INDUSTRY NEWS
MARCH 2018 Volume 5 Number 50
The industry magazine for tube and pipe producers and processors
It’s that time again!
page 33
Industry news p.2
Products p.12
transfluid p.27
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Welding p.30
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IN THIS ISSUE INDUSTRY NEWS
COMMENT
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nternational Metal Tube March 2018, yet again I am bringing you the latest news just before the opening of yet another Tube Dusseldorf on the 16th April. This will be at least my fourteenth Tube Dusseldorf and how things have changed, however what is pleasing is that there are still some very familiar faces still around from those very early days and I look forward to seeing them yet again.
If you are attending Tube Dusseldorf then make sure you read through this issue and make sure you visit those advertising as they have much more to show you in person, if you wish to make an appointment with me to discuss how to take an active role within the pages of IMT magazine, one of the four E-newsletters this year or our website www. internationalmetaltube.com then please contact via Email: imtmagazine@virginmedia.com as soon as possible. With Tube Dusseldorf opening its doors on the 16th April, IMT will do a roundup of what we have seen that was new and incorporate this into our end of April E-newsletter. If you have yet to sign up for the newsletter then please go to https:// confirmsubscription.com/h/j/96BDACC14092F764 as soon as possible. Wish all of you who are either exhibiting or visiting Tube Dusseldorf a great show.
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Vince Maynard Front cover photo by Messe Dusseldorf
IMT Contact Information PUBLISHER & EDITORIAL DIRECTOR Vince Maynard +44 (0) 1732 505724 Mobile +44 (0) 7747 002286 Fax +44 (0) 1732 860052 imtmagazine@virginmedia.com TRANSPORT & LOGISTICS EDITOR David Young imtmagazine@virginmedia.com CIRCULATION June Bray Fax 01268 711567
ISSN 2047-9662
REPRO PRINT & DIGITAL BY ASTAC Business Media 01622 850063 07557 280769 anton_print_1@mac.com PRINTED BY Brown Knight and Truscott Tunbridge Wells, Kent, TN2 3BW United Kingdom Tel: +44 (0)1892 511678 PUBLISHED BY Hartswood Media, Hallmark House 25 Downham Road Ramsden Heath, Essex, CM11 1PU, UK T- + 44 (0) 1268 711560 F- + 44 (0) 1268 711567
PRODUCTS & EQUIPMENT
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transfluid
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EXHIBITIONS IMT March 2018
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INDUSTRY NEWS
Gratnells Engineering invests further in state of the art laser technology
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ratnells Engineering has recently invested in a new state-ofthe-art BLM LT Fiber machine, allowing the Harlowbased company to expand their capabilities in 2018 and ensure clients benefit from even faster turnaround times. This brand-new machine sits next to the existing LT5, a Laser tube cutting machine designed to cut from small to medium diameters and thicknesses of metal tubular sections. The LT Fiber allows tubes of any shape to be cut, process of special sections and even open shapes without any additional special equipment required. The laser cutting range boasts an automated unloading and support system for pre-cut lengths up to 6100mm, automatic weld seam detection, and a module that maintains the cleanliness of the internal tube surface whilst machining. Anti-crush technology makes the machine capable of processing even the lightest of tubes without deforming the walls. This high-tech equipment is also great for scrap reduction by setting the sequence
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of parts to be cut and minimising end of bar scrap; meaning less overall waste, which is good for the company and for the environment too. The additional BLM LT Fiber machine is already helping to increase factory efficiency by allowing unloading to various positions, with finished parts from one machine being unloaded whilst production continues
uninterrupted on the other. The need to manually separate parts from different orders has also now been eliminated. Tube laser cutting continues to grow in popularity as it offers a quick route to a precise finish, eliminating conventional, timeconsuming stages such as marking out, sawing and finishing whilst delivering significant cost savings. Loic Jones, Operations Director,
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says “Gratnells Engineering decided to invest in state-of-theart laser technology to enable us to offer fast production runs with the best quality finish, to our customer base. This substantial investment will allow us to continually support the ever-demanding needs of modern manufacturing clients�. The Gratnells Engineering factory can turn around tube laser cutting jobs within 3-5 days from receipt of order and, using sophisticated software, can process parts from a variety of media including 3D models, xt files and solid works. This is particularly beneficial for bespoke automotive and pointof-sale components where the minimum quantities can start at one. Gratnells Engineering has also recently updated www. gratnellslasercutting.com, a website that outlines some of the key benefits of the technology and streamlines the decision-making process for customers even further.
INDUSTRY NEWS
SSC Laser expands its team with three senior appointments
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SC Laser Cutting, one of the UK’s leading providers of laser cutting services, has announced three senior appointments to support recent business growth. The company, which has recently announced a record year for profit and growth in 2017, has appointed two business development managers and a tube sales manager (north) to join their growing team. With a background in tube bending and section manipulation, Merill Readett joins the company as business development manager and is tasked with developing and maintaining relationships with new and existing customers across Scotland.
Merill said: “Due to my technical background, I’m able to help customers when it comes to more technical aspects of engineering and identify key areas where SSC is able to support them. “I’m really excited to have been brought on board and look forward to assisting with the development of SSC’s offering in Scotland.” Carl Swift has joined SSC Laser as business development manager for the North West region following a seven year career history within the industry. He commented: “As business development manager, you must be able to deal with people in all job roles and areas of expertise and I’m really looking forward to building
Merill Readett, business development manager - Scotland
relationships with both new and existing customers of SSC across the North West region.” Mark Preston has also joined the company as tube sales manager and is responsible for the management of the tube laser department for the Northern regions, covering the West Midlands, North East, North West and Scotland. Mark stated: “I’m passionate about what I do and committed to making sure both myself and my team are hitting targets each and every month. I will endeavour to ensure the whole team demonstrates drive, enthusiasm and hard work in order to perform to the highest possible standards.” Andy Evans, managing director at
Carl Swift, business development manager North West
Mark Preston, tube sales manager - North
MMK’s Mill 2000 produces its ten millionth tonne of rolled metal
Magnitogorsk Iron and Steel Works’ (MMK) cold-rolling mill 2000 has produced 10 million tonnes of finished products. Launched in 2011, the unit is one of MMK’s most modern and hightech facilities. Mill 2000 has a production capacity of 2,100,000 tonnes per year and is a key element of PJSC MMK’s new cold-rolling complex
at sheet rolling facility No. 11. The main purpose of the complex is to produce high-quality cold-rolled and galvanised steel to be used as internal and external cars parts, as well as in the construction industry and by manufacturers of household appliances. According to President Vladimir Putin, who took part in the launch of the complex, the unit has
not just great regional but also national value. “This really is a major event, not just for MMK but for all Russian metallurgy and the country’s automotive industry,” emphasized Vladimir Putin. The complex was commissioned in two stages, the first stage included Mill 2000 and the continuous pickling line, which went into operation in 2011. A
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SSC, added: “Merill, Carl and Mark each bring a wealth of knowledge of the industry and experience in building customer relationships, and have already made great progress within the organisation. “We are confident that they will be fantastic brand ambassadors for SSC across the company and will assist with our aggressive plans for continued growth.” SSC Laser Cutting operates from offices and manufacturing sites across England and Scotland, offering specialised services in flat cutting, tube cutting and production of precision-engineered laser cut parts. For more information about SSC Laser Cutting, please visit www. ssclaser.co.uk or call 01889 270241.
year later the second stage of the complex was completed, it included a continuous hot-dip galvanizing unit and combined hotdip galvanizing and annealing unit. In the years following the launch, the complex’s products have been rated highly by the country’s car manufactures; both the traditional domestic companies - AvtoVAZ, GAZ, UAZ and KAMAZ, as well as foreign car manufactures who have localized their production in Russia, such as Ford, Volkswagen, Renault, and Nissan.
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100th hot stamping line sold Order from Chinese automotive supplier confirms continuing trend towards lightweight technology advanced by Schuler
Hot Stamping has established itself on the market as an economical technology for lightweight automobile construction. stricter crash tests in the USA. The technology was first introduced to large series production of the Ford Sierra in Europe and the Ford Mercury in
the USA. The side impact beams and bumpers were created on Schuler systems at the time. After the turn of the millennium, the industry increasingly saw this
About the Schuler Group Schuler is the technology and global market leader in the field of forming technology. The company provides presses, automation solutions, dies, process expertise and service for the entire metalworking industry and lightweight automobile construction. Its customers include automobile manufacturers and automotive suppliers, as well as companies from the forging, household appliance, packaging, energy and electronics industries. Schuler is a leader in coin minting presses and implements system solutions for the aerospace, rail transport and large-dimension pipe manufacturing sectors. In the 2016 fiscal year, Schuler generated sales of 1 174 billion euros. After acquiring toolmaker AWEBA and a majority stake in Chinese press manufacturer Yadon, Schuler has a presence in 40 countries with roughly 6 600 employees. Schuler is majority-owned by the Austrian ANDRITZ Group. www.schulergroup.com
method’s potential for reducing vehicle weight while keeping pace with increasing safety requirements. Because press hardened components have a greater tensile strength that coldformed high-strength steels, the use of material can be reduced, thus making the components lighter. In 2006, the body of the Volkswagen Passat was the first to use twelve press hardened components. To allow this to happen, Schuler had built six hot stamping lines within the shortest possible time, and installed these at the Kassel plant. “This laid the foundation for growth that is still continuing,” said Daniel Huber, general manager of the Schuler site in Waghäusel, Germany. Currently, some 500 million hot stamped parts are produced annually on more than 400 systems worldwide. And, according to Mr. Huber, experts anticipate further growth: “Schuler identified this development at an early stage, and set up a Competence Center for press hardening at our Waghäusel site in the year 2006”. This was followed in 2016 by the Hot Stamping TechCenter in Göppingen, a research and demonstration facility at the company’s headquarters.
