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AccuForm
Modular 2Dx, Tilting Table, with integrated Indexing Tool changer
The AFM-2Dx line of equipment is
designed with the old four-slide technology in mind but without the
long-lasting intricate setups, costly tooling and the need for an
expert operator. The AFM in the model number stands for “AccuForm
Modular” which means that the machine can be configured in Modules.
The basic version of the AFM-2Dx line has a feeder module and a bender
module. Each module provides its own operation but all modules are
controlled and synchronized from the same computer system. On the
AFM-2Dx line, the computer system is mounted on the Feeder module.
The feeder module is feeding the wire, through a straightener, to the
Bender module. The bender mechanism bends the wire, according to
pre-programmed data and “shears” it with an integral hydraulic cutter.
The turret option (-T) adds one servo axis to the Bender module, for
automatic and programmable bending tool-change along with a second
bending pin. This provides the flexibility to programmatically change
the tool that the wire is getting bend on, making available 4-8
different bend radii. Two Bending pins are available with the turret
option; usually one is a roller for generated radii and the other is a
hard pin for “tight” bends.
 Optionally, additional modules can be added to the configuration of the
machine depending on the specific production requirements, for example
in-line Chamfering Module (AL1) or in-line die module (AD1). Plenty of
modules are available and our engineering team is creating more every
month in order to satisfy every request from our customers. Please
refer to the Modules & Accessories pages for more options.
In order to get familiarized with our concept of wire bending and to
better understand the principals that we use, we will describe a simple
right angle, 90-degree wire bend operation with the following steps:
The feeder module feeds the first length of our wire sample
The bender is positioning to be ready to operate at –30 degrees
position.
The Turret is positioning to the pre-selected tool position
The bending Pin engages
The bender locates at the required position in order to provide a
90-degree bend to the wire.
The feeder feeds the second length of our sample part.
The cutter “cuts” the wire.
The above steps are really simple and also familiar to anyone that has
worked with wire bending. In conventional programming, a CNC user would
have to enter in a computer, all of the above steps individually. Now
let’s try to speed up the above production: We need the first four
steps to be done at the same time and we do not want to worry where we
have to position the bender (besides the fact that we need a 90 degree
bend). Although this would seem complicated, our SmartEditor™ software
generates the algorithms needed by the motion controller automatically.
We have built an algorithm that builds motion algorithms! All of the
above steps can be represented with just three numbers and a bend
radius (tool selection). The user programs what he or she needs to do
and not what needs to be done!
The user simply enters lengths and angles that comprise the desired
part and SmartEditor™ does all the rest. User intervention is allowed
if an intricate operation is required as well as absolute coordinate
programming, for the more advanced users, where one can enter the exact
steps of the equipment.
Besides the simplicity of the programming, exceptional is the machines’
construction. Since extreme speeds can be accomplished, the main frame
is constructed out of solid steel plates for improved stability,
minimizing vibrations and increasing speed and accuracy of the
equipment. The weight of the AFM-2D2 is approximately 2000 Kgr. (4,500
Lbs.). Using the latest technology servomotors, the feeder and the
bender can rapidly accelerate to maximum speeds, and depending on
installed options, provide the fastest production rates in the market.
For common features please read our page: Common attributes for the
majority of our equipment.
 AFM-2Dx Details:
For Wire Detail Specs please see: Wire diameter Range,
Wire Tensile
Strength Capacity
 (1.3) Two Plane Wire Straightener:
Every machine is equipped with a two-plane wire straightener.
On size #1 machines each plane consists of 9 “V” groove roller
bearings; 5 are stationary and 4 are adjustable.
On size #2 machines each plane consists of 11 “V” groove roller
bearings; 6 are stationary and 5 are adjustable.
Two different diameters of rollers allow straightening a wider range of
wire with just one set of straighteners.
Please consult table for applicable tensile strength / diameter
properties.
(1.4a) Wire Feeding Device:
Used for the feeding and positioning of the wire. Consists of four
rollers (all driven), one wire guide, sprocket-belt reduction unit, Hi
Torque Drive (HTD) Belts and one brushless servomotor.
Feed Speed: 120 meters/min.
(1.4b) Wire Length Measuring Device
Used as a feedback for the wire positioning. Consists of a pair of
rollers: one stationary and one with adjustable pneumatic load. The
stationary rollers directly coupled through a flexible coupler to an
incremental rotary encoder providing accurate position feedback to the
servo controller.
(1.7) Bending Head and Cutting unit:
On the Turret version, the bending heads and tool clusters are supplied
with both hard and roller pins.
Max. Bending angle +/- 230º
Drive AC brushless servo motor
Transmission Precision planetary gearbox
The cutting unit is hydraulic, providing reliability and longevity for
high tensile and heavy cutting requirements. Double acting hydraulic
cylinder is used for minimum maintenance (no spring return).
(1.1) Hydraulic Unit:
Used for supplying high-pressure oil to the wire cutter. Consists of
- 20 gallon Oil tank:, with sight glass and oil filter
- Electric motor 5Hp, Size #1 or 7Hp, Size #2, 5 g.p.m. / 1600 PSI
hydraulic gear pump
- double solenoid valve and a pressure relief valve (factory preset at
1600 PSI)
 (1.6) Tilting Bender Frame:
The Bender module table is made out of heavy steel plates covered by
steel sheets, providing increased stability and dampening over
vibration. The front-top is covered by a 7-gauge stainless steel sheet
metal. The main body can tilt to positions between 0° and 90° with two
electric brake high-ratio gear motors. This offers flexibility to the
user when it comes to large parts production. For smaller parts the
table can be tilted to 60 or 90 degrees for easy collection to a
container or conveyor.
Wire Payoff unit (Turntable):
Model P270-5 Fully Automatic Powered Payoff Unit, capable of handling
coils weighing up to 2000 Kgr. (4000 Lbs.) 5 Hp AC motor, automatic
speed control with AC Vector Drive, adjustable tension for dancer
control arm. Speed range: 5-70 RPM, Rotating base Ø: 1140 mm (45").
Heavy-duty construction with oversized tapered bearings assures
maintenance free operation. All electrics are supplied from main
electrical cabinet; there is no need for a separate electrical
connection box.
(1.2) Utility Requirements: USA:
480 VAC, Europe: 380 VAC, 3 Phase 50/60 Hz, < 1 CFM air supply.
(1.5) Computer: Industrial Panel
PC, Integrated acoustic wave touch panel (SAW), LCD color monitor 15”,
industrial sealed keyboard with integrated pointing device, high
capacity storage hard drive (40 GB), 3.5” floppy drive, CD-ROM, 56k
modem, Fast Ethernet network ready and video camera for machine
monitoring, videoconferencing or service. Operating system is Windows®
XP Pro.
Additional Features:
- Modular frame construction for easy field installation of
accessories.
- SmartEditor XP Pro® programming, office version
available for off-line programming.
- Dual processor allows concurrent production and programming
new parts.
- Instant Production Statistics for estimating.
- “Dial-A-Service” tech support via modem or Internet.
- Optional extra I/O’s for auxiliary equipment.
- Bender Tool changeover in 8 minutes. Highest overall forming
speeds in the industry.
- CAD import of DXF files directly into SmartEditor programming
software.
- 2-year limited parts and labor warranty.
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