TPT September 2007

Technology Update

Laser measurement module to ensure tube bending precision

Unison developed the Breeze Angle-Sure measurement system to support a recent order from a defence equipment contractor. This manufacturer typically produces precision tubular parts in single or very small batches just-in-time, to support ship production. As parts are often fabricated from exotic alloy tubing that can cost as much as US$2,000 per foot, the impact of scrap is significant. Unison’s new measurement system self- calibrates before each measuring cycle, and provides a robust automated system that is virtually maintenance free. Users also have the option of storing the results of each bending process, to help optimise bending programs and to monitor the quality and consistency of supplied tubing materials. The low power category II lasers used will not cause eye damage unless stared at for an extended period. The beams are visible, and the system is further protected by automatic power-down when not in operation. Unison – UK Fax : +44 1723 582 379 Email : enquiries@unisonltd.com Website : www.unisonltd.com Horn Machine Tools (Unison agent) – USA Fax : +1 559 431 4431 Email : hmt@sierratel.com Website : www.hornmachinetools.com Since The Bronx Engineering Co Ltd of England was formed in the 1940s, the company has designed and manufactured over 1,000 machines. In 2001, USA-based Taylor-Wilson (founded in 1896) and the tube and bar finishing division of The Bronx Engineering Co merged to become Bronx/ Taylor-Wilson (BTW). All of the intellectual property and staff from this division became BTW and since then have designed and manufactured almost fifty straightening machines. Bronx/Taylor-Wilson owns and holds all the intellectual rights, drawings and technical data for all historical to modern day ‘Bronx’ tube straightening machines, and so can supply not only new machines of the latest design, but also spare parts or service for

Unison, UK, has developed a laser measurement module for its all-electric tube bending machines that dynamically measures the accuracy of bend angles and automatically compensates for any errors. It allows manufacturers to bend tubing to the required angles without scrap. This can overcome the common problem caused by variances in the ‘spring back’ characteristics of materials

› Unison’s laser measurement module measures the accuracy of bend angles and automatically compensates for errors

from different metal production batches with minor differences in grain and temper. The new module is targeted at manufacturers of precision and high-value tubular parts, such as those used in shipbuilding applications. The Breeze Angle-Sure non-contact optical measurement system measures bend angles by monitoring changes in the reflection distance of two laser beams. It takes a reference measurement from the straight edge of the tubing and then, after the bend is made, the system automatically commands the clamping die to move away. This allows the material to spring to its natural position, and takes a second Bronx/Taylor-Wilson, USA, has negotiated a deal to provide two upset pipe straighteners for leading pipe producer, Ipsco. The machines will process 7 5 / 8 " upset product and will be installed in early 2008 in Ipsco’s Pennsylvania and Texas facilities. These latest additions will bring Ipsco’s number of Bronx/Taylor-Wilson upset tube straightening machines to three. fi An early Bronx machine, and its modern counterpart

measurement from which the actual bend angle is calculated. Any difference to the programmed bend is displayed, along with a simple selection button that commands the machine to automatically re-grip the tube and apply an additional force to achieve the required angle. The system automatically calculates the required adjustment, taking into account the actual spring back characteristics of the tubing material from the first bend. It ensures that angles can be fabricated first time to accuracies of ±0.2°, and can be fitted onto Unison’s Breeze family of tube bending machines for tubing diameters of 3" (75mm) and above. A similar scenario is taking place with the TMK group, a producer of API pipe within the Russian market. TMK will also be installing three Bronx/Taylor-Wilson straighteners at Sinara, Tagmet and Volzhsky. Bronx straighteners have also been installed by pipe producer Baosteel. Two further OCTG pipe straightening machines are ready for final commissioning at KSP in Kazakhstan – one six roll machine and one in a ten roll design – which will be used to process 13 3 / 8 " API pipe.

Latest orders for Bronx straightening machines

Other recent contracts include upset drill pipe straighteners for Vallourec & Mannesmann and Grant Prideco, and a pipe straight- ener for Lone Star Steel (the company’s fourth Bronx straightener since 1991).

existing Bronx installations. Bronx/Taylor-Wilson – USA Fax : +1 330 244 1961 Email : sales@btwcorp.com Website : www.btwcorp.com

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S eptember /O ctober 2007