Photo: Schuler
Photo: Schuler
Photo: Schuler
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chuler delivered the first three hot stamping lines to automobile manufacturer Ford in the USA. What was a brand-new method at the time has since established itself on the market as a global forming technology for automotive lightweight construction – and the trend continues unabated: Schuler has now sold what is the 100th hot stamping line to a Chinese automotive supplier. “Compared with forming aluminum, carbon fiber-reinforced plastics and dual phase steels, this technology is an inexpensive alternative for lightweight automobile construction,” as Daniel Huber explained, the head of Division Hydraulic at Schuler. Oemer Akyazici, the CEO of Schuler China, added: “Chinese automobile manufacturers and automotive suppliers, such as Shanghai Superior Die Technology Co., Ltd. (SSDT) or Baowei are increasingly turning to hot stamping.” The method, which involves heating sheet steel blanks to 930 degrees and cooling them during forming, was first introduced in the early 1990s – initially to improve passenger safety in vehicles – for example, to reinforce the doors in the Saab 9000, thus helping it to pass the
In 2016, Schuler opened the Hot Stamping TechCenter in Göppingen, a The method involves heating sheet steel blanks to 930 degrees and research and demonstration facility at the company’s headquarters. cooling them during forming. The effect: excellent tensile strength. 4 IMT March 2018 www.internationalmetaltube.com
INDUSTRY NEWS
Elvalhalcor announces the order of a new four-stand tandem aluminium hot finishing mill
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lvalHalcor has awarded a contract to the German SMS Group GmbH, to supply a new four-stand tandem aluminium hot finishing mill for its Oinofyta plant, near Athens. This order is part of a EUR 150 million investment in equipment, technology and infrastructure, announced by the Company on the signing of the loan agreement with the European Investment Bank on December 22, 2017, for its financing. This investment represents the first phase of the Company’s five-year plan to more than double its flat rolled aluminium products capacity. With the new four-stand tandem mill, the future spectrum of hot rolled strips will range from 1.8 mm to 12.7 mm in thickness and up to 2.6 m in width, and will secure ElvalHalcor’s
About ElvalHalcor
position as one of Europe’s leading producers of wide aluminium sheet. This investment allows for the increase of ElvalHalcor’s current presence in aluminium packaging, industrial, transportation and architectural applications and sets the base for expansion in the automotive and aerospace sectors.
The new investment also supports the further modernization of the plant, introduces the latest industrial technology, increases energy efficiency and improves the environmental footprint. The new hot rolling line will start production in the first quarter of 2020.
ElvalHalcor S.A. Hellenic Copper and Aluminium Industry is a leading global industrial producer of aluminium and copper. The Company was formed in December 2017 via a merger by absorption of Elval Hellenic Aluminium Industry S.A, a leading international aluminium rolling company, by Halcor Metal Works S.A., the largest copper tubes producer in Europe. ElvalHalcor Hellenic Copper and Aluminium Industry is part of the aluminium and the copper processing and trading segment of Viohalco S.A., the holding company of various metal processing companies in Europe.
CNC PIPE CUTTING AND BEVELING IN ONE OPERATION Beaver 16 CB, machine for CNC cutting and beveling pipes. Purpose Process Machine range Wall thickness Controls
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Software Machining Pre-setting
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Tooling
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Touchscreen Feeding
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CNC pipe cutting and beveling in one operation makes one cut and two bevels in one process from O.D 60 to 410 mm (from 2” to 16”) up to 80 mm automatic cycle: electrical clamping, feeding and pipe stop. CNC controlled by FANUC single point machining process pre-setting all your bevel shapes according to DIN / AMSE standard. automatically adjusted by CNC to get right bevelshape /angle. all controlled over a touchscreen radial and axial feeding
Copier Bevelmachines is the manufacturer and engineer of the Beaver 16 CB, we have different models for different pipe diameters. All the machinery that Copier Bevelmachines manufactures are for the pipe fabrication or the pipe end working market. Go to our website www.bevelmachines.com and www.endworking.com to get more information about our machinery.
COPIER BEVELMACHINES Giessen, The Netherlands | +31-(0)183441313 | sales@bevelmachines.com
www.internationalmetaltube.com solid, sharp and state-of-the-ar t
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INDUSTRY NEWS
Largest foreign location for VOSS after merger
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ollowing the takeover of Larga in 2016, VOSS Fluid is pushing ahead with the integration of the longestablished Italian company: VOSS Fluid Larga was renamed VOSS Fluid S. r. l. on January 1, 2018. The German quality manufacturer for tube fittings has also merged its Italian subsidiary with VOSS Fluid S. r. l. at the Osnago site and invested in additional capacities there. The result is that VOSS has highquality production facilities for hose fittings and ready-to-install hydraulic lines which add even more quality to the portfolio. In addition, a common inventory control system was introduced for the combined site. Voss is using these measures to increasingly standardize its manufacturing processes in Italy and to position itself even more strongly as a comprehensive system provider. 6
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The merger of VOSS Fluid Larga S. r. l. with the long-standing Italian VOSS subsidiary in Osnago - some 30 km north of Milan - has created VOSS Fluid’s largest foreign location with 120 employees. VOSS Fluid S. r. l. produces millions of hose fittings in familiar VOSS quality. In addition to the sale of the individual components, readyto-install hydraulic lines are also produced and offered here. In addition to modern tube connection technology, the company supplies all components for the hose connection of mobile and stationary machines and systems. As a result, users reduce the number of their suppliers and obtain uniform product quality at the highest technical level - especially with a view towards leakproofness and corrosion resistance. Customers will benefit from these standardized manufacturing
processes in the future, as VOSS can react to every application with a combination of hose fittings and other hydraulic components. The range of hose fittings is ideal for hydraulic hoses with a nominal diameter of 5 to 51 mm and includes connection systems for all common hose types.
Development into a comprehensive system supplier The integration into VOSS Fluid S. r. l. is the next logical step in the development of the Wipperfürthbased company. VOSS Fluid has grown as an expert in hydraulic connection technology. A further milestone in the company’s history followed in 2016, when it was possible to take over the Italian market player Larga, also integrating hose fittings into the product range. With that,
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VOSS Fluid added these hydraulic components to its product portfolio and at the same time increased its production capacities for global distribution. Italy expects a strong year for mechanical engineering Through VOSS Fluid S. r. l., the company is also strengthening its position in the Italian market, which is currently experiencing an enormous boom in the mechanical engineering sector. In 2017, Italy’s manufacturers of machine tools, robots and automation systems recorded double-digit growth rates on average. This was the fourth consecutive year of growth for this specialized Italian industry; a development that experts predict once again for the year 2018 as expected by the association UCIMUSISTEMI PER PRODURRE, according to its own bulletin. VOSS Fluid S. r. l. can only profit from this.
INDUSTRY NEWS
SigmaTEK’s Vice President announces new assistant
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igmaTEK Systems’ Vice President, Jandre TerreBlance, has added a new addition to his team, Anna Collins. Anna is the new Executive Assistant to TerreBlanche and in this role, she will assist with administrative tasks and supporting the North American
Sales team. She will be the main point of contact between the sales team and the headquarters in Cincinnati, OH. Collins previously worked at the Cincinnati Children’s Hospital for 8 years and has over 14 years of support and administrative experience. She lives with her husband Ryan and her two children, Sierra and Bryson.
“Anna will make a great addition to the team. Her enthusiasm and positive outlook bring a fresh perspective on our work here at SigmaTEK,” says Jandre TerreBlanche, Vice President of SigmaTEK. “Her strong work ethic and determination will be very beneficial as the company adopts a new ERP system.”
SigmaTEK Releases SigmaTUBE X1.1 SigmaTEK is proud to announce the release of SigmaTUBE X1.1, which offers new features such as new partial common line nesting, new supported shapes, IFC file import, a new help center and more. For customers with the Advanced NC module, SigmaTUBE now supports partial commonline geometries which includes both 4-axis and 5-axis toolpaths. There are also three new tube shapes that are supported with the new SigmaTUBE X1.1: triangle shape, C-shape and D-shape tubes. SigmaTUBE users can now also import .ifc files from third-party structural modeling programs. SigmaTUBE X1.1 features a new tangency tolerance configuration option. SigmaTUBE users can use the tangency tolerance option to auto generate toolpath parts with variable flange thickness. This
allows users to generate toolpath for angle and channel parts that do not have uniform thickness. A new constant chuck tessellation configuration option has also been added to the new SigmaTUBE X1.1. A constant chuck tessellation can now be specified for straight profile cuts on round tubing. This allows a user to preform a 360 degree rotation using set angle rotations instead of relying on the full tessellated toolpath and decreases the number of lines output in the NC for these cuts. The new SigmaTUBE Help Center is the hub for all SigmaTUBE information. Here, a user can view tutorials, help pages, videos, and more. Legacy content has been updated and rewritten to follow the SigmaTUBE workflow, making it easier to find what you are looking for.
About SigmaTEK Founded in 1993, SigmaTEK Systems, LLC is headquartered in Cincinnati, OH (USA) and has an extensive global support network with branches in North America, South America, Europe, Asia, Australia and Africa. This year, SigmaTEK is celebrating 25 years of business and looks forward to celebrating with your continued business. For more information visit www.sigmanest.com or call 513-674-0005. SigmaTEK develops and sells SigmaNEST®, a comprehensive software solution for nesting, NC programming and cutting of steel sheet, plate, tube/pipe, and wood. SigmaNEST is the leading CAD/ CAM nesting system for plasma, laser, punch, oxyfuel, waterjet, router, knife, tube/pipe and combination cutting machines. SigmaNEST ensures superior material utilization, machine motion optimization, and maximum part quality balanced with cutting speed, work flow integration, material handling, accurate estimates and information management.
Oak representatives to join in Tube Dusseldorf trade show Burr OAK Tool will attend the Tube Dusseldorf trade show April 16th through the 20th. Located at the Dusseldorf Exhibition Center in Dusseldorf, Germany, OAK Sales Engineers and Product Managers will co-host booth number F10 in Hall 5 along with
European partner SMI. OAK and SMI representatives will be available to hold discussions with show visitors who are interested in production solutions for the heat exchanger manufacturing industry. For over 70 years, Burr OAK
Tool Inc. has designed customized production machinery for the heat transfer and tube processing industries. OAK machines are installed and successfully operating in over 70 countries. Providing quality machines, service and parts to customers
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worldwide reinforces Burr OAK’s slogan, “Global Experience. Local Solutions.” For more information contact Burr OAK Tool Inc., 405 West South Street, Sturgis, MI 49091. Telephone: 269-651-9393. Website: www.burroak.com.
