TPT November 2016

56 / 84

54 NOVEMBER 2016
T E CHNOLOG Y
Cycle time and environmental benefits
of new tube processing system
AS part of its ongoing programme of replacing machines
deemed to have reached a natural end of life, Worcester,
Bosch Group, has introduced its first BLM 4-Runner tube
processing system. The new machine is designed to deliver
cycle time savings of between 25 and 30 per cent compared
to the machine it replaced, as well as delivering environmental
benefits to the company.
As a manufacturer of domestic heating and hot water
appliances, one of Worcester’s key targets is energy efficiency,
as demanded by its customers. The company has a corporate
policy of ensuring that any machine tool purchases reflect
this energy/environmental remit. Previously, tube processing
at Worcester had been carried out by hydraulic-powered
machinery. The switch to the BLM 4-Runner, with its all-
electric, servo-controlled operation, provided a step forward in
environmental terms, with the added advantages of improved
quality and consistency and reduced cycle times.
“It is part of our long-term vision to replace all of our old
hydraulic BLM Planet machines with modern all-electric,
servo-driven tube processing systems,” said Chris Packer,
group leader – manufacturing. “The 4-Runner’s servo control is
important for a number of reasons, such as improved accuracy
of bends, consistency and cycle times, but of equal, if not
greater, importance was the fact that they are far more energy
efficient compared to hydraulic machines, and this was key to
our purchasing decision.”
The BLM 4-Runner is a modular-based machine that can be
configured to include de-coiling, straightening, end-forming,
bending, cutting off and unloading. The machine at Worcester
is fully configured in this way, delivering finished components
from coiled copper tube up to 22mm in diameter.
The bending capability of the 4-Runner allows left- and right-
hand bends to be formed, as well as fixed and variable radii
bends in single and 3D planes. The machine is also capable of
completing compression and draw bending techniques.
For end-forming, the BLM 4-Runner features a multi-station
end-forming unit with either four or six ram-type forming
stations or four ram stations and one rotary station. A variety
of cutting devices can also be specified; depending on the
material being processed, these include internal or external
orbital swarfless cutters, or conventional saw blades.
A key benefit of the BLM 4-Runner’s all-electric system is
its consistency of bend. With servo-driven positioning every
bend is the same. “The variations that we find on our hydraulic
benders have been totally eliminated since the switch to the
4-Runner,” said Rob Crane, production engineer.
Commenting on the environmental gains of switching from
hydraulic to all-electric, production leader Adam Timms said,
“The total lack of hydraulic oil makes it much easier to maintain
the quality of the working environment. The cleaner working
environment also makes it much easier to maintain our Five S,
total productive maintenance (TPM) and planned maintenance
initiatives (PMI).”
In addition to the 4-Runner, Worcester has taken delivery
of a fully electric BLM Tube-Form ELE end-forming machine.
With a ram capable of applying eight tonnes of pressure, the
machine allows the company to produce more complex forms,
with up to six punches available, and also on larger diameter
tube than could previously be achieved.
BLM Group UK Ltd – UK
Fax: +44 1525 402 312
Email:
Website:
Tube bending on the BLM 4-Runner