You might think that manufacturing spirals can only be done by craftsmen with many years of experience and great attention to detail. But this is not necessarily the case.
With the help of suitable tools, spiral production can be carried out continuously and accurately. This has been proven by metal manufacturers serving industries, including power plants, petrochemical production facilities, food manufacturers, and manufacturers of industrial heating and cooling products.
However, it is not only the large manufacturers that use this technology, but also the craftsmen who make stairs and handrails. In all these cases, manufacturers need to meet strict specifications so that the final product is not only acceptable in appearance, but also provides the original design intent.
Just consider the complexity involved in manufacturing a single heat exchanger with two spirals, either a smaller spiral is surrounded by a larger spiral, or two spirals with the same diameter and pitch are inserted Another inside. The final spiral machining must meet the predetermined tolerance, otherwise the final product will not achieve the expected performance.
Since it is impossible to perform multiple rolling during the spiral rolling process, customers need to balance power and precision in the equipment they use. Therefore, the machine must have powerful functions to reach the required capacity at one time, and must accurately reach the required tolerances, said Federico Bonfogo, senior technical sales manager of the Faccin Group, the owner of the ROUNDO brand.
The ROUNDO profile bending machine is designed to assist in the production of such high-tolerance spirals. Bonfogo once again referred to the heat exchanger to describe what the company’s technology can do in this extremely challenging bending application.
In the heat exchanger, in the same spiral, you may find tubes of different materials welded to each other. Each tube is designated for its task, because each tube can withstand different steam pressures. However, each material reacts differently to stress during bending. This means that the profile bending machine used for spiral production must be sensitive enough to cope with the rebound characteristics of each material.
Bonfogo said that in this case, advanced hydraulic technology can help operators deal with the natural characteristics of metal. The operator of the section bending machine can fine-tune the bending to obtain a uniform shape when processing the spiral.
The standard function of the hydraulic system of ROUNDO profile bending machine helps to achieve this production accuracy. The operator can manipulate the joystick to control proportional movement for roll rotation and adjustment. They can also adjust the variable translation speed of the profile to further fine-tune the spiral diameter after the profile passes through the bending rolls.
For customers who need higher accuracy, Bonfogo said that the machine can be equipped with a micro-hydraulic adjustment device for the lower roll. In this way, additional fine-tuning can be achieved through separate commands on the control panel, which are connected in parallel with the adjustment device of the main roller.
Since customers will require many different types of profiles, and each profile has its own mechanical properties and characteristics, spiral rolling becomes very complicated. Even the same type of profile may have multiple sizes, which will affect the rolling diameter and pitch of the spiral.
Bonfogo said that the large guide rollers on the ROUNDO profile bending machine act like a calibration device to ensure delivery of the required size. In addition, each unit includes different small rollers for calibrating different types of cross-sections. These calibration rollers can be placed in multiple positions on the calibration unit frame, so that a series of calibrated bending diameters can be achieved.
Bonfogo said that the standard profile bending machine can roll left and right spirals without having to disassemble and reassemble the calibration unit according to the feeding side of the profile. This can help operators increase productivity and create spiral structures without having to spend time preparing for different settings.
Bonfogo said that this segmented pipe bender can not only handle standard operations, but can also easily adapt to spiral rolling, which can meet the needs of companies engaged in various internal manufacturing operations. For any fab, even if it does not have the ability of an in-house spiral forming manufacturing expert, it can transfer from one spiral manufacturing to another without spending extra time to change the configuration of the section bending machine.
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