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PRODUCTS & EQUIPMENT PROTEM
Ten tips to improve productivity in machining operations You can easily improve your productivity if you have a reliable machine 1. A reliable machine to achieve the highest productivity You can easily improve your productivity if you have a reliable machine. What is worse than a monthly break down of a machine? Having to stop production to send the machine in for repair, which results in a large loss in production time. The selection of a reputable manufacturer is necessary to avoid this inconvenience. In a niche market, expertise and experience is a guarantee of quality. PROTEM designs and manufactures equipment used for the construction, maintenance and dismantling of tubular components. Our machines are designed, manufactured and assembled in our premises in France and Germany, ensuring perfect control of the process and the ultimate quality of our equipment.
while maintaining the highest productivity.
2. Equipment based on your needs
3. Effective machining equipment
Whatever your needs, PROTEM (PROfessionalism, Technical know-how, and Expertise) will help you make the right choice for the proper machining equipment. In meetings and discussions, we will ask for the diameter range of your tubes. We will also define your needs in order to have the exact technical specifications you require to achieve the necessary results for your machining operations. Your production volume and your machining specifications will enable us to select the right machine that will meet your expectations. Machining time optimization consists of choosing the right equipment and tools to ensure reliability in the machining process
What is your desired production volume? Assembling pipes by butt-
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welding is a finishing operation which comes at the end of the tube manufacturing process. The performance of the machining equipment will have a direct bearing on manufacturing time. An analysis of machining
performance is necessary to choose effective machining equipment. You must take into account the cutting head gear drive and the feed stroke. With these two parameters and the tube material, you will be able to calculate the machining time as well as the total tube manufacturing time. The technical features of PROTEM machines are available on request. We invite you to contact us through our website to receive the technical data you require.
4. Simple machine set-up From the initial set-up to the end of the machining process, you need the proper equipment so that it is as fast as it is efficient. The technical features you should verify are: The portability of the machine: PROTEM has some of the lightest weight machines on the market.
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PRODUCTS & EQUIPMENT PROTEM
motor. What is the best drive in this case? PROTEM proposes three different types of motors to best meet your needs; pneumatic, hydraulic or electric. The budgetary constraints, the availability of a compressor, on-site machining, the compact design for tight spaces; all these factors will determine your choice of motor. The power of these motors varies. For example, for heavywalled tubes, a double hydraulic or pneumatic drive should be considered. To be able to do perfect and efficient machining, the motor is fundamental to maximizing your production.
6. Simultaneous machining operations They can be set up easily. Because of their light weight, they can be used by a single operator. The Clamping System: Machining performed with the right clamping system will have significant impact on the execution speed and the machining quality. To learn more about different clamping systems, we invite you to consult the article,
Tube Clamping During Machining Operations. Automatic Feed: Weld joint extraction and beveling operations on heat exchangers takes a lot of time and requires the right technology. The US-TP series are fully automated beveling machines. The clamping and the feed are automatic and adjustable.
The automatic feed offers a significant time reduction. With this technology, you will drastically increase your productivity.
5. The right motor for higher production An electric drive that gets hot after two bevels! Your machine probably doesn’t have the right
When we look at the market most beveling machines have a tool holder with two or three tools on it. In the standard version, the tool holder on the PROTEM beveling machine can accomodate four tools. Machining operations, such as facing, beveling and counterboring can be carried out simultaneously. Two or more tool bits used simultaneously ensure a perfect balance of forces during the machining operation. Other machining operations can be done, such as, performing compound bevels on heavy pipes, removal of weld joints on tube sheets and/or cutting tubes to length on tube sheets. Saving time will be important, particularly for applications that machine thousands of tubes, like heat exchangers, for example.
7. Use the right cuttin tools PROTEM offers a large range of cutting tools that make a variety of angles and specific shapes (I, V, J, X, compound bevels, counterboring, etc.). Carbide or HSS tool bits ensure a perfect welding preparation.
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PROTEM PRODUCTS & EQUIPMENT
Carbide tools are naturally harder than the HSS tool bits with cutting speeds that are four times higher. These carbide tools are used with tubes made of hard steel at higher cutting speeds. Also, the coating used on tool bits is a standard practice used in machining operations, such as, high speed machining. The coating improves the tool’s performance and can resist high temperatures that are a result of high machining speeds. PROTEM offers TiN Coating
(titanium nitride) that is specifically made to reduce operational costs because of its greater wear resistance. The TicN Coating (titanium carbonitride) is an extremely hard ceramic material that is specially recommended for materials that are particularly difficult to machine.
8. Versatility to achieve higher productivity Multi-function, versatile machines are in high demand because of their ability to perform many machining
operations on various components (tubes, elbows, plates, valves) by using a single machine. The reduction in investment costs for this kind of machine is about a minimum of 30%. The purchaser invests in one machine instead of three. Additionally, there is a reduction in training costs, as the operator will only have to train on one machine. For example, PROTEM beveling machines (US series) can machine tubes and re-surface flanges by utilizing the flange facing
attachment option. For larger diameters, we offer a special kit that increases machining capacity. For heavy-walled pipes, buying a new machine will not be necessary, the copying carriage option is designed to perform compound bevels for wall thicknesses over 50mm (1.968�). PROTEM also offers high speed beveling machines (CTA or BB series). They are available with options, such as, an automatic clamping system, tube conveyors, tube storage table and chips conveyors. Any or all of these options will drastically increase your productivity. The versatility of a machine is very important to any project. Anticipating your future needs will help you to save time and money.
9. Operator training to improve productivity While the use of a PROTEM machine that is durable, light weight, and portable, makes a huge difference in productivity, operators should also be fully trained and understand machining basics, such as, how to achieve a perfect weld. A good understanding means properly knowing the importance of tube preparation before welding. Also, what are the things that should be controlled prior to machining for safety reasons. With its many years of experience and all its expertise PROTEM has developed training 10
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PROTEM PRODUCTS & EQUIPMENT
programs designed to familiarize users, during maintenance operations, with the procedures to be implemented when installing and setting up our equipment. This knowledge will improve your productivity and reduce your costs by reducing the reject rate and re-machining costs.
10. Evolutionary machines Over time, your needs change and technology evolves. PROTEM will continuously offer new functionality on the equipment you already have. Our team will select the parts and upgrades for your machine. This is the key to lasting machine success in optimum conditions. We offer maintenance contracts or machine upgrades which consists of upgrading the essential components to give added life to your machine. These services are essential to protect your investment over the long-term and will improve your productivity with machines that provide superior safety and state of the art technology.
In addition to these ten tips to improve productivity in your machining operations, a summary of the key elements so consider in choosing the right equipment is shown below
The manufacturer: Expertise Experience Business method Proximity
DESTINATION PROGRESS. WITH TUBE MANIPULATION MACHINES FROM TRANSLFUIDÂŽ.
Responsiveness
The machine: Weight Clamping System Feed Stroke Cutting head gear drive Power of the motor Simultaneous machining operations Versatility and options
Tools and options: Carbide tools HSS tools Hydraulic power pack
www.transfluid.net
Services: Operator training Maintenance and repair Commercial support After-sale service On-site machining
TUBE 2018:
to We look forward
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your visit!
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PRODUCTS & EQUIPMENT
Bending brake and fuel-supply lines with supreme flexibility on three levels
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engler Tube Tec unveils ERBM-LR, its new CNC single-head tubebending machine for brake and fuel-supply lines, at Tube 2018 – Hall 5, Stand E22 Witten/Düsseldorf, March 8th 2018. Dengler Tube Tec will be showcasing an innovative new product at Tube 2018 (Hall 5, Stand E22) with the ERBM-LR tube-bending machine. The robust automatic tube-bending machine has been developed for machining particularly complex bent parts with different tube diameters (3.2 to 12 millimetres) within a brake or fuel-supply line and tube lengths of between 150 and 2,300 millimetres. The ERBM-LR can be freely programmed on three levels and can execute both left- and right-hand bending, draw bending and roll bending at each individual bending point. All movements are performed around the stationary pipe. This is Dengler Tube Tec’s response to demand from its customers in the automotive industry, who handle increasingly complex brake and fuel-supply lines made from steel or aluminium. ‘This patented new development has enabled us to close a gap in our product range, since brake and fuel-supply lines increasingly have protective hoses with multiple pipe diameters,’ says Norman Köchig, Head of Design at Dengler Tube Tec. The CNC single-head tubebending machine has nine NC axes and is supplied with numerous extras as standard. Customers receive a fully operational bending cell. To implement the new operating principle of the ERBM-LR, which is protected by multiple patents, extremely high demands were placed on the development of the design and control technology.
