TPT May 2009

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Production & Processing of Automotive Tube
55 May 2009 ›
rolled radii, this being a
simple solution and one
that works well for simple
run of mill products.
The only other option
being hydroforming, but
it requires a far higher
investment as well as a
high cost of any design
change.
The new effective
Pedrazzoli system achieves new levels
of technology. It includes a sophisticated
twisting head assembly, that allows
effective use of three interpolated rolling
axes and combined bending on a different
plane. This is particularly useful in
those areas where complex shapes and
reduced radii are required. All axes are
in true interpolation mode, even mandrel
positioning, which is an important factor in
repeatable production.
The finite positioning of these axes has
proved to be very critical in repeatable
production. The rollforming software has
a built-in learning function that absorbs
results and self educates for continual
honing of success results (ie working
to remedy the nature of material during
bending).
Pedrazzoli Tube Technology (PTT) Ltd,
UK, a new division of Italy’s Pedrazzoli IBP
SpA, is the manufacturer of tube bending
machines with specialist models for
automotive and aircraft applications. The
range now features the new models EB20,
EB76 and EB120/150, which are based on
the highly acclaimed Ebwin control.
In the area of large dimension tube bending
and the automotive field, Pedrazzoli
offers the Bend Master 120EB and the
Bend Master 168 EB. These models are
specifically designed for the sectors where
modern rolled sections are increasingly
complex.
The new all-electric machines have
multiple (triple) stacks for compound draw
bending with one rollforming module (for
variable radii in 3D forms). This is coupled
with a powerful electric boost capable of
continuous collet boosting of over 380KN.
This feature has proved to be extremely
versatile in the production of frame sections
that are advanced in design. It allows
for accuracy and repeatability with far
tighter tolerance bends than the generally
accepted industry standard.
Existing rollforming machinery available
today utilizes the bend axis to form the
The Ebwin control system and software
is developed in-house by the company’s
R&D department and is equipped with
a user-friendly operator interface with
touchscreen.
It is also possible to supply the machines
with the IMS2 new generation control for
compatibility with existing Pedrazzoli IMS
machines in their workshops.
The establishment of Pedrazzoli Tube
Technology (PTT) Ltd took place following
Pedrazzoli IBP SpA acquiring the
intellectual rights of Eurobend Ltd.
Pedrazzoli IBP SpA – Italy
Fax: +39 0424 509049
Email:
Website:
Weil engineering, Germany, has introduced
a revolutionary clamping concept for thin-
walled tubes. The roll-forming and laser
welding machines enable tube production
without tool change, cycle time loss, and
any additional costs.
The new Flexistar production cell can
change the diameter automatically without
an increase in cycle time after each rolling
and welding process. There is program
control within the machine parameters,
and any diameter or tube length can be
rolled and welded down to a lot size of 1.
This totally eliminates all tool costs and
changeover times.
The automatic diameter adjustment for
rolling and welding is the core of the unit.
The tube is guided with the help of
outside positioned, flexible clamping rails
underneath a fixed welding source, which
continuously welds. With this unique
process, there is complete automation
of production from blank to the finished
welded tube.
The current machine concept is designed
for diameters of 2-16", with lengths between
10-90", and metal gauges of 0.008" to
0.100". Tubes can now be continuously
produced with a total cycle time of less than
20 seconds.
Typical applications
are tubes for exhaust
systems, catalytic
systems, double/triple-
walled tubes (such as
metal bellows), and
chimney tubes.
Weil engineering
is the leader in
manufacturing laser
welding systems.
The company has an
extensive network
of numerous sales
representatives around the world and a
subsidiary, Weil Engineering North America
LLC, USA.
Weil engineering GmbH – Germany
Fax: +49 7631 18 09 49
Email:
Website:
 The Flexistar production cell for thin-walled tubes
Short, thin-walled tube production without tool change
Complex bending for automotive applications
 Pedrazzoli’s Bend Master 168 EB is
ideal for automotive applications