TPT September 2013

Article

Schwarze-Robitec GmbH

The automatic, CNC-controlled machines are also suited to complex tube systems with several bends or large batch sizes. “Compared with the induction bending processes, our cold bending process offers huge time savings in the production process,” Schwarze-Robitec plant manager Jürgen Korte explains. “Whereas hot shaping of these work pieces takes around eight hours, our customers require an average of only six minutes for one bend.” Depending on the specific application, Schwarze-Robitec offers the machines from its heavy duty machine series for various diameters and wall thicknesses up to 610 x 21.4mm. The machines are available in semi-automatic design with SR control and in automatic design with CNC control. All machines can be equipped with a tube magazine and tube feed and enlarged up to fully automatic bending cells. Very different but similarly exacting requirements now also exist for boiler tubes and tube serpentines in power plant construction. The production of smaller boilers with greater capacity, for example, requires the use of extremely tightly bent tubes. Depending on the tube diameter, it is not uncommon for the required minimum bending radius to be 1xD (sometimes under 1xD). The semi-automatic booster bending machines and automatic CNC pressure bending machines from Schwarze-Robitec are designed precisely for these requirements. The unique cold-bending process from Schwarze-Robitec offers utmost precision and surpasses the tolerance requirements for wall thinning and out-of-roundness of European standard EN 12952, American Society of Mechanical Engineers ASME B31.1 and all other international standards. The CNC-controlled booster bending machines are also equipped with a tube positioning device, which facilitates fully automatic bending of tube systems. For efficient processing of very large and complex tube serpentines, Schwarze-Robitec offer the CNC Twin series machines: this machine series, which is available in three different sizes up to diameter 88.9 x 11mm, uses two vertically and horizontally movable bending heads (1x left-bending, 1x right-bending), which alternately bend the tube clockwise and anticlockwise. The FL 3600 tube bending machine from Schwarze-Robitec guarantees the quick and economical production of huge membrane tube walls Economical production of boiler tubes

The CNC 100 DB Twin booster bending machine from Schwarze- Robitec reliably bends even high-strength materials with a bending radius under 1xD

Consequently, the tube serpentine does not need turning after each bend, which ensures quick and economical production processes and the manufacture of large leg lengths. “Of course, our machines also guarantee the processing of high- strength materials, for example, such as high temperature steel alloy T91,” managing director Bert Zorn adds. Moreover, they are able to produce different bending radii within one tube system. Furthermore, adding a Terminal End Bender to the machine is easily possible. Precise processing of complex tube walls Schwarze-Robitec also offers a specialised bending technology for the bending of entire membrane tube walls, which is common in the construction of modern boilers and power plants: the FL machine series processes tube walls with a maximum width of 3,600mm and a length of 25,000mm or more, quickly and accurately by means of the compression bending process. The machines are equipped with a modern CNC control, which also takes into account the springback when bending the membrane tube wall. Only recently, the bending specialist delivered one of the world’s largest membrane tube wall bending machines to an Indian customer. With this machine, customers are able to bend tube walls precisely in particularly large dimensions. The users secure considerably reduced costs and production times as well as lower installation costs. Equally, this machine offers the option of diagonal bending. “Overall, we have been developing and producing tube cold bending machines designed especially for the specific requirements of power plant construction for over 45 years,” Schwarze-Robitec managing director Bert Zorn summarises. “Every machine is a customised solution, which we adapt precisely to the individual production needs of the customer.”

Schwarze-Robitec GmbH – Germany Email: sales@schwarze-robitec.com Website: www.schwarze-robitec.com

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September 2013