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Whereas other machine concepts adjust the position of the bending starting point by advancing the pipe and in some cases even rotating it into position, with the ERBM-LR all translational and rotary positioning movements are carried out by the machine units themselves. This eliminates the need to take into account the vibration characteristics of the pipe to be bent when performing the positioning movements. The longitudinal and rotary movements can be performed at the highest possible speed – from the first bend to the last. The new bending machine features the same control and drive concept as all the other bending machines from the specialists in tube-bending machines. The machine control, drive booster and drive motor components all come without exception from the tried and trusted product range from Bosch Rexroth. Wherever possible, all other components in
the machine are also standardised and are compatible with the other bending machines. ‘Thanks to this clear policy on the use of globally available and high-quality branded components and the standardisation of the components used in all bending machine model ranges, our customers are able to maintain an extremely cost-efficient and efficient stock of spare parts,’ says Andreas Pfeiffer, Head of Engineering and Sales at Dengler Tube Tec. In spite of the new machine’s many freely programmable functions, all the parameters have once more been accommodated in the familiar and straight-forward programming interface. This means that, regardless of the machine type that is to be operated, operators switching over to the new machine will find it takes very little to adjust to it. ‘The harmonisation of the user interface for the vast range of
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machine types, and with it the easy operation of our machines, is one of the most important reasons our customers give for the widespread use of the machines in pipe production,’ says Dr Ralf Sondermann, Head of Control Engineering at Dengler Tube Tec. The new machine type can naturally also be presented on our proprietary simulation software DBOF/SIM. This powerful simulation program can be used to check the bending properties of the pipes in advance, determine the cycle times and view the required attachments. Graphic simulation of the bending process significantly increases operational availability of the ERBM-LR by Dengler Tube Tec. For more information: Dengler Tube Tec GmbH Wullener Feld 62, D-58454 Witten Phone +49 (0)2302 91416-0, Fax +49 (0)2302 91416-22 info@dengler-tubetec.de www.dengler-tubetec.de
ORBITAL PIPE CUTTING & BEVELING SPLITFRAME CLAMSHELLS PRODUCTS & EQUIPMENT
OD Mount Clamshell for diameters 1’’ to 168’’ Hydraulic, Pneumatic or Electric drives
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Cutting & Beveling simultaneously
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Tsubaki high tech drive chains make steel looper tower accumulator ultra reliable
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eading chain maker, Tsubakimoto, has helped a steel mill in the Netherlands improve the long term operational productivity of its annealing line by replacing lifting chains that failed frequently with ones that have proven to have a working life of 10-15 years or even longer. As part of the mill’s role of coating sheet steel, a key process is annealing: a heat treatment designed to improve the workability of the metal by heating then cooling the metal to increase ductility and reducing hardness. This is performed as a continuous process, so the individual sheets of steel must be welded together end-toend to form an endless strip. Production volumes are such that the welding must be performed automatically. To ensure a steady flow of steel through the annealing line, a looper tower has been installed both ahead and behind of this. These act as accumulators to store a quantity of steel and feed it onto the processing line at a steady rate. At its heart are four hard working chains that raise and lower platforms to accumulate or dispense steel as required. For the annealing process to be effective, the surface of the steel must be clean, so it is important that it does not pick up oil or grease from the drive chains. Thus there is a need for precise lubrication; neither so much that excess can transfer onto the steel nor so little that the chain becomes dry and fails prematurely. In reality the mill operators found access to the chain for maintenance difficult due to the 14
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The new G8 Super (Heavy Duty) Drive Chain is aimed at applications requiring the movement of large loads at low speeds. height of the tower. As a result, maintenance schedules tended to become fitful and reactive, which led to the original chains suffering from issues of ‘kinking’ due to poor lubrication penetration. This was followed by failed links due to wear and/ or overload. Inspection of the
chain after it had been in use for some time indicated that it also suffered from uneven wear rates, which caused further overload on the remaining chains. Eventually the mill called in Tsubaki, to see if its engineering expertise and advanced chain
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products could improve the situation. Transmission chain has been serving industry for decades. For 100 years Tsubakimoto Chain Co. has been a leader in R&D, having made significant advances in the technology designed to address demanding and unusual
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applications. It also steadily advances its chain manufacturing processes to ensure quality and competitiveness. The company explains that rather than simply pursuing cost reductions, it believes its primary goal is to differentiate Tsubaki by forward-thinking investment and a focus on product development. As a result, it has a number of innovative chain technologies such as lube-free, corrosion resistant and harsh environment products. After a visit to the steel mill, Tsubaki recommended replacing the existing chain with some of its standard BS chain, GT4 Winner. The technology within these has been refined through several generations of design. The G8 RS Roller Chain is the company’s standard line that meets the needs of most applications. These eighthgeneration designs offer a 20% improvement in service life over the previous designs; a special corrosion suppressing oil is applied to the chain in the final stage of manufacture to inhibit rust and improve durability. Developed in-house, this oil does not leave a sticky residue on the chain surface, which could otherwise transfer to the sheet steel.
The new G8 Super (Heavy Duty) Drive Chain is aimed at applications requiring the movement of large loads at low speeds. This chain provides great strength as a result of a new heat-treatment process, thicker material, and innovative geometry while remaining the same size as the standard type of chain. Because the looper tower needs very long lengths of chain, the mill had experienced problems with uneven chain length due to wear and stretch. Tsubaki has addressed similar issues previously and has developed its unique Match and Tag service, which guarantees a maximum chain length difference of 0.50mm independent of the total chain length, so that they can be used in pairs or larger groups. Tsubaki also fitted new sprockets made to the same high specification, supplied the chain in super long lengths to reduce fitting time and agreed to provide annual monitoring of the chain. As a result of fitting Tsubaki chain, the looper tower now runs continuously with ultra reliability, requiring little maintenance beyond the annual inspection and keeping the steel’s surface clean for effective annealing.
The Test Of Time For 90 years, MAC® has been a leader in nondestructive testing.
About Tsubaki Established in 1917, Tsubakimoto Chain Company is the world’s premier manufacturer of power transmission products with strong market positions in premium quality industrial drive & conveyor
Visit us at Tube 2018 Düsseldorf
chains and associated power transmission components such as cam
Hall 6, Stand I-12
clutches, reducers & linear actuators. With a turnover exceeding $1,5 Billion US Dollars & 6,500 employees, the Tsubaki group includes 33
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Beaver CB series for pipe cut- and bevelling by Copier Bevelmachines Beaver CB, Cnc pipe cutting and bevelling machine
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e are happy to introduce our latest machine development for metal pipe cutting and bevelling in one production line: the Beaver CB series. Available in several sizes, overall from 1�up to 48�. Copier Bevelmachines is
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manufacturer of pipe end working machinery for many years now. The company offers stationary equipment for pipe shops, mainly pipe bevelling machines, pipe cut and bevelling machines, CNC pipe end working machines and pipe spool welding machines. Since all our customers have to
cut or saw the pipes before they start bevelling we developed a production line capable of cutting and bevelling metal pipes. This machine is called the Beaver CB. To have these features in one machine is very efficient and effective. The Beaver CB is modular built. You can have the basic cut- and bevelling machine, but you can expand with several types of roller benches, with manual or automatic pipe handling. Also length measuring is possible, it makes it very easy to cut a pipe to several different lengths. One operator could control the complete production line from the operator panel. You also can connect it to the overall shop control system and send the orders to the machine. With the Beaver CB series your output will be higher because length measuring, cutting and bevelling is combined in one machine. The Beaver CB is a completely CNC controlled machine with both radial and axial feeding, it cuts with up to three cutting bits from outside to inside of the pipe and
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during this process it performs a bevel shape with the required angles. All ASME code bevels are pre-set in the machine.
Pre-set bevel shapes The operator could select one of the pre-set bevel shapes and dimensions that have been saved in the software of the CNC program. These bevel shapes are mostly based on the ASME or DIN bevel shapes and dimensions. The machine automatically changes tools according to the bevel shape and angles. The machine works with a single point CNC machining process and because of that could cut and bevel up to 60 mm thick walls. The Beaver CB will perform a bevel shape on both ends of the cutted pipe if required.
How does it work? On the front infeed conveyor you put a metal pipe. The operator fills in the pipe parameters like pipe diameter, wall thickness, type of steel, bevel type and pipe length. The operator also enters
PRODUCTS & EQUIPMENT
all the lengths of the pipe parts that needs to be cut from the starting length. The push up infeed conveyor pushes the pipe into the Beaver CB and knows where to clamp it in order to make the cut on the required length as entered in the program. The machine starts cutting and during the cutting process it performs a bevel on both pipe ends. After that the pipe pieces are processed to the outfeed conveyor from where they can be dispatched.
User friendly The Beaver CB is a user friendly machine mainly because everything is straight forward in the CNC
programme that we designed together with the company FANUC. The machine operator works in an operator level and cannot change settings if not allowed. Only the administrator can change program settings. To work with this machine you do not have to be a trained CNC machining expert but you have to understand the basic process of course the CNC program.
Output Obviously the output of the Beaver CB is much higher that when you would invest in a band saw in combination with bevelling machines. Another advantage is that you do not have the internal
transport anymore from the saw to the bevelling machine. Another big advances of the Beaver CB series is the exact 90 degree cut it makes.
Flexibility The Beaver CB is flexible and suitable for many pipe fabrication jobs because your most common bevel shapes and bevel angles are pre-set in the CNC software of the machine. Besides that the machine automatically performs these shapes by single point machining. You can do all different types of bevel shapes without changing tools. Also the full machining range can be done without
adjusting the tool position. Altogether it is a great machine to increase the output and the flexibility of your pipe shop! Contact us if you are interested in a quotation or if you are interested in a demonstration on this Beaver CB in our factory in the Netherlands. Copier Bevelmachines Bedrijvenstraat 13 4283 JJ Giessen The Netherlands Telephone : +31-(0)183441313 e-mail: sales@copierbv.com Or visit our websites : www.bevelmachines.com www.pipespoolwelding.com
End working machines from Copier Bevel Machines ARLA is well known in the end working industry for it’s highly accurate CNC Rotating tool lathes and accurate clamping sets for metal pipes, cylinders, axis and solid round bars. ARLA sold machinery in the cylinder industry and in the automotive industry mostly. In the end of 2016 ARLA has been taken over by the Dutch machine manufacturer Copier Bevel Machines. Copier Bevel Machines is maintaining the ARLA brand for state-of-the-art CNC Rotating tool lathes for the full range of diameters up to 323 mm (12”). The existing portfolio of Rotating tool lathes of Copier Bevel Machines is more for machining larger diameter pipes and heavier wall, typically for the oil and gas related industries. Copier Bevel Machines is the specialist in Rotating Tool Lathes for machining metal pipes, tubes, fittings, cylinders and solid round bars. The solutions that Copier Bevel Machines offers on Rotating tool lathes can be manual controlled, PLC controlled
or fully CNC controlled. With the rotating tool lathes and it’s solutions for pipe cutting, bevelling and welding Copier Bevel Machines is the last couple of years more and more involved in selling solutions to pipe spool fabrication industry worldwide. Copier Bevel Machines has a
strong position in the pipe spool fabrication market because of its expertise on rotating tool lathes and it’s capability to offer one of kind solutions besides it’s standard portfolio. The main industries that the company focusses on are offshore construction,
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manufacturers of pressure vessels and heat exchangers, pipe spool welding companies, shipyards, chemical plant construction and oil and gas related industries. Meet Copier Bevel Machines on the Tube and Wire exhibition this year in Dusseldorf in Hall 6.
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PRODUCTS & EQUIPMENT
New In-line measurement solutions for dimensions and shape with PROFILEMASTER® and STEELMASTER gauges from ZUMBACH
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akers of seamless pipe, tube, profiles and bars now have access to ZUMBACH gauges, which have just been enhanced, now offering even more significant advantages: • New PROFILEMASTER® models SPS 80, 200, 400, 550 and 800 complete the line of hot and cold in-process gauges for rounds up to diameter 600 mm (23.62 in.) or profiles of up to 550 mm (21.65 in.) edge lengths. PROFILEMASTER® gauges are based on the principle of light-section technology and machine vision, and can handle any shape or profile. Relevant dimensions can be entered into the program and are then monitored during the production run at all times. Typical applications are hot seamless pipe and profiles of any kind, cold rolled/welded tubes and pipes (ERW) and inspection stations for tube, pipe, profiles and bar.
