TPT September 2008

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Carell Corporation is the manufacturer
of a range of products including 3 and 4
roll plate rolls, angle benders, ornamental
benders, rebar benders, CNC tube and
pipe benders, mandrel benders, and
ornamental iron workers. This machinery
is highly reliable and ensures minimum
downtime.
The company provides a wide range of
models, options and tooling. Carell operates
an in-house machining shop to satisfy the
growing demand for custom tooling at all
levels of complexity.
The company’s fully stocked parts
department contains a wide selection of
tooling, and repair parts ready for rapid
delivery.
Certified factory trained technicians are
available at Carell Corporation to assist
during and after the warranty period.
Website:
to complete this labour-intensive task. The
bundles usually consist of between two and
five bent tubes, and several clips that hold
the bundles together.
Typically, an operator will load straight
tubes into dedicated or CNC tube benders.
The bent tubes produced by the benders
are batch processed and then moved
to the assembly area. To complete the
necessary volumes, two to three assembly
tables may be required. At this stage,
the operators at each assembly table
will manually load each clip into the clip
pockets, then load each tube in the correct
order.
CMP’s new automated systems have been
developed to revolutionise this process. The
turnkey cells, completely designed and built
by CMP, incorporate a robotic approach to
eliminate labour cost and to reduce work in
process inventory (WIP).
The new systems typically incorporate
between two and five CMP dedicated tube
benders, various numbers of robots, end
of arm tooling, clip feeding bowls, one
automated assembly table and perimeter
guarding.
The automated assembly approach is a
single piece flow process. One operator
loads the dedicated benders and clip
feeding bowls, and the benders each
produce one part at a time, and wait for the
robot to remove the bent tube. At the same
time, another robot or robots load clips into
the assembly table.
After the tube loading robot loads the
tubes into the assembly table, the bundle
is automatically clipped together and
discharged to the packing area.
The company claims that its new
systems can reduce labour cost by
between 50 and 75 per cent. CMP will
adapt the automation to the specific
requirements of each user, employing
a high standard of design and
manufacturing services.
Website:
CML USA is a manufacturer of tube and
pipe bending machines, with over 40 years
of experience. The company supplies the
Ercolina 050KD Top bender model, which
is suitable for bending pipe, tube, squares,
rectangles, solids and other profiles. The
machine is capable of bending ferrous and
non-ferrous materials from ¼″ to 2½″, and
accepts Ercolina’s optional two-axis A40/P
positioning table for multiple and sequential
bends.
The company’s heavy-duty gear case
accommodates radii up to 11⅞″ centreline
radius. Standard tooling is available from
stock in multiple radii with centreline radius
as small as two times diameter. Operator-
friendly control programs bend angles to
180° with individual springback setting, and
a linear scale provides a visual reference
of counterbend axis and increased
repeatability.
A standard motor brake ensures bend
angle accuracy, and the patented swing
Alpha Metall GmbH & Co. KG
Matthias-Erzberger-Str. 13
D-66806 Ensdorf · Germany
Phone +49 (0)6831 5069 51
Fax +49 (0)6831 5069 58
ISO 9001 CERTIFIED
Experience since 1982
Turnkey Technology
Inside Tube Deburring Systems
Range: I.D. 14,0 up to 610,0 mm
MADE IN GERMANY
 CMP’s robotic tube bundle assembly system
Carell Corporation
USA 5263
CML USA Ercolina
USA 4179
