch for quick changes in production and higher productivity, regardless of the new sections to be made – round, square, special and even open profiles. No manual adjustments are necessary. This advantage results in higher output and a lower cost per part.

The LT7 further supports productivity and quality enhancements through its mechanical rigidity, which allows high levels of acceleration without compromising accuracy. Other patented technologies enhance its ease of use, including:

• Active Scan eliminates errors induced by distorted tubes.
• Active Tilt uses focus head movement to provide fastest processing of small features.
• Active Focus provides error free cuts regardless of changes of material and thickness.
• Active Marking offers dynamic part marking for complete production traceability.
• Active Speed ensures higher cutting quality on the most critical jobs.
• Active Piercing increases piercing speed and reliability even on inconsistent material quality and thickness.

Two exclusive software programs enhance the versatility of the LT7 Lasertube, helping to keep production under control and bring design ideas to life: Protube and Artube. The Protube monitoring system helps users to make accurate time and cost estimates based on processing time for an entire production batch. The system also prepares work orders and sends them to the machine, while a remote management feature provides real-time production progress monitoring, system operating statistics, estimates to the next batch change and more. Protube can be integrated with an ERP system to automatically distribute work orders to all connected BLM machines and technologies. Artube is a 3D CAD/CAM software that allows users to move from a design idea to a part in one click: simply enter tube dimensions to desired cuts to go straight to production. The software can also design a more complex frame through clear, three-dimensional graphics or users can import other CAD programs and send everything needed to start production to the machine immediately, without errors.

BLM Group USA, 46850 Cartier Drive, Novi, MI 48377, 248-560-0080, Fax: 248-560-0083, sales@blmgroupusa.com, www.blmgroup.com.