• PROFILEMASTER® systems are available in multiple designs, depending on the requirements of the customer and product. The systems are best suited for the continuous measurement and monitoring of dimensions and the complete cross-section of profiles made of steel, metal, plastics or rubber. • The new series of STEELMASTER hot and cold gauges, based on highspeed laser scanning, now offers up to 12’000 measurements per second, with new Calibrated Single Scan (CSS) technology. This results in a highly accurate and fast non-contact measurement of diameter, ovality and width/height at production speeds of 100 m/s (19,685 ft/min) and beyond. STEELMASTER Gauges are available in static (SMS models), oscillating (SMO models) or rotating (SMR models) configurations and for diameters of up to 500 mm (20 in.) or beyond upon request.
Zumbach at TUBE 2018 ZUMBACH – Swiss Prime Measuring since 1957 - will join the international trade fair for tube products TUBE 2018 in Dusseldorf. Novel and intelligent solutions as well as cost efficient solutions for in-line measurement and control of tubes, pipes and profiles are going to be the focus of Zumbach’s exhibition booth. See us on stand 5 D19 18
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PRODUCTS & EQUIPMENT
Fast track delivery Discover Raccortubi Group solutions at TUBE 2018
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arcallo con Casone, February 26, 2018 - Deliveries in 4 weeks for special items? Raccortubi Group is pleased to present its fast delivery solutions at TUBE 2018 in Dusseldorf. When dealing with Raccortubi Group, in fact, you can count on the long-lasting expertise of engineers and technicians who, while mixing passion with knowledge, can find unexpected solutions to the most urgent requests – even when special products are concerned, in a very short time. In addition, the extensive availability of raw material in sheets and plates in duplex,
super duplex and 6mo up to 50mm, and in titanium up to 15mm, allows for fulfilling deliveries in 4-6 weeks thanks to a dedicated production line at Petrol Raccord called Fast Track.
Case History An urgent request from a client in the Far East was received, for duplex manifolds to be delivered by airfreight within 4 weeks from placing the order. While the Technical Department at Petrol Raccord promptly started the design of these tailor-made pieces with all the relevant calculations, the internal production was planned accordingly. Therefore, immediately after the customer’s approval, such a tight delivery
schedule could be smoothly met also thanks to the in-house laboratory where the final quality tests could be carried out without constraints before shipment. All these elements were fundamental in matching the demanding conditions of the contract for the supply of two manifolds 20” diameter in Duplex F51 with 11 double extruded outlets each, up to 55 mm thick and 20 meters long. Of course, the Group’s wellestablished relationships with valuable suppliers were so beneficial in guaranteeing the almost immediate provision of raw material as the first essential step of an efficient supply chain. This is just one example of the reason why Raccortubi is
proud of a business model that enables to be so much flexible. It delivers products coming from its own manufacturing mills, many of them from its own stock and made with the internal availability of raw material, with a precise and efficient production planning thanks to which the Group is able to face many lastminute requests. Raccortubi will be showing all its manufacturing and supplying solutions during the world’s most important trade fair for the tube and tube processing industry as TUBE. Raccortubi Group team will detail the number of our possibilities from 16 to 20 April 2018 in Dusseldorf (Dusseldorf Exhibition Centre) at stand D02, hall 3.
simply smart.
TUBOMAT
Join the best!
16.-20. APRIL 2018 HALL 5, STAND 5E25
CUSTOMIZED PIPING PROCESSING ENGINEERED TO PERFECTION Sawing | Deburring | Bending | Cutting-ring assembly | Flaring
TRACTO-TECHNIK GmbH & Co. KG
57368 Lennestadt · Germany · Tel.: +49 2725 9540-0 · pbs@tracto-technik.de www.internationalmetaltube.com www.pipe-bending-systems.com
IMT March 2018 19
PRODUCTS & EQUIPMENT
Elebia Launches NEO Hook for Lifting Bell Furnaces
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lebia has unveiled a new 20t capacity automatic hook specifically designed for lifting bell furnaces. Automation and remote operation of the NEO is suited to environments where metals are heated to extreme temperatures in movable dome coils. The Barcelona, Spain-based manufacturer has introduced the NEO safety hook, which can also be used for lifting and manoeuvring loads that have an oversized lifting point (up to 100mm diameter), to a growing portfolio of products. A standout feature of the latest innovation is a multi-colour-coded light-emitting diode (LED) status indicator that displays green when it’s open and blue when it’s closed, for example. Oscar Fillol, founder and CEO at Elebia, said: “In regular lifting operations with bell furnaces, the operator has a limited line of sight
and poor visibility of the lifting hook’s position and engagement with the lifting point. The status indicator is an additional safety measure. It can be viewed in all operating conditions and displays on the [optional] eMax remote control unit.” Intrinsically safe, it is not possible to make a lift with NEO while the hook is in an intermediate state (red). The hook will only lift the load once the closure mechanism is locked, indicated by blue coloration of the LED status indicator The eMax remote control includes a full colour liquid-crystal display (LCD) screen and offers the user a variety of information about the lifting application, including weight, hook status, and alarms that alert the operator to overload or unbalance situations. It is only supplied as an option because there are many instances in bell furnace lifts where an operator
Elebia’s latest innovation, NEO, offers a myriad of safety and efficiency benefits to end users lifting bell furnaces and loads that have an oversized lifting point. will not need to know how much weight is being lifted. However, Fillol said, because of restricted visibility he anticipates that the remote control option will prove popular. Among other key features are a 4:1 safety factor; one-week autonomy, covering 3,000 cycles or over 250 hours in standby mode; and a customisable top link. A three-hour charge will return the battery to its full capacity and the hook will remain closed even if the battery expires during usage. Further, due to the geometry of NEO’s design, the load will always be positioned in the centre of the hook. Fillol added: “The hook has a failsafe design that makes it impossible to drop suspended
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loads. NEO is designed under the same failsafe principles as our automatic lifting hooks and the automatic lifting clamps. It presents a multitude of advantages over standard lifting hooks without a security latch, commonly found in this industry sector, and lifting hooks with a motorised latch. Importantly, hooks without a latch, or when the latch isn’t properly closed, can be tip-loaded, which isn’t possible with NEO.” Two final details to note are, one, a metal tip that can be inserted to facilitate NEO’s positioning into a narrow space; it is reinforced to protect the hook against impacts. The dedicated space for the placement of the pin has enough of an area to load a lifting points of up to 100mm in diameter; and, two, a pushbutton that can be used instead of automation. However, Fillol does not anticipate its widespread utilisation. Contact for editorial enquiries: Esteve Fornells, efornells@elebia. com
PRODUCTS & EQUIPMENT
Inflatable rubber plugs: Lightweight but strong and highly resistant to petrochemicals
I
t has long been possible to seal sections of a pipe using an Inflatable Stopper. However there are applications where existing stoppers aren’t quite good enough for the job in hand. Now, thanks to the new Range of Inflatable Rubber Plugs from the Pipestoppers® Division at Huntingdon Fusion Techniques HFT®, a whole new number of applications can be attended to. These new Plugs can be inflated quickly using compressed air lines and are ideal for fast, reliable and safe stopping and blocking of pipes, joints, channels, inlets and a number of other uses. Lightweight Inflatable Rubber Plugs can withstand temperatures from -40°C (-40°F) to 70°C (158°F) and are highly resistant to oils, hydrocarbons and petrochemicals. Available in sizes 2 - 78” (51 to 1,981 mm), each Plug has a wide degree of flexibility in diameter. Ron Sewell, Chairman for HFT® said: “Inflatable Rubber Plugs are used during new pipeline installation or for carrying out routine maintenance and repairs. They seal off sections of a pipe quickly, safely and are very simple to use. Inflation can be carried out almost instantly with a
compressor and they can be inflated with hand or foot pumps too”. The Plugs are manufactured from high quality rubber, comprising a mix of styrene, butadiene and isoprene. Typical applications include: Blocking pipes, tubes, dams, inlets, storage tanks, manholes and channels. For use in water, sewage, fluid production (milk, beer, chemicals), petrochemical, pharmaceutical, gas pipeline systems. Restricting, diverting and
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bypassing flow during pipeline maintenance or modification. Keeping pipeline free of dirt and contaminants by capping and blocking the ends. Can be floated down pipes and stopped at a desired location by holding onto the inflation hose. The Pipestoppers® Division at Huntingdon Fusion Techniques HFT® supplies a range of Mechanical and Inflatable Pipestoppers® and Plugs to suit every application.
For further information, please contact: Michaela Reay, Marketing Associate Huntingdon Fusion Techniques HFT® Press: michaelareay@ huntingdonfusion.com www.huntingdonfusion.com
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PRODUCTS & EQUIPMENT
Pipe ID 4.0: Monitoring plants in real time
Image: Schuler
Schuler introduces comprehensive process control system for the manufacturing of large pipes including product data acquisition
Schuler’s Pipe ID 4.0 is a comprehensive process control system for the manufacturing of large pipes in real time.
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system operators gain a basis for calculating the OEE. Permanent logging of parameters also enables a cycle-accurate response in real time, where necessary; condition monitoring allows checking the system at regular intervals for damage and wear, and thanks to
smart diagnostics, fault analysis is accelerated significantly. With large pipes, product data acquisition is of particular importance when it comes to inspecting the high grade steel pipes (X100) in accordance with the API 5L standard regarding
dimension or welding quality by means of ultrasonics, hydrostatic testing and X-rays. Schuler upgraded the analog X-Ray system to a digital version, so it can be easily integrated into Pipe ID 4.0. It includes a server station that stores the results of these tests
Photo: Schuler
F
or its spiral pipe plants, Schuler continuously develops optimizations aiming at similar objectives: creating a stable and safe process flow which offers high quality large pipes, low costs of operation and a high degree of automation. This is also true for the company’s latest innovation, Pipe ID 4.0 – a comprehensive process control system for the manufacturing of large pipes in real time featuring a track and trace system, overall equipment efficiency (OEE) monitoring, condition monitoring, smart diagnostics and power monitoring. Schuler has already implemented machine monitoring in other production lines, e.g. for the manufacturing of railway wheels. The production data acquired includes all planned and unplanned downtimes including their causes, fault messages, target/ actual production and the quality of the parts. In this way, the
It features track and trace, overall equipment efficiency (OEE), condition as well as power monitoring and smart diagnostics. www.internationalmetaltube.com
PRODUCTS & EQUIPMENT
as well as all of the other machine parameters. With network label printers or paint marking and barcode scanners, all of the pipes in the plant can be traced and tracked, and their quality e.g. regarding close tolerances ensured. Even the coil storage area is managed in the database, which means that the coil data is assigned to the produced pipe. Mobile devices like tablets or smartphones can also be used for monitoring and evaluation.
