Tube Benders
TRA Tube Bending Systems
As one of the first to provide tube bending systems with reliable PLC controls systems, TRA continues to redefine the standard of quality for production tube bending systems. Using a modular system, we provide a customized tube bender with the quality of an off-the-shelf system. We provide fully automatic, machine loaded and unloaded production tube bending systems to the automotive and motorcycle manufacturing industries, as well as many others.
Full Production Tube Benders
Our full systems are designed for high-volume production of multiple tube designs and utilize an easy-to-learn, easy-to-use programming system for adjustments directly from the TRA-OI-15 HMI. Since our systems are built on top of our modular design concept, you may choose from single head-bending modules, dual head-bending modules, or both with any number of forming, piercing, or press modules. Tooling can be quickly changed using the same QuickChange technology originally developed for robotic weld cells. Parallel transfers move tubes through the machine as all modules work in sync. The entire system is controlled with an industrial strength PLC controls system.
Our full production benders are fully automatic, from loading raw tubes to ejecting finished parts. Raw tubes are singulated and passed through a TRA SeamFinder module specially designed and programmed to locate a seam on the thickest of tubes.
Robot Tube Bender
We leveraged our robotic expertise to develop a new modular tube bending system. Using the same modular design as our full production bender, we created a robust production tube bender with a smaller footprint by utilizing the latest in robotic and controls technology.
Our Robot Bender is the first robotically assisted tube bender that can be operated and adjusted without ever picking up a robot teach pendant. By eliminating the need to modify robot programs, we reduced the need for training.
Our unique design also allows for unprecedented freedom for configuration and options for modules. Run more varieties of tubes, increase utilization, eliminate changeover time, and get more from your capital investment.
Prototype Tubes
The specialized nature of tube benders and the parts required to build them can result in lead times that extend past your need for tubes. TRA has the capability and equipment to fully process your tubes in time to meet production deadlines.
TRA: One Source
Take advantage of our capabilities and let us build the machines for your complete process. With TRA building your tube bender, weld cells, and custom equipment you can eliminate the hassle and potential problems of coordinating multiple vendors.
Bender Modules and Components:
Seam Finder The raw tube moves from the Un-bundler to the seam finder, which locates the weld seam in the tube and orients it to the desired location using servomotors for tube rotation. If the seam is undetectable, the tube is ejected for cleaning. Once this is done, the tube is transferred and another tube is moved to the seam finder.
Single Bend Head This bender module consists of a 3-jaw chuck attached to a geared servomotor for chuck rotation, mounted to a traverse carriage and a single head bender. Both chuck and bend-dies traverse via proportional valve/hydraulic units in the Y axis. The 3-jaw chuck grips the end of the tube and moves it through programmed bends.
Dual Bend Head The dual head bender module consists of a removable center gripper/rotator unit and two bend head modules. Two proportional valve/hydraulic drives mounted to traverse carriages (Y axis) move each of the bend head modules located either side of the removable center rotator. The center rotator/gripper rotates the tube as required while the bend heads move to position in order to complete the programmed bends -- the bend heads will act simultaneously as much as possible. Optionally, the dual heads can include proportional valve/hydraulic driven X-axis offsets to accommodate offset style bends programmable from zero to 155 mm on each bend head.
Vertical Press This station performs forming and crushing operations on tubes. We utilize quick-change arrangements for the die sets, tooling, and idle stations as needed for this station.
Horizontal Press This module is often used for side action flattening, piercing and trimming operations. We utilize quick-change arrangements for the die sets, tooling, and idle stations as needed.
Pierce This station accomodates hole piercing and lancing operations with dedicated pierce pallets. We utilize quick-change arrangements for the die sets, tooling, and idle stations as needed for this station.
Overthrow Transfer Units These units transfer tubes between modules using 180-degree gripper units and optional pneumatic cylinders to extend and retract the gripper assemblies away and towards the center of rotation. This transfer unit is often utilized to transfer tubes to and from bending modules.
Parallel Transfer Units These units transfer bent tubes between the final bend module through any other modules such as vertical presses, horizontal presses and the discharge chute. They incorporate manually adjustable gripper assemblies to be set for the individual products.
Six Axis Handling Robot In our FlexBender system, the robot picks up the tube from the seamfinder and manipulates the tube to complete bends in bending modules. The robot can also tend multiple tubes at once in various other modules. Using a robot instead of a traditional transfer unit allows the addition of other modules, such as 4-post vertical presses.
Discharge Unit A chute and material handling system delivers completed tubes to a storage tote located outside the perimeter safety fence.
Safety Perimeter Fence, Interlock Accesses, Deadman The complete machine will be enclosed with wire-mesh style fencing with access and interlocks connected to the safety circuit. Any access door will disable the cell. Each machine will incorporate a deadman-style, operator-held panel to protect the operator when inside the perimeter fence. The operator is able to maneuver items when the perimeter fence is broken only when holding the deadman switch on this panel. This panel over-rides the operator control HMI when the perimeter fence is accessed.
Main PLC Control Unit Allen Bradley ControlLogix platform with AB servo-drives, Rexroth/Parker hydraulic drives and TRA-OI-15 Operator Interface Touchscreen (HMI). Communication to all of the modules is via this control unit by EtherNet or DeviceNet networks.
