AccuForm
Modular Double Head Bender, AFM-xDHx
AFM-xDHx Machine Description
The AFM-xDHx line of equipment is designed with the old four-slide
technology in mind but without the time consuming intricate setups,
costly tooling and the need for an expert operator. The DH in the model
number stands for “Double Head” which means that the machine has two
individual bending heads. Each bending head positions along a straight
wire and bend it according to pre-programmed data.
A wire feeder module feeds the wire through a straightener and cuts to
user pre-defined lengths. These straight pieces are placed in a hopper
mechanism, which supplies the benders. An automatic gripper, that
optionally (3D option) can rotate, holds the straight wire while it is
getting bent. After the part is complete, it is ejected to a part
holder or an optional robotic “Pick & Place” arm. The AFDH machine has
three independent coordinate systems, or four with an optional Welding
Module:
The Feeder / hopper coordinate
The Left Bender and Slide coordinate
The Right Bender and Slide coordinate, and
The Welding Module coordinate.
Since all coordinate systems are independent to each other, they all
can work simultaneously, synchronized by a master, which is the Feeder
Module coordinate simply because all of them need wire. Although the
above seems complicated our SmartEditor™ software generates the
algorithms needed by the motion controller automatically. We have built
an algorithm that builds motion algorithms!
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, machines’ construction is
exceptional. Since extreme speeds can be accomplished, the main frame
is constructed out of solid steel plates that incorporate special
granite with epoxy resin in order for improved stability, minimizing
vibrations and increasing speed and accuracy of the equipment. The
weight of the Double Head Bender Module is approximately 5500 Kgr.
(12,000 Lbs.). Using the latest technology linear servomotors, the
bender slides can accelerate up to 4½ G’s, depending on installed
options.
For common features please read our page: Common attributes for the
majority of our equipment.
The
turret option (-T) adds one servo axis per bending head, for automatic
and programmable bending tool-changer along with a second bending pin.
This provides the flexibility to program changes in the bending tool
mandrels, making available four 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.
Technical Specifications
- Size 1: Each plane consists of 9 “V” groove roller
bearings; 5 are stationary and 4 are adjustable. Two different
diameters of rollers allow straightening a wider range of wire
with just one straightener. Wire range is: 2.7 - 8.0 mm
(0.106”-0.315”)
(*) For wire diameter smaller than 2.7 mm (0.106”) a mini
straightener option is recommended.
- Size 2: 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 straightener. Wire range is: 4.0 -12.0 mm
(0.157”-0.472”)
- Size 3: Each plane consists of 14 “V” groove roller
bearings; 8 are stationary and 6 are adjustable. Two different
diameters of rollers allow straightening a wider range of wire
with just one straightener. This size straightener has a built-in
Anti-Torsion system. Wire range is: 6.4 -16.0 mm (0.250”-0.630”)
For all of the above, wire linearity is <= 1:1000 at 6mm wire
diameter.
|
Wire Feeding Device:
Used for the feeding and positioning of the wire.
- I. Size 1 & 2:
Consists of four rollers (all driven), one wire guide,
sprocket-belt reduction unit, Hi Torque Drive (HTD) Belts and one
brushless servomotor.
- II. Size 3:
Consists of eight (8) rollers (all driven), one wire guide,
sprocket-belt reduction unit, Hi Torque Drive (HTD) Belts and one
brushless servomotor.
|
Bending Heads, Hopper and Cutting unit: Each bending head is
an independent system controlled by a bend axis and a linear position
axis capable of reaching speeds of up to 5m/s and acceleration rates of
over 4 g’s. Each side, left and right, belong to independent coordinate
systems for production flexibility and speed. They can be synchronized
or programmed completely independent.
On the Turret version, the bending heads and tool clusters are supplied
with both hard and roller pins.
Linear slide Max. Slide Distance: 1780 mm (70”) Slide speed: 5 m/sec.
Resolution: 0.01 mm (0.0004”) Drive: AC brushless linear servomotor
Bending unit Max. Bending angle: +/- 230º Bending speed: 1600º/sec.
Resolution: 0.01º Drive: AC brushless servomotor
For size 1 we use a pneumatic actuated cutting system. For sizes 2 and
3 we use hydraulic cutting system, providing reliability and longevity
for high tensile and heavy cutting requirements. The location of the
cutting unit is manually adjustable in order to provide flexibility on
the production setup. It cuts the wire to a pre-programmed length and
then feeds it to a hopper.
*(Optional: 3D) Rotating Clamp: Constructed of heavy-duty tool
steel, rotates the wire when fed into the unit at 700˚/s. The rotating
clamp holds and rotates the wire around the center of the bender, thus
enabling the generation of three-dimensional parts. Maximum part length
with a 130° bend is 70” measured from the bend point to the side of the
rotating clamp.
Max. Clamp Rotation: 230° Precision: +/- 0.025°
Drive: AC brushless servo motor Transmission: Precision planetary
gearbox & belt.
Wire Payoff Turntable: Automatic wire feeder with a Rotary
Straightener option is available and includes a 4400 lbs capacity
powered payoff unit, pre straightener, length measuring device cutting
unit and straight wire transfer mechanism.
- Size 1 & 2: 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, adjustable
tension for dancer control arm. Speed range: 5-70 RPM, Rotating
base Ø: 1140 mm (45"). Heavy-duty construction with oversized
tapered bearings, assuring maintenance free operation. All
electrics are supplied from main electrical cabinet; there is no
need for a separate electrical connection box.
- Size 3: Model P270-75 Fully Automatic Powered Payoff
Unit, capable of handling coils weighing up to 2700 kgs (6000
Lbs). 7.5 Hp AC motor, Automatic speed control, Adjustable
tension for dancer control arm, Speed range: 5-50 RPM, Rotating
base Ø: 1900 mm (75"). Heavy-duty construction with oversized
tapered bearings, assuring maintenance free operation.
|
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.
|
|