Image: Schuler Image: Schuler
The server station also forms the backbone for the fiber optical network every machine is connected to by managed industrial switches. This enables an overview of the workflow process including a quick status of the single machines and big pictures of the stations under work and with fault, the production time of single pipes and a fault report. An interface to the customer ERP network is integrated. Up to 50 operator terminals all over the plant grant access to information about the actual working time, the number of pipes per time unit, the production rates, the status of the plant and error messages of the working stations – like the offline welding station, the hydrostatic testing machine, the cross seam welding and repair stand, the inspection stand or the pipe end beveling machine. This reduces operation effort as well as costs for maintenance and repair. Additionally, with its new robots for tab plate welding and cutting, final pipe measuring, grinding and pipe stenciling, Schuler developed a fully automatic system which can be used for both pipe ends. The minimum cycle time for diameters ranging from 20 to 88 inches is approximately five minutes. Short coil and diameter changing times, a high flexibility and low downtimes further increase the degree of automation that Schuler’s spiral pipe plants dispose of. www.schulergroup.com/large_pipe
Image: Schuler
Fiber optical network with ERP interface
Up to 50 terminals give an overview of the workflow process (top and middle) or the individual working stations (above). www.internationalmetaltube.com IMT March 2018 23
PRODUCTS & EQUIPMENT
Outokumpu avoids downtime with Doosan ‘DPF free’ heavy lifting
O
utokumpu is a global leader in stainless steel production with a crude capacity of 3.1 million tonnes and a history that stretches back a century to the origins of the highly durable metal alloy. Production facilities cover all continents and are located in Finland, Germany, Mexico, Sweden, the UK and USA, giving rise to sales of 5,960 million euros in 2016. In Sheffield, a city synonymous with the corrosive-resistant material, the company manufactures stainless steel rod coil, which is used in major infrastructure projects across the world, providing longevity to multibillion pound investments such as skyscrapers, motorways and bridges. At the ASR Mill on Stevenson Road, just a mile away from the 24
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company’s foundry, huge onetonne coils of stainless steel rod are produced and meticulously managed through a process that balances the requirements of both the rolling mill, with its tight schedule for manufacturing particular sizes and grades, and the finishing cycle where optimum use of acids depend on careful sequencing of rod sizes and grades. The result is a constant need for storing and retrieving heavy coils of metal throughout the production cycle. Handling large loads in such a punishing environment and to a demanding schedule calls for a robust and reliable forklift truck fleet. Failure to perform at any point can have a significant impact on the production cycle, affecting customer orders and tight timelines.
“Any forklift truck downtime can be critical for us,” says Phil Sowerby, Engineering Manager at Outokumpu. “We are on a constrained site, so we have to use forklift trucks to move coils between processes – whether it’s annealing, to get the properties we want, or descaling products. Then, of course, we use trucks to bundle up particular products for an order – customers order various sizes, shapes and grades of stainless steel rod, so we also need reliable trucks to load lorries for despatch.” Realising that the time was coming to renew the fleet, a particular concern for Phil Sowerby was the industry-wide use of Diesel Particulate Filters (DPFs) on new diesel forklift trucks – needed by most manufacturers to comply with the latest EU emission standards. Such filters require a
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regeneration cycle to be performed every 25 hours or so, significantly increasing downtime and fuel costs and negatively impacting on-site performance. Fortunately, there is an alternative. After many years of running a mixed fleet, consisting of Doosan trucks and others, Outokumpu took a strategic decision to source a fleet of new forklift trucks from a single supplier. As there was a long-established service and support relationship with Ability Handling, Doosan’s local dealer, Phil Sowerby was introduced to Doosan’s latest 5.5 tonne capacity D55 Diesel counterbalance truck – which comes complete with the revolutionary Doosan designed “DPF free” G2 diesel engine as standard. Clever design of the combustion chambers and piston heads,
PRODUCTS & EQUIPMENT
coupled with an ingenious fuel injection system, results in a cleaner burn with Doosan’s G2 engine, producing much less soot. Critically, the need for a Diesel Particulate Filter has been engineered out. “For us, a major requirement was that we didn’t want a truck with a DPF as we knew we would have to take the truck out of service every shift and do a regeneration cycle for twenty minutes or more,” he says. After extensive on-site trials and consultation with the drivers, Outokumpu placed an order with Ability Handling for nine new Doosan D55 diesel powered forklifts – complementing two smaller Doosan diesel counterbalance trucks already on site; a D33 and a D35, used for lighter duties. Phil Sowerby points out: “We had experience of Doosans in our mixed fleet and we knew they were really reliable, they performed well and the drivers liked them. We were also taken with the Doosan design, it was straightforward and functional – it wasn’t unnecessarily complicated. And the oil-sealed brakes offered protection from
dust and grit.” He adds: “We operate an industrial site where we’re moving around a 1000 tonnes per week, so we wanted a truck that was easy to maintain in the field and that wasn’t going let us down.” The trucks supplied to Outokumpu were standard models but with hardened steel under pans fitted to offer protection from steel wire off-cuts, and forward and reversing projected warning signals, in addition to a white noise system, for extra pedestrian safety. Other features were speed limiters, weatherguard cabs with PVC doors, and accumulators to dampen load handling – all under a five year Doosan warranty package. The specification included the use of a special 2.5 m long plastic-coated pole attachment for coil handling, making careful calculation of load centres and lifting capacity of vital importance. Service support and parts backup was a critical factor in the decision to single source the fleet from a local dealer, as Phil Sowerby explains. “Having had a mixed fleet we could compare service levels,
responsiveness and how long it takes to get parts. Ability Handling has always performed well, and we have a good relationship with them. So with our positive experience of Doosan too, this gave us the confidence to go with them. “Coordinating the movement of coils through production and finishing, and ensuring customer orders are collated and loaded for despatch involves constant heavy
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work. We have timed collections, so we know who’s coming every day and we know what they want – that’s why it’s essential that our forklift fleet works reliably. We can’t afford downtime.” Media contact at Doosan Industrial Vehicle Louise Boston, Marketing manager Tel: 01604 825 600 louise.boston@doosan.com
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PRODUCTS & EQUIPMENT
More efficient tube bending Lang Tube Tec exhibits numerous tubebending samples at ‘Tube 2018’, as well as timesaving and cost-saving new features of its tube-bending machines - Hall 5, Stand E22
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fter its initial unveiling as a fully electric tubebending machine at Tube 2016, Lang Tube Tec has added valuable new features to the 160CNC-EMR: These features accelerate and optimise production, making the process more efficient. One new innovation is the system for quickly changing tools, for example. The machine is the world’s first fully electric tubebending machine to be capable of bending tube diameters of up to 165 millimetres on three levels with a bending radius of 1*D. Visitors to Hall 5, Stand E22 can see a number of tube samples of bent parts illustrating the new functionality. The tube-bending machine 160CNC-EMR, which features 13 axes, has been specially developed for machining particularly complex bent parts with different radii and short clamp lengths. The machine is ideal for exhaust pipes, axle parts and frame parts. It is used in automotive production - in particular utility vehicles - but also in aviation and shipyards. The innovative quick-change tooling system from Lang Tube
Tec - which drives innovation for complex bending tasks in manufacturing processes simplifies the operation of all tubebending machines. It can be retrofitted on most machines in the SMALL to STRONG model series and features swivelling tie rods, a pneumatic clamping system for fixing the bending die withat the touch of a button, mountable slide rails and clamping jaws, as well as a quick-change system for mandrels. The new collet - which is electrically activated by means of two spindles, thus covering a specific diameter
range - also saves time and money. This further optimises tool-change processes. In addition to the features producing time optimisations, the integration of cutting systems in the bending tools optimises material waste, thus providing considerable cost savings. Two different cutting systems are available, depending on requirements. One system has two cutting blades for separating tubes with a thick wall, with a scoring blade being used to score the tube and a chopper blade
then being used to separate the tube, guaranteeing an optimum cut which allows subsequent processing to be carried out without additional reworking. For tubes with thins walls, this separating cut is performed using just one - electrically powered knife. Both systems are capable of bending and separating the tube in a single production step. Further optimisations have also been implemented in the machine control system. The add-on module CMM Simulate allows a finished CNC program to be sent directly from the office to the bending machine. Other new functions of the Bend Motion Control machine control system from Lang Tube Tec include automatic cycle time optimisation, an automatic set-up cycle and the control of access authorisation for operators, fitters and maintenance personnel via RFID chip. For more information: Lang Tube Tec GmbH Wullener Feld 52, D-58454 Witten Phone +49 (0)2302 9615-220, Fax +49 (0)2302 9615-230 info@lang-tubetec.com, www. lang-tubetec.com
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transfluid PRODUCTS & EQUIPMENT
Interview with Stefanie Flaeper, General Manager of transfluid Maschinenbau GmbH
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hat do the current trends in pipe forming and bending technology look like? Basically, we assume that there’s a higher demand than ever before for more flexibility in processing pipes. This is because it is foreseeable that there will only be large-scale series in the future. Production needs to adjust to these circumstances. In principle, this also applies to developments in bending technology. The demand for more dynamic production of complete kits featuring diverse geometries and diameters continues to increase. How is the general reception of software-controlled process optimisation with regard to industry 4.0? Connectivity is in constant demand in the most diverse areas. However, not every customer desires complete networking. In particular,
wherever data protection is involved. At transfluid, we are suitably prepared to implement the right connection and integration solutions. All controller adjustments have already been implemented with new control systems.
robot bender, it’s an extremely efficient and effective solution for processing long pipes with small pipe diameters. Of course, it is also capable of assuming handling tasks as well. Programming takes place according to XYZ coordinates, and CAD is able to be imported.
