Machine manufacturers Gehring and Wafios are pooling their expertise to offer the global automotive industry complete turnkey production lines for hairpin stators.

The first step towards the new network arrived in November 2020, when the family-run Nagel Group took over machine manufacturer Gehring, which further strengthened its role as a technology partner for electro-mobility production systems. The next important step is intensive co-operation with forming specialist Wafios. Together, Gehring and Wafios will be developing stator assembly lines for important automotive locations worldwide, from initial idea to commissioning.

The co-operation combines Gehring’s decades of experience in designing systems for automotive series production and Wafios’ technological leadership in the field of straightening technology and wire forming, which is particularly important for the production of hairpins.

The low cycle times of high-volume production, in which electric motors are produced in under one minute, is a major challenge for stator production and its very complex wire-bending processes.

Says Tobias Single, head of E-mobility at Wafios: “We have mastered this complexity and can offer efficient, process-capable and futureproof solutions on the solid basis of our existing know-how. In addition, the bending process contributes significantly to quality: anything that we do at the beginning, whether right or wrong, makes the processes further down the line easier or more difficult.”

This is where Wafios comes on board as the right partner for Gehring, because the company’s FMU E bending machine has already proven itself many times over in the small series production of hairpins for the automotive industry.

For further information
www.wafios.com

Automation, increasingly networked machines, and changes in the automotive industry: tube-bending machine manufacturer Schwarze-Robitec is strategically repositioning itself in view of changing market requirements. With Heike Ahlers as head of strategic sales and marketing, and Philipp Knobloch as global sales director, Schwarze-Robitec is entering the future with two experienced sales experts and longstanding employees in new roles.

“In view of Industry 4.0, increasing networking and the trend toward automation, our customer markets are changing at breakneck speed – and with them, our sales process is changing,” explains Ahlers. “The sale of complex and customer-oriented machines and systems needs a high level of customer and market knowledge, and requires a holistic understanding of different customer demands.

Adds Knobloch: “We are aligning ourselves with the market even more than before and want to grow more strongly. Individually configured special machines and customer-specific solution concepts are becoming increasingly important. This is an exciting task for me and my dedicated team.”

Both sales experts have been closely associated with Schwarze-Robitec for years. Ahlers joined the business development department in 2013 and was instrumental in setting up the company’s US subsidiary in 2015. Since 2016, she has been head of sales and marketing. Philipp Knobloch, who joined Schwarze-Robitec in 2014 as junior sales manager, most recently spent four years as sales manager responsible for sales at national and international level.

Managing director Bert Zorn is confident about the future: “With our dedicated sales team headed by two experienced experts, we are well prepared for challenges that arise in our customer markets.”

For further information
www.schwarze-robitec.com

A British-built Unison Breeze all-electric tube bending machine will soon be assisting Milltek Sport Ltd, a manufacturer of performance exhaust systems, in exhaust prototyping and development work at Germany’s world-famous Nürburgring racetrack.

Derbyshire-based Milltek invested in its first Unison Breeze machine, a 76 mm (maximum tube diameter) capability single-stack model, almost 10 years ago. A second Unison Breeze machine, an 80 mm multi-stack tube bender, followed in 2017.

The latest Unison Breeze machine to be purchased by Milltek – an 80 mm single-stack model – will be located at Milltek Sport GmbH, the company’s recently opened €1.5m development and testing centre in Nürburg. It will be used for exhaust system research and development, small production runs for some of the world’s leading high-performance cars, and custom tube manipulation work for several race teams.

As Milltek uses only highly robust T304L stainless steel for its exhaust products, the all-electric Breeze’s ability to successfully complete tight bends in thin-wall tube down to 1D radius, as required for many of today’s high-performance exhaust systems, was a key factor in the purchase decision.

“Investing in this 80 mm Unison Breeze machine will allow us to further expand the capabilities we have on site in Germany, as well as better cater to the growing demand for 80 mm diameter performance exhaust products,” says Milltek Sport’s managing director, Steve Pound. “Whereas, up to now, we’ve sent CAD designs from our German facility to our HQ in Derbyshire for prototyping, we’ll soon be able to design, prototype, trial and then complete batch and small production runs on site at the Nürburgring.”

For further information
www.unisonltd.com

Glenrothes-based precision sheet metalwork manufacturer, Fife Fabrications, has invested a significant six figure sum in new technology as part of its ongoing growth plans. This investment in its fifth E-Brake press brake, the SafanDarley E-Brake 130-3100 Ultra, will further build its capabilities and services to facilitate future growth.

Installed in March 2021, the machine features lifting aids as a safety feature for managing larger panels and a bigger opening height to form taller flanges or parts. Like all E-Brakes, the Ultra will be fully integrated into the company’s ERP system.

Fife Fabrications’ managing director John Penman is pleased to be investing in new equipment to enhance and supplement its precision metalwork technology offering with the addition of the E-brake Ultra.

“Fife Fabrications has always been focused on continual investment in lean technology, people and ordering processes, which means we can provide the lowest possible overall cost to customers,” he says. “The timing of this investment will facilitate many learning opportunities for staff, trainees and apprentices at Fife Fabrications, offering clear benefits to our team, as well as to customers.

“The aim is to further build our capabilities and expertise, and continue providing customer service that is a cut above,” continues Penman. “It also supports our investment in developing young talent to further support the upskilling of young people in Fife. This helps to address the skills gap in our industry and in Fife more generally, as well as creating a pipeline of young talent for our business. Our investment in state-of-the-art technology from SafanDarley, with tooling from Wilson Tool, will ensure our services can move to the next level and increase our capability to design and deliver the highest quality products for customers.”

For further information
www.safandarley.com

The new Morgan Rushworth EXR multi-beam folding machine is now installed in the Bison Machinery showroom for demonstrations and product trials. The EXR is said to be an extremely versatile folding machine fitted with a rotating top beam to allow both straight and box and pan folding, even within the same part.

The Morgan Rushworth EXR range of CNC folders features a rotating upper beam with one straight rail and one set of high divided tools that can both be utilised in the same folding program without any manual tool change. Such a versatile design enables high accuracy, high consistency and high productivity as there is only one initial tool set up to carry out. This configuration is suitable for many folding operations, including rectangular panel work with return edges to the four sides. The operator sets the program, folds the two long lengths with the straight rail, before the upper beam rotates automatically and the two ends are folded with the high divided tools.

The back gauge is integral to the rear support table, which is suitable for the folding of large sheets as the weight of the material is supported, resulting in a single operator performing traditional two-operator jobs. The standard 2D touchscreen CNC controls all upper beam clamping and rotating, folding beam and back-gauge movements, with an optional 3D touchscreen available to further assist the operator. Both controllers provide a view of the folded part, calculating whether the job is possible or not, the developed length and the bending sequence – including whether to turn material over or around.

Features of the EXR folding machine include: bending angle from 0-150°; 20° 1 mm sharp nose clamping beam rail with 25 mm clearance; 10 and 25 mm wide folding beam rails; and fast 1 m powered back gauge.

For further information
www.bisonmachinery.co.uk