Fully automatic solution from transfluid for efficient exhaust manifold production
Streamline operations are particularly required in such cases, in which a product cannot be installed until several components are available. This was the reason why in a recent project, transfluid developed a system solution for the efficient production of a complete exhaust manifold made of 4 or 6 different stainless steel tubes.
For this purpose, a 6-meter long tube is first loaded onto the tube-bending machine. Each individual tube is fitted with up to 4 bends. After the bending process, the tube is cut, chip-free, on the bending machine directly using a blade cutting process and is then inserted by robot into the corresponding forming machine. It forms an asymmetric geometry, which fits each individual bend progression. After processing, the components are then fed directly into a welding cell. It welds the tubes to flanges. This way, one complete module is always available as a unit.
Chaotic production for improved operations
As in this case, complete tube sets are in part used during tube processing. It gets more complicated and demanding when dealing with a wider range of tube sizes and geometries. The experts at transfluid have developed special automation systems, that allow a chaotic production to be implemented as an especially efficient solution.
„This kind of production comes very close to a „one piece flow“, thus significantly reducing the time period from tube production to installation.“ explains Stefanie Flaeper, CEO at transfluid. „It is in any event the most effective solution. And it is also the solution that can significantly streamline operations despite an increase in complexity. We have already implemented this successfully for several customers.“
More flexible to better results
Often, a higher degree of complexity is needed for hydraulic systems during production. „Here, our customers frequently want to produce a complete piping kit, which consists of up to 8 nominal widths as a unit, for example“, explains Stefanie Flaeper. In these cases, the machine setup is somewhat more complex. However, it offers several distinct benefits as compared to conventional tube production, during which in part a significant number of tubes have to be produced one after another, which are then combined to a single tube set. Here, machine set-up is not required, production is time optimized and there is almost no need for warehousing and commissioning areas.
For production of this kind, transfluid integrates chipless cutting systems, forming machines or cutting ring pre-assembly systems and bending machines into the thus optimized process. These systems can be linked with one another, thus allowing monitoring from the outside, creating processes as early as during machine set-up and can thus be utilized in Industry 4.0-capable processes. This way, the transfluid automation systems allow an exceptionally efficient chaotic production, after which a completely produced component is available after each work cycle.
These and other solutions for tubes will also be the topic of discussion during the in-depth debates to be held on the occasion of the FABTECH trade show at the transfluid booth Bl1069.
transfluid Maschinenbau GmbH – the solution for tubes
transfluid is sought after worldwide as a partner for manufacturing tube bending machines and tube processing machines. 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.
transfluid’s product portfolio offers perfect solutions in five different machine categories, that meet all the requirements in tube processing. 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 and special knive separation processes. The category t clean encompasses tube cleaning machines. These ensure the cleanliness of workpieces and tubes. Additionally, with the new tu go range, transfluid offers a standardised portfolio of machinery, which is available from stock for immediate delivery. transfluid offers the powerful software t project for rapid and reliable tube processing. It can be used as an effective online solution for bending machines and the majority of CAD systems.
Company-Contact
transfluid Maschinenbau GmbH
Stefanie Flaeper
Hünegräben 20-22
57392 Schmallenberg
Phone: +49 2972 97 15 – 0
Fax: +49 2972 97 15 – 11
E-Mail: s.koehler@psv-marketing.de
Url: https://www.transfluid.net/en/homepage.html
Press
PSV
Stefan Köhler
Schlachthausstraße 10
57072 Siegen
Phone: +49 (0) 271 7700160
E-Mail: s.koehler@psv-marketing.de
Url: http://www.psv-marketing.de
