Russian boiler manufacturer Krasny Kotelshchik bends 90-m long tubes into membrane walls consisting of numerous 180° single bends.

Modern power-plant construction requires powerful machines that can bend challenging materials according to strict specifications. The large dimensions involved require particular structures in the bending process. Here, tube-bending machine manufacturer Schwarze-Robitec designed the CNC 60 DB Twin booster bending machine for the Russian company, complete with 90-m long tube magazine and supporting table featuring a 10 m radius. The machine was recently put into operation.

Modern power plants continuously supply the exact amount of electricity required to the grid. The higher the process temperatures, the higher the level of efficiency. Constantly starting up and shutting down the power plants leads to extreme fluctuations in temperature.

Boiler and power-plant manufacturers aim to maximise the surface area to ensure the highest level of heat transfer. Tubes therefore need to be bent in narrow radii and must fulfil strict tolerance specifications in terms of wall thinning and ovality.

Krasny Kotelshchik bends tube serpentines consisting of numerous 180° single bends in sequence. Each tube section alone is up to 10 m in length. As a result, the corresponding tube system cannot be rotated as a whole for each subsequent bend. Instead, the CNC 60 DB Twin booster bending machine supplied by Schwarze-Robitec bends in both directions using two bending heads. The bending head that is not required moves to the side under the tube system. For this reason, the machine is installed in a pit in the production hall.

Schwarze-Robitec has also set up a supporting table measuring 20 m in diameter above the pit and around the bending head. The tube system is laid out on the supporting table during the bending process. Krasny can thus avoid any unwanted deformations caused by the enormous weight of the tube systems.

For further information www.schwarze-robitec.com

LVD is this week commencing Insights 2020, a series of technology events, both virtual and live, taking place in the months through to December.

Insights 2020 kicks off with six virtual technology sessions covering topics such as adaptive bending, bending automation and fibre laser cutting over the course of three days (15-17 September).

The Insights 2020 platform is designed to provide sheet-metal fabricators with access to the latest technology and new product launches, delivering timely industry insights and intelligence to advance the critical business of sheet metalworking during these challenging times.

In addition to the September virtual events, Insights 2020 virtual technology sessions are scheduled for October, November and December. Each month delivers fresh topics, and all sessions offer attendees the opportunity to ask questions of technical experts in real time.

For those willing and able to attend in-person functions, live technology days at LVD’s Experience (XP) Centre in Belgium are 1½ day events providing an in-depth look at the latest technology, including new products for 2020, live demonstrations, interactions with technical staff and networking opportunities. Events are restricted to a maximum of 25 people, and increased safety measures are in place alongside all necessary health and safety protocols.

Insights 2020 technology days are scheduled for 27-28 October, 3-4 November and 25-26 November. New products will be unveiled at all three events.
For further information www.lvdgroup-insights.com/en_uk

Enhancements to Radan 2021 include many to the Radbend module. For instance, a new option improves collision checking during automatic sequencing.

Product manager Olaf Körner explains this is particularly valuable when bending long, thin parts such as guttering. “If the channel is particularly deep and bent in the wrong sequence, it could become jammed in the press brake, clamped around the tools. This type of part can be sequenced in such a way as to guarantee that collisions won’t happen.”

Radbend also now reduces handling when calculating sequences automatically, by lessening the need for tool and part rotations.

“Every time operators have to turn a part around, either by themselves or with a colleague, it takes time,” says Körner. “This new piece of functionality calculates a better sequence, meaning it can be fed into the machine in little steps, improving the handling.”

And the tool editor now shows important additional information by default, making it more user-friendly.

A number of items of new and enhanced functionalities have also been added to the Designer module. For example, Designer now indicates bends where the design radius differs from the expected result radius when using V-width as the unfolding method. This factor is important for the unfolding process, and the finished look of the component.

Feedback is now provided on overlapping unfolds, as Körner explains: “Sometimes, when a 3D model is unfolded, it doesn’t work – faces clash on top of each other. The user is now notified of this and shown the issue graphically.”
For further information www.radan.com

The folding of sheet metal can be automated using a new bending centre from Bystronic.

With the new solution, it is said that users can lower production costs, boost accuracy and consistency, and at the same time increase flexibility for dealing with small to large batch sizes.

‘Bending Cell’, as the system is known, is based on the company’s Xpert Pro press brake and is served by a seven-axis robot that is able to cope with a wide variety of component sizes and shapes. A gripper changer, tool changer and magazine, and material storage unit may be either factory-fitted or retrofitted at a later time, allowing not only component handling but gripper and bending tool exchange to be autonomous. The modular system enables existing Xpert Pro machines in the field to be automated.
Intelligent offline programming software saves time by determining the optimal bending sequence for every job. Moreover, the program for the next order can be downloaded without interrupting the current process.

While the robot is bending, staff can perform other tasks such as the supply and removal of sheet and parts, or operating a laser-cutting machine or welding system. The cell is simple to use, as both the robot and press brake are controlled using the same touchscreen. Importantly, the ByVision Bending user interface provides the user with an overview of the current job status and remaining production time, even on mobile devices (optionally).

Bending Cell is available as a turnkey automation solution for Bystronic’s Xpert Pro 100, 150, 250 and 320 press brakes. Maximum press capacity is 320 tonnes and bending length is up to 3 m. Five robot types are available with handling capacities ranging from 90 to 270 kg.

For further information www.bystronic.co.uk/en_uk