transfluid – the solution for tubes As a globally demanded partner for the production of tube bending and tube processing machines, transfluid Maschinenbau GmbH emphasize on guaranteeing the customer the optimum in added value. With the process of CNC-controlled rotary tube forming the company is the world's market leader. Since 1988 transfluid has been further developing its technologies for tube machining, so that it can provide customer-oriented, tailor-made solutions – for plant and machine construction, the automotive and energy industries, shipbuilding and medical device manufacturing. Products: t bend – tube bending machines t form– tube forming machines offer the perfect tube shaping solutions t motion – automation systems as fully developed concepts for bending and forming technology t cut – tube cutting machines tu go – standardised portfolio of machinery for immediate delivery t project –powerful software for rapid and reliable tube processing
Trademarks and products by transfluid
t bend stands for a wide range of tube bending machines, which fulfil the highest demands in terms of industrial applications.
The tube forming machines in the t form range offer the perfect tube shaping solutions. Tube forming is important as an individual or supplementary process, in order to obtain optimally tailored tubes.
Automation systems are offered as fully developed concepts for bending and forming technology, under t motion.
t cut covers the field of tube cutting machines. Here, transfluid is able to provide a range of different systems, for example for chipless orbital cutting.
Additionally, with the new tu go range, transfluid offers a standardised portfolio of machinery, which is available from stock.
For rapid and reliable tube processing transfluid offers the powerful software t project. It can be used as an effective online connenction for bending machines, production, measurement systems and the majority of CAD systems.
This transfluid solution with turning head permits collision free right-left bending. With this dynamic solution tubes can be processed efficiently.
t motion – automation systems as fully developed concepts for bending and forming technologies
The client is king. This is also the belief of engineering company transfluid, based in Schmallenberg. Customers often request tube processing machines with specifications that are particularly challenging. And every time, the experienced engineers at transfluid will work hard to find the best possible solution.
A very good example is a real project transfluid has worked on, requiring the production of a stainless steel manifold with a very complex shape, which needed complicated bending, forming and calibration of the ends. This was the specific challenge: to only manufacture the tubes needed for one manifold, so that the client can take four or six pieces to get always one manifold in the welding process, even for the large-scale production. The result: when on single tube fails in the automated welding unit it can be further processed, the cell gets a signal and produce one single tube extra. That´s one-piece flow.
Ready for all requirements
The individual requirements of the customer also included the production of a sequence of at least four tubes that were not same, without pre-cutting the tubes. The automated cell included a loading magazine for long tubes, a device for the orientation of the weld seam, a bending machine with five bending levels and capable of cutting the finished component, when the bending process is complete. In addition to this, the components were calibrated both internally and externally at the same time with a finger expansion. The final complex bending shape was put in an axial combination machine at the end to finalise the endforming of the opposite end. This machine can perform the final exact cut in an orbital and chipless way. This makes it possible to reshape the tube axially with one clamping process.
Clean cuts for precise solutions
The loading magazine can take a whole bundle of tube in one go. The tubes are then separated by using eddy current seam detection to recognize the welding seam. The welding seam is positioned and the tube is fed to the bending machine with a linear handling system. As these components are very compact, it is possible to produce up to 20 units from one tube. There are up to four bending levels plus one cutting level available to bend the individual components.
After the bending part of the process, the tube is cut in a controlled manner with long-lasting carbide blades. Result: A clean cut and a component with a perfectly round tube end.
A robot takes the tube and uses an expander to calibrate the tube. This is necessary, because the cut on the tube is finally very close to the bend. With this last step the processing of side on the component is complete and it is placed in the deburring device to obtain a smooth cut. After the deburring a robot takes the component to a combination forming machine for further processing on the opposite tube end. A Robot move the tube in compound clamps to the combination machine for forming, calibration, trimming in a chipless orbital method and an axial forming an asymmetric geometrie in three steps, with very tight tolerances and complex results.
The asymmetrical and very challenging forming is not a problem for the expert engineers at transfluid. Because the forming of the tube ends depends on the tube processing, the forming is done with so-called “additional clamping technique”, to reduce the amount of tools.
The established rolling technique gives professional results
At this point a robot will place the four different components in separate containers. A separate unit will manufacture an EGR tube in parallel with complex 28x1 bend geometries. A flange with a 45 mm diameter has to be formed on this tube. During this process the longitudinal seam should not be damaged and the flare should not split. To complete this delicate step transfluid puts into operation their established rolling technique. With this technique it is possible to form tubes that have already been bent and have a very short clamping section.
transfluid Maschinenbau GmbH
transfluid is a valued partner all over the world for the production of tube bending and tube processing machines. transfluid have been developing their customer-focused technologies for tube processing since 1988 and offers tailor-made solutions for the construction of plants and machines, for the automotive, energy and shipbuilding sectors and the manufacturing of medical equipment.
Robots have already been used for some time as efficient and flexible bending machines to process tubes. These systems are constantly developed further and improved. For the experienced engineers at transfluid this means first of all to make the software user-friendly, so it is possible to work in an efficient and professional way. These bending systems from the high-tech engineering company can take isometrics data and generate bending data without separate programming of the robot system.
The next stage has been designed and improved
transfluid has now designed the next step in the development of its range of tube bending robots and improved it again. The online connection to CAD systems has always been possible, which reduces the set-up time a lot. Another important aspect is to simplify the software connection because of the robot programming capabilities of each customer.
The latest generation of machines can process isometrics data online. There are also positions stored in the control system, for where the piece is picked up and dropped off. In addition to this, it is also possible to retrieve the position for the necessary supports for long tubes. Because of this, a complete new complex bending geometry can be programmed and bent quickly, in max. 30 minutes. This including the set-up of the bending tools.
Synchronized and coded for clear identification
The transfluid bending cells with two robots bend long tubes at both ends. This way tubes can be supplied with forming, hoses or connection systems. The preparation and cleaning of the tubes becomes a lot easier. It is much better to process straight tubes, when the bending machine can bend at both ends. These benefits can be enjoyed both when bending with one or two robots.
With a set-up with two robots it is possible to process tubes of up to 6,000 mm without any problems. The two robots work in a synchronized way. Additional equipment like clamping or support devices also synchronize with the processing robot. The robots recognize the component with a code, generate the bending sequence and they can also choose between different radii and diameters. It is possible to work with a total of six different tube diameters or radii without having to change the dies.
Advanced processing, greater output
With the new developments and improvements from transfluid, a production cell with two robots can do more than bend a tube at both ends: each of the bending robots can also process different geometries. Both machines are working all the time and the system can be used efficiently and with a significantly higher output.
Bending and handling without costly programming
The latest generation of transfluid bending robots also offers safe handling: the grabbing coordinates on the tube for the pick-up from the magazine and for the dropping off can be retrieved from the pre-programmed parameters. This means that the user has to do almost no programming of the bending sequence or the handling steps. The machine simply refers to pre-loaded data.
Even tubes with long lengths, which are nearly impossible on conventional bending machines, can be processed without any problems, as the long sections will not cause any collision problems. This is possible, because the last bending is done on the “floating” tube, just before the drop off. The whole system is operated by a bending machine control unit. The benefit is that it is possible to work both with x, y and z coordinates, but also with lengths and bending angles, just like a standard bending machine.
Short learning curve and fast set-up
It is not necessary to have special knowledge of robot programming. In order to keep the set-up times as short as possible, the robots have pre-programmed tool settings, including axes for the set up position. This keeps the set-up time short for the operator. With the latest generation of bending robots transfluid has once again expanded the possibilities of tube processing and made it more efficient.