In which areas is robotics producing faster processes? Robots are certainly not the fastest solution in automation. We offer high-performance, linear handling systems in this area. However, robots can be used with high flexibility for a variety of components. Wherever transferring previously bent parts to further processing steps is involved, robots are the best solution in terms of efficiency Furthermore, the robot is sometimes can also become a bending machine , which makes it outstanding for implementing complex geometries. And as a
How sensible is it to retrofit older pipe processing machine to make them suitable for 4.0? Old bending machines are essentially able to be converted if they feature new controller components and these permit connection and controlling of processes. This is a basic requirement. Conversion of old systems to this standard is very questionable, and it depends completely on the individual case. If an older system only completes a rudimentary task in the process, an upgrade may be sufficient. In any case, and regardless of suitability for industry 4.0, new systems
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enable faster, better, and more economical processes. Plus, this is much more sustainable. What does a sustainable machine application involve, and what needs to be considered especially during maintenance and upkeep? Of course, it is important that service is easy to complete, downtimes are avoided, and that a supply of replacement parts is available to the customer or manufacturer. The service intervals need to be recorded, displayed, and acknowledged. Preventative service activities, e.g. via maintenance contracts, and predictive maintenance enable the life span and processing ability of systems to be improved significantly. In particular, predictive maintenance is more and more interesting for our customers to ensure long-term production and long life for their machines. 2017 has already indicated this trend.
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© transfluid
transfluid PRODUCTS & EQUIPMENT
Flexible production cell featuring bending robots and encoding transfluid develops an efficient bending system for short and long pipes
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hen the requirements are complex, a solution is required that provides dynamic and diverse results. And sometimes, this can also lead to several results, like in the case of transfluid Maschinenbau GmbH’s current project. In this case, the special developed automation system bends 6 m long pipes with small diameters at a consistently high speed. Simultaneously, the transfluid production unit is capable
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of producing shorter pipelines of 500 mm featuring diverse bending geometry in large quantities. Handling the coated pipes during the process is also demanding. Because of the sensitive surfaces, special care and treatment are required during processing. Chain conveyor and clever encoding To ensure that production can be implemented safely, quickly, and thoroughly, transfluid has equipped two robots that are used as bending machines with different magazines. One magazine is a so-
called “chain conveyor”. It guides long pipes to the bending robot. According to the markings placed on the pipes by the encoding beforehand, the robots are able to detect which geometries need to be produced. In this case, they are capable of bending a long pipe from one side to the centre. Following processing, the workpiece is placed on a slide. The bending cell also possesses a separate step conveyor. This feeds in short pipe lengths, including two different pipes if this is required. Depending on the case at hand,
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each robot processes a different geometry or pipes with another diameter. This enables a large series of short components to be processed efficiently at the same time.. Long components can be processed just as effectively For high versatility “An additional challenge for the development of our solution was that all the pipes have previously end formed ends on both sides or they already have cutting rings mounted ,” explains Stefanie Flaeper, General Manager at transfluid. “With robot technology,
© transfluid
transfluid PRODUCTS & EQUIPMENT
As with any conventional bending machine, the necessary data may be loaded into the bending robots with a data file directly from the CAD system and transformed into a bending geometry.
The bending robots are able to bend short and long tubes equally effectively. bending geometry may be started at an extremely short distance from the bend on both previously mounted ends. And the process, i.e.
preparing the ends first and then bending, is able to be implemented consistently for any pipe with this bending technique.” This makes prior processing of the ends significantly cheaper and faster . Because of this process, there are no geometric limitations, and the pipe canbe sealed beforehand with caps. This makes it immediately available for use after bending. Data file for bending directly from the CAD system In addition to flexibility,
an additional strength of the automation system offers another advantage that cannot be underestimated: The robots do not need to be programmed. As with any conventional bending machine, the necessary data may be loaded into the bending robots with a data file directly from the CAD system and transformed into a bending geometry. This makes the psychological barrier raised by programming a thing of the past. The systems are also able to be linked online with all relevant
measurement systems. To learn more about how to make pipe machining faster and more commercially effective, visit transfluid at the Tube 2018 trade fair in Hall 5 at Booth G34. Example-Video YouTube: https://www.youtube.com/ watch?v=48DzHy7B1Us Contact information: transfluid® Maschinenbau GmbH Hünegräben 20-22 D-57392 Schmallenberg www.transfluid.de
transfluid Maschinenbau GmbH
www.transfluid.net
© transfluid
transfluid is sought after worldwide as a partner for manufacturing tube bending machines and tube processing machines. transfluid has been developing its technologies for tube machining since 1988, so that it can provide customer-oriented, tailor-made solutions – for plant and machine construction, the automotive and energy industries, shipbuilding and medical device manufacturers.
One magazine is a so-called step conveyor. It guides pipes to the bending robot. www.internationalmetaltube.com
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WELDING
Accurate Stainless and Titanium Weld Purging with the PurgEye 200 ®
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uality Weld Purging is essential when welding metals such as stainless steel, zirconium, nickel alloys and titanium. The area around the weld must be purged of oxygen to as low as 50 parts per million (ppm) before, during and after welding to ensure all joints are metallurgically sound and oxide-free. To remain at the forefront of Weld Purging Technology, Huntingdon Fusion Techniques HFT® have launched the updated hand-held PurgEye® 200 Weld Purge Monitor®, now with PurgeNet™. Ron Sewell, Chairman for HFT® said: “The correct use of a Weld Purge Monitor®, designed and calibrated specifically for weld purging, will ensure that all welds remain free from oxidation and metallurgical imperfections.” “The PurgEye® 200 is designed and manufactured with the HFT® revolutionary PurgeNet™, allowing networking to a range of accessories. Typically, one
accessory allows direct interface to an Orbital Welder or any other automatic welding machine, so that the oxygen level in the vicinity of the weld can be monitored and the welding machine can be switched on or off according to pre-set oxygen levels. A second accessory is an audible and visual warning device that will signal externally when oxygen levels are lower and higher than pre-set levels.” The portable PurgEye® 200 has an OLED (organic light emitting diode) display, which will give brighter, clearer and sharper readings for viewing at greater distances than before and at wider angles. These OLED displays are mainly symbol based rather than text based, making the menus internationally comprehensible. The PurgEye® 200 operates either from long life rechargeable batteries or mains power. Charging can also be carried out from a dock (optional). Along with louder, pre-settable audio alarms for rising or falling oxygen levels, the PurgEye® 200
comes complete with a faster response long life sensor and integral electro-mechanical pump to extract samples from a weld purge zone, in the event that there is insufficient flow rate or positive pressure to activate the sensor
correctly. The PurgEye® 200 Weld Purge Monitor® reads down to 1 ppm (very accurate to 10 ppm). The Monitor is IP65 rated, which means it can be used in very demanding areas where instruments are used on site, such as in desert or tropical conditions. PurgeLog™ software also records Weld Purging results to provide quality control documents for each weld. The monitor also has the capability to switch between percentage oxygen and parts per million shown on the display. Huntingdon Fusion Techniques HFT® has a Worldwide Exclusive Distributor network, which can be found at www.huntingdonfusion. com. More information, please contact: Michaela Reay, Marketing Associate Huntingdon Fusion Techniques HFT® Press: michaelareay@ huntingdonfusion.com Sales: hft@huntingdonfusion.com www.huntingdonfusion.com
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WELDING
TPE, a tube manipulation and welded assembly manufacturer sets up a new web site
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PE, Stoke-on-Trent on 23rd of March ‘went live’ with their brand-new website, which includes both video and gallery show casing just some of the services the company has to offer. A family owned business, TP Engineering Ltd, based in Stoke on Trent, Staffordshire (UK) was founded in 2002 for the sub contract of tubular emission products for various leading trade names in the automotive industry. In 2013 the company formed the
division TPE to offer manipulated tube and welded assemblies for all industries due to increased interest. TPE manufacture and develop manipulated (bent) tube and welded fabrications from one off batch runs to low and high-volume production for all industries with the added extra of warehousing and distribution available if desired for JIT processes. They have the experience, expertise, tooling and capabilities to handle a diverse range of tube and pipe manipulation from 4mm – 100mm diameter. With the added capability of a 6-meter bed for sizes 4-30mm, ideal for extra-long applications, balustrades etc, 1d, twin stack, boost capability from 30-100mm and the advantage of left and right-handed machines up to 76mm. This coupled with the ability to offer various tube forming techniques, ranging from swelling, reducing, flaring, beading and flattening but to name a few in
materials ranging from Brass up to high grade Stainless Steel. In their 37,500 ft facility, fabrication welders carry out both MIG (Pulse) and TIG welding in various materials ranging from Braze to Stainless Steel. They also offer the capability of both automatic rotational, robotic welding cells and automatic tube cutting lines. The company has in house capability to manufacture fixtures / jigs ready for production. This enables them to cut costs and lead times for customers, a better service. With manufacturing operations approved to ISO 9001-2015 along with Conformity of Production approved by leading testing and development centres based in Spain, Germany and Poland,
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enforces the quality of their processes. Projects can span from Tier 1, 2 and 3 in the automotive industry to furniture and completed tubular frames for the food industry. Speaking on behalf of TPE, Director, Duncan Hall stated “Any two days are never the same, you never know what the enquiry is going to be for. But what we do is treat every enquiry the same, every enquiry is important, a project and we don’t just manage them, we live them. Information is key for our customers, it isn’t just price, quality and service, regular updates of what is happening is paramount. Even with best made plans we all know, customers’ demands of the project can change at any time, so having that direct contact with a flexible manufacture like TPE, helps.” If you have any specific need or would just like to find out more, please visit their new web site at www.tpengineering.co.uk and use the contact page to find email and phone number information.
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EXHIBITIONS
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EXHIBITIONS
Trade fairs are breaking all records: wire 2018 and Tube 2018 - bigger and more international than ever
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Photo by Messe Dusseldorf
he global economy is flourishing, and with it also leading trade fairs in the wire, cable and tube industries – wire and Tube Düsseldorf. From 16 to 20 April 2018 the two industry heavyweights will open their gates at the Düsseldorf Exhibition Centre while also celebrating an anniversary. For 30 years the two trade fairs have been impacting developments in their industries, both nationally and internationally. Both are held jointly every two years at the Düsseldorf Exhibition Centre, and their product areas – wire, cables and tubes – have now led to worldwide satellites in Russia, Brazil, China, Southeast Asia, the United States and India, as well as a joint venture in Iran. Moreover, the two leading Düsseldorf trade fairs have announced record figures – just in time for their 30th anniversary. Occupying a total exhibition space of 118,000 sqm, around 2,600 companies will be presenting everything that these industries have to offer in terms of technology and service. Featuring 1,419 exhibitors from 51 countries and a space of over 65,000 sqm (net), wire has grown
by around 6,000 sqm (nearly 10%) and has almost 100 more exhibitors than in 2016. The logistics and engineering departments are being challenged in Hall 13, in particular by the big mesh welding machines, as they require the installation and connection of thick cables in the service ducts. This is because the machines need focused voltage, rather than a voltage build-up. Tube, too, has grown rapidly and is now 2,000 sqm (3.8%) bigger than before. In total, 1,216 exhibitors from 57 countries will be present, filling a net space of 53,000 sqm. International diversity of exhibitors is continuing to grow, so that Tube 2018 will have six more exhibitors’ countries than the last event in 2016 (which had 51 countries).
