All-electric CNC tube bending machine can deliver virtually instant, software-controlled multi-stack tooling changeover between batches up to 150mm diameter tube.

Unison has introduced an all-electric tube bending machine that combines the flexibility of multi-stack tooling with the power to bend tubing of up to 150mm outside diameter It brings the accuracy, repeatability and fast set-up benefits of all-electric machinery to the larger tube sizes used in applications such as shipbuilding, truck exhaust systems, and structural tubing for buildings

Called the Breeze 150, the machine can be used for high-precision applications and includes novel operating software.

Unison claimed that the software virtually eliminates the high costs normally associated with machine configuration for small-batch and 'just-in-time' parts production.

Unison also said that energy consumption of the electric tubebender is a small fraction of an equivalent hydraulically-powered bender.


* Advanced programming - Breeze 150 offers advanced programmable control over the rotary draw bending process, with a maximum bending torque of 92,000Nm.

Bends of up to 180 deg can be made, with a high degree of repeatability of +/-0.1 deg of bend angle and plane of bend.

The machine includes a number of features to further support precision bending including the following.

* A swing-away wiper die system to simplify tight radius bending applications.

* Split tooling to aid bending of square section tube.

The versatility of the machine is also greatly aided by a stack height of 630mm for tooling, allowing users to store multiple toolsets on the machine for rapid changeover between batches.

* Control software includes automatic set-up - A key element of the new machine is the Unibend Control Software, which includes advanced features such as automatic set-up.

This will automatically sense and clamp a tube, ready for bending.

Unison told manufacturingtalk that it greatly reduces the time required for initial set-up.

Unlike traditional hydraulically powered benders, users also have complete control over the bend operation, and can modify the bend speed, clamping pressure, pressure die position and force, and mandrel positioning parameters applied to achieve the ideal bend.

Following set-up, all the operating parameters are stored, allowing the machine to be configured for further batches of parts in a few minutes, and without creating any scrap.

Alan Pickering of Unison said: "All-electric actuation combined with multi-stack tooling can revitalise tube bending operations, speeding changeover between batches, boosting the flexibility of a company's process, and reducing scrap".

He added: "This can often deliver payback on the machines within a few months, especially in today's environment with spiralling material prices.

This latest machine in our draw bending range extends the benefits of all-electric machines to a range of new larger size applications".

The control software runs on a standard Windows PC, providing further flexibility for users.

This includes powerful diagnostic aids, which allow the engineering team at Unison to help manufacturers immediately with any bending problem, or machine performance issue.

The machine includes a webcam, which Unison can remotely access.

In combination with a software 'black box' which automatically stores the last 500 instructions entered by the operator and details of machinery positions from the servo motor sensors, Unison can help users to optimize their processes, as well as provide remote maintenance.

* programming - tube bending operations may be programmed in three ways.

1 - Programs may be automatically generated by transferring data from CAD software, and Unison has interfaces for all popular packages, and will develop interfaces for any others required - including a manufacturer's proprietary design software.

2 - A simple programming template is also available, allowing users to create a program by entering the distance between bends, the angle of bend required, and rotation of the tube.

3 - A further option is copying or reverse engineering, by using a tube measuring system to recreate the coordinates from a sample or prototype.

* Servo motors - in place of hydraulic force, the Breeze 150 employs servo motors to control the bend process, including clamp, pressure die, mandrel and follower.

This all-electric actuation provides significant benefits related to energy consumption, repeatability, and noise reduction.

As the actuation elements of the machine only draw significant current when a bend is being made, energy usage is greatly reduced.

The machine's idle power consumption level of around 1kW/h accounts for the vast majority of usage.

Noise is also measurably reduced, with Breeze 150 operating at around 55-60dB, a level equivalent to normal speech, said Unison.

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