Technology Advances Ensure Accurate Fabrication and Bending of Tube and Pipe
The integration of AI, machine learning, and automation in tube and pipe fabrication signifies a major leap forward in manufacturing technology.
Posted: August 28, 2024
Technology advancements in metalworking processes promise to enhance efficiency, improve product quality, and reduce operational costs. As technology continues to evolve, we can expect further innovations that will push the boundaries of what’s possible.
New Square and Rectangle Plug Assemblies for CNC Tube and Pipe Fabrication
Bend-Tech (Osceola, WI), a leading developer of versatile CNC plasma-cutting equipment and integrated software for tube and pipe fabrication, has introduced new square and rectangular plug assemblies for better-quality cutting of non-round tube or pipe. The plugs are designed for Bend-Tech’s Coolant Support System. The plug assemblies are available in a variety of shapes and sizes and feature a durable plastic frame with a replaceable rubber gasket.
The plug assemblies are designed with a wingnut which, when tightened, exerts pressure to expand the flexible gasket. This creates a secure fit inside the tube or pipe. The coolant hose then connects quickly and securely to the plug. The plugs help CNC tube and pipe plasma cutters produce a clean, quality cut with less slag and dross build-up, and minimal clean-up prior to welding.
Bend-Tech’s square, rectangular, or round plug assemblies are ideal for fabricators working with aluminum and stainless-steel tube and pipe with a smaller outside diameter, such as handrail fabricators, automotive fabricators, oil and gas and others. With plug assemblies that fit their material, operators can confidently and easily flow coolant through tubes and pipes for a better-quality cut.
The plug assemblies are designed and manufactured at Bend-Tech in a range of widths and heights. The company is currently receiving orders for standard- and custom-sized plug assemblies, with an average turnaround of approximately two weeks.
Straighten, Shape, Bend and More with Tube Forming Machine
BLM GROUP’s (Novi, MI) 4-RUNNER H1 straightens, shapes, cuts and bends, with compression or variable radius method. It can perform multi-radius right-hand and left-hand bending operations and can work diameters up to 12.7 mm (.5”) from coil. The system is particularly suited for making flat and three-dimensional serpentines; these parts are typically used in the refrigeration, HVAC, automotive and household appliances industries.
It can be equipped with either a heavy end-forming module with six ram or four ram stations and one rotary station featuring either an external orbital or disc cutting system; or a light end-forming module with three ram or one ram and one rotary station.
All machine movements are managed by an electric axis with all part positions and power parameters saved together in the part program. No additional mechanical adjustments are required, helping the system achieve both fast setup and accurate positioning of all production phases and maximum repeatability.
BLM GROUP demonstrated the capabilities of its 4-RUNNER H1 tube forming machine, highlighting its ability to de-coil/straighten, bend, end form, and cut from coil stock all in one piece of equipment at a past trade show. The 4-RUNNER H1 processed two different heat exchanger-type parts suited for HVAC or refrigeration equipment, highlighting the system’s serpentine bending capabilities as well as its ability to perform multiple processes on one machine. Both tubes included multiple bend radii and end forming of one end of each tube: an expansion, and a bead form.
Split Frame Machine Squarely Mounts on Tube and Pipe O.D.
A new clamshell style split frame machine that is easy to set up on site and can be precisely aligned and attached quickly without shims or guesswork is offered by Esco Tool (Holliston, MA).
The Esco COHOG® Split Frame Machine is easy to set up using indexable tooling and squares itself to the pipe O.D. with clamp legs that securely provide eight points of contact. Featuring a robust stationary ring that is machined from 7075 aluminum, which is hard coated for maximum strength and stability, this robust machine offers smooth cutting action on any material.
Featuring clamp pads that each accommodate four different pipe sizes using one set of pads, the Esco COHOG Split Frame Machine incorporates a one-piece module that mounts to the tool slide and holds a pre-angled bit of 30º, 37-1/2º, or custom angles. Most cutting inserts have multiple cutting edges, are simple to replace, and yield more cuts per blade and lower cost.
Perform Perfect Hole Cutting, Increase Throughput, and Perform Fewer Secondary Finishing Operations
Significant time savings and cutting accuracy can be achieved when cutting pipe and vessel heads with HGG Profiling Equipment’s (Houston, TX) SPC 1500-3000 PT/VC cutting machine, which is designed to completely automate layout, marking, cutting, beveling, and grinding profiles from 3” to 118”. By simply importing the customer’s specifications into HGG’s proprietary ProCAM software, the entire tape measure-paper drawing-chalk markup pre-cut practice is eliminated as is the time required to complete those tasks. Customers have realized up to 90% reduction in time due to the machine’s FitPerfect technology which was developed especially for pressure vessel and vessel head cutting. Featuring a longitudinal and transversal axis designed to create a perfect circle in one plane, holes can be cut without rotation of the vessel resulting in accurate perfect hole. The height axis adjusts the cutting torch to the fluctuating level of the material surface while the AutoFocus Robot performs beveling along the cutting path, safeguarding the true dimensions of the hole. The result is a perfect and smooth weld preparation along the fit line of the nozzle hole connection. This is especially beneficial to shops handling thick-walled profiles, where weld