These results confirm impressively that wire and Tube both have number one positions as the world’s leading trade fairs. wire 2018 will be held in Halls 9 to 16. On display there will be plants and machinery for the production and processing of wire, tools and auxiliary materials for process engineering, materials, fibre-optic technologies and special wires and cables. There will also be innovations in measurement, control and test engineering. Tube 2018 will take place in Halls 3 to 7.0, and also in Halls 16, 17 and 18. The range of showcased products will cover
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machinery and equipment for tube production, treatment and processing as well as raw materials, tubes and accessories. There will also be pre-owned machinery, process technology tools, auxiliary resources and measuring, control and test equipment. Furthermore, the line-up will include pipelines, OCTG technology, profiles and plastic tubes. This year, once again, 70,000 visitors are expected from around 130 countries. The latest information on the two trade fairs can be found on the relevant websites, at www.wire.de and www.Tube.de.
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EXHIBITIONS
Is laser cutting the light at the end of the tube?
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aser cutting machines are now being used for a wide range of projects across a number of industries, and the rise in usage of these innovative machines is showing no sign of slowing down. The tube and metal pipe sectors are no exception to this – relying on incredibly precise cutting methods to create products for a host of different uses. Bradley McBain, managing director of leading laser cutting and metal fabrication equipment supplier, MBA Engineering, discusses how laser technology has helped boost a range of industries by offering a number of unique benefits, specifically focusing on those which utilise metal tubes. The laser cutting industry has gone from strength to strength. And constant developments mean there’s always something bigger and better heading to the market – so what does this mean for companies that rely on accurate cutting methods? Some of the best laser cutting equipment offers accuracy of 0.03mm, making it the go-to method for projects requiring precise machining. This can apply to a range of industries, from food and drink to automotive and aerospace, but it is also incredibly sought after within the tube and pipe industry. With pipes being used to transport gasses or fluids it’s vital that they are manufactured to the most stringent specifications. For example, it’s imperative pipes used within the oil industry, including top tensioned and steel catenary risers, export lines and coiled line pipes, are cut very precisely to perform to maximum potential, making precision cutting to exact measurements a must. 34
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Another key example of the importance of accuracy when cutting tubes and pipes can be found within the nuclear industry for heat exchangers. These clever devices allow heat from a fluid to pass onto a second fluid, without the two mixing together or coming into direct contact. Usually, a hot fluid flows through a tube coiled inside a larger shell, with a colder fluid running through in the opposite direction. These must be manufactured accurately to ensure no contamination of fluids. Not only is it essential that tubes and pipes are cut accurately in terms of measurements, tubes requiring cut-outs also need to be produced to precise specifications. If there is a need for a metal tube with cut-outs, frequently used in the medical world, companies need to source a laser cutting machine that effectively create slots, scallops, V notches and tabs exactly where they’re needed without compromising the rest of the product. When it comes to accurate, precision metal cutting, industry professionals will struggle to identify a laser cutting solution that outperforms Kimla technology. Kimla laser cutting machines offer consistency – something invaluable to manufacturers everywhere, providing a reliable service where uniformity is key. A large quantity of uniform parts is a common order placed with metalwork manufacturers and these parts must be exactly the same. Compared to conventional tube cutting methods such as sawing, drilling or milling, which can leave a harsh or jagged edge, there is usually no additional finishing processes needed
when laser cutting as the cuts are clean. By removing these secondary finishing processes, manufacturers can generate huge savings in production costs, as well as potentially providing valuable extra floor space thanks to replacing separate laser cutting and finishing machines with one piece of equipment. Automation is another factor playing a huge part in assisting the tube world and forms a major part of Kimla technology. An automatic feed and offload system within a hybrid machine is a big step for the laser cutting industry and one that provides endless possibilities for tube and pipe cutting. Kimla’s advanced control systems also make the machines ideal for the tube and pipe industries. While the majority of competitor laser cutting systems only allow the user to control the speed and position of the laser head, Kimla’s control systems are much more sophisticated. They allow users to edit, correct, make geometrical changes, alter distribution and generate a laser path, all while continuing to work. Alongside this, the lasers use precision control technology
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to reduce inaccuracies, even at very high speeds. With all this in mind, what lies in the future for tube and pipe cutting? Kimla is already developing a new, innovative method of cutting tubes and pipes – a tube hybrid laser, which will combine flatbed lasers with the ability to cut tubes. These cutting methods will be shaping the way for tube and pipes, as they become more precise with even more intricate designs. The demand for these materials could increase as more uses are found for these metal shapes within a wider range of industries.
EXHIBITIONS
Beijing Essen Welding & Cutting moves to Dongguan Asia’s leading fair even closer to what’s happenings in the sector
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or the first time in its over 30-year existence, Beijing Essen Welding & Cutting will take place on the fair site in Guangdong / Dongguan from May 8 to 11. With this change, Asia’s most important trade fair for joining, cutting and surfacing technologies is moving even closer to the prospering market. Dongguan is one of the regions in the People’s Republic of China with the strongest exports. Because of the high international networking and the well-developed infrastructure, it will offer ideal conditions for a fair and will invite the visitors to make use not only of the proven service but also of a new ambience. This year, around 750 exhibitors from 20 nations will introduce
their products, achievements and services at Beijing Essen Welding & Cutting. The range on offer will extend from systems for computer-assisted fabrication via equipment for the processes in joining, cutting and surfacing technologies right up to the safety-
relevant equipping of workplaces and the measuring technology needed for exact working. In this respect, foreign companies will also have the opportunity to present themselves to the Asian market on numerous joint booths. Moreover, these will again include
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the joint booth of the Federal Republic of Germany which will be promoted by the Federal Ministry for Economic Affairs. Beijing Essen Welding & Cutting is being organised by Messe Essen, the Chinese Mechanical Engineering Society (CMES), the German Welding Society (DVS), the Welding Institution of CMES, the Chinese Welding Association (CWA) and the Welding Equipment Committee of CWA. Moreover, a large number of other international associations will support the event. With numerous forums, the trade fair will thus once more become an important communication platform for the exchange and transfer of knowledge and will strengthen specialist further education.
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EXHIBITIONS
SIKORA at TUBE 2018 Premiere of innovative measuring technologies for online quality control of steel tubes
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IKORA AG, with its headquarters in Bremen, Germany, is a manufacturer and supplier of advanced measuring, control, inspection and sorting technologies for the hose and tube, wire and cable, optical fiber and plastics industries. At Tube in Dßsseldorf, from April 16 to 20, 2018, the company presents for the first time a broad portfolio of innovative systems for nondestructive quality control and process optimization during production of steel tubes at its booth 6J32. S-WAVE 6000: Diameter and ovality measurement of steel tubes by means of millimeter waves based radar technology For more than ten years SIKORA has been successfully active in the plastics market. The applied technologies for quality control measure and control online product parameter such as diameter, ovality, wall thickness as well as eccentricity for the highest quality of the end product and optimal process efficiency during the production. The operator’s advantages that result from using SIKORA measuring systems, suggested the proven technologies to be transferred to the steel market. The SIKORA S-WAVE 6000 is based on progressive, high resolution radar technology and represents an innovative alternative to the optical triangulation technology. The advantage of radar technology is that reliable measuring values are generated even under difficult environmental conditions. Therefore, the automotive industry uses in the area of autonomous driving radar technology guaranteeing reliable measuring values under all weather conditions. The S-WAVE 6000 measures online and contactless, 36
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simultaneously from several directions the diameter and ovality of steel tubes. In addition, in this way fast rotating steel tubes can be precisely measured. The system requires neither coupling media nor a calibration. The temperature of the tube has no influence on the measurement. Due to the slim design the S-WAVE 6000 can easily be integrated in the production process in arbitrarily large distance to the tube. The S-WAVE 6000 is even able to provide reliable measuring values when the tube moves outside the center of the measuring head. The technology is suitable for blank, rough as well as cold or warm surfaces. Thickness measurement of steel plates by means of millimeter waves technology Radar technology based on millimeter waves additionally convinces with the measurement of the thickness of steel plates. Similar to the optical triangulation method the distances to the steel plates are measured at the top respectively at the bottom. The advantage is that the radar waves are directed over a reflector on the product to be measured, thus the radar transceivers carry out the measurement from a protected position. Dust, steam and even dripping water do not influence the measuring result. For this application as well, surface quality is no issue with the result that blank, rough, cold and warm surfaces are precisely measured. Wall thickness measurement of plastic coated steel tubes by means of X-ray and millimeter waves technologies At the Tube SIKORA also showcases systems for the measurement of plastic coated tubes on the basis of X-ray and millimeter waves
Wall thickness measurement of plastic coated steel tubes by means of X-ray technology
technologies. A plastic coating is among others applied at freely installed, underground and under water laid steel tubes for corrosion protection. For the joining of produced tubes compliance with specified dimensions for example for the wall thickness is essential. Therefore, for the measurement of the wall thickness of the plastic coating, SIKORA‘s X-ray based X-RAY 6000 PRO for tubes with a diameter up to 200 mm is used. For larger dimensions the previously described S-WAVE 6000 is used. Both methods are independent from the material of the product to be measured and the temperature, they do not require coupling media and no calibration. Immediately
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with the online measurement precise measuring values are accessible. These are visualized at the monitor of the processor system ECOCONTROL 6000 and allow the operator, if required, to intervene in the process for optimization. Thus, SIKORA systems are essential components to ensure the highest quality and an efficient process during the manufacturing of plastic coated steel tubes. SIKORA AG Bruchweide 2 28307 Bremen, Germany Phone: 0421 48900-0 Fax: 0421 48900-90 Email: sales@sikora.net Website: www.sikora.net
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