Fully automatic, integrated complete machining:
Sawing, deburring, punching, doming, flattening and unloading of tubes in one machine
The companies RSA cutting technologies GmbH, Schwerte and sema Systemtechnik GmbH & Co. KG, Hüllhorst have developed and successfully brought into operation an integrated high performance machining center for sawing, deburring, punching, doming, flattening and unloading of tubes made of steel and square and rectangular tubes for the PERI GmbH, Weißenhorn. PERI represents constant innovations in the scaffolding technology and formwork and is one of the world’s largest manufacturers in these areas. Comprehensive and individual comprehensive solutions with tailor-made logistics-, service and engineering performances
PERI-performance requirements completely satisfied
The challenge was to be able to produce individual scaffolding parts as well as shuttering props with the sawing and machining center much faster than before. Up to now there were individual processing stations for each process together with set-up times of up to 30 minutes. The aim of the new line was to connect all processes in one system and to reduce the changeover time to less than 5 minutes, which is now being successfully implemented in daily operations at PERI.
Unique new development
The modular and therefore adaptable and extensible sawing machining center has a RSA developed, standardized and user-friendly operating concept that allows a programming of all stations - incl. punching, doming and flattening unit of the company sema – via one single control system.
In general, the machining center is characterized by a particularly efficient chaining of different processes in one single system with shortest processing times. For example, the cycle time incl. all single processes like rod feeding from the magazine, sawing, deburring, double-side punching of up to 8 holes for a steel tube 48,3 x 3,25mm in record-breaking 6 sec!
In the same low cycle time, alternatively a tube of 38 x 3,2mm can be punched and domed from one side.
This is not achieved by high-prices special tools, but with a thoughtful and fully optimized overall process, which allows parallel processing steps. For instance, standard HSS saw blades are used on the RSA saw, which can be reground up to 15 times. The punching units get by on standard tools. In total, a warrantor for low unit costs.
High performance machining module consistently controlled
Key component of the new system is the single cut high performance saw RASACUT SC of RSA, supplemented by the fully automatic deburring system RASAPLAN and the custom-built punching and doming unit of sema as well as the unloading unit RASAPORT of RSA.
The punching and doming unit of sema (the technical term doming means the mechanical, chip less preforming of a rounding, in this individual application to slot pipes easily together) can optionally punch each tube on one or both sides at different tube positions with up to 4 clearance holes and can deform the end of the tube via doming unit. The punching of blind holes is also possible. The modern programming and control system allows different hole patterns. RSA produced a higher-level control for the special system, whose user-friendly operating concept includes all plant modules, which also have their own control systems.
Another feature of the sawing and machining center is that round, square and rectangular tubes, which should not be punched, are guided through the punching unit without a reduced output. For this purpose, belt transports are used in the area of the punching unit.
The modular overall concept of the sawing and machining center also allows the integration of further modules – among other things measuring, washing, drying and marking. The top technology partners of the Tube Innovation Days (www.tube-innovation-days.com), to which belong RSA and sema, have for each machining and processing task in the tube production and processing the appropriate solution. Here, the uniform operating concept remains avaliable. The sawing and machining center is unlimited industry 4.0 compatible. It can be fully operational networked with EDP/BDE-systems to manage, for example, customer products, to report plant conditions, to remind maintenance, to request raw materials or to report the finished material development.
High performance plant components
The equally universal as precisely applicable high performance single cut saw RASACUT SC of RSA covers a wide tube diameter spectrum with high output and minimal set-up times. For example, changes in length and blade change are done in less than 1 min., format change in less than 5 min. Stopper and saw blade are positioned fully automatically. A high cutting quality by the variable feed at the tube inlet and outlet as well as the precise, fast and surface-friendly material clamping via presetting of force and way are further characteristics.
The fully automatic brush deburring system RASAPLAN of RSA for simultaneous inside and outside deburring is also designed for a high output. When changing a diameter or length section, any set-up time is omitted because the necessary settings are made automatically. Reproducible deburring results in very short time as well as the gentle handling of the workpiece surfaces are of primary importance.
When developing the sema punching and doming unit, the focus was also on the shortest possible cycle times and maximum flexibility. In contrast to previous systems, not the tube but the tool is highly dynamic processed. Thereby, a higher accuracy of punching to each other is achieved with tighter tolerances. To achieve the greatest possible flexibility of the tube length at minimum set-up time, a tool side can be driven and positioned via a servo drive. All prescription data is stored in the overall control and can be easily selected in the control panel.
The integrated doming unit for forming of the tube ends is modularly integrated into the total installation. When selecting, it is pneumatically driven and locked in the working position. The punching and doming unit is thanks to their modular design, flexible configurable according to different customer requirements. So the flattening and simultaneous punching of tube ends can be carried out via additional modules.
When flattening, the beginning of the tube and its end are flat converted and simultaneously a hole is punched, e.g. to manufacture typical antiroll bars for staging.
For the unloading of the finished tubes the RASAPORT AS is responsible, a belt trough of RSA with lowerable belts. According to the filling level, the belts are let off. For the adaption to the different lengths of tubes sections, the belt trough has movable side stanchions. The unloading via portal or industrial robot is also possible.
Individual system concepts possible
Both RSA and sema are by their decades of experience in tube production and processing and due to well-proven common interfaces able to develop a unique system concept that can integrate ten or more machining processes in one fully automatic process. Michael Braetz, Managing Partner, sema Systemtechnik GmbH & Co.KG concretizes: “The modular structure of our tube processing system allows an adaption and future expansion to special current and future requirements. For production costs, which meet the most strictest requirements. And even with a large variety of part, high production rates can be achieved, not least by very rapid changeover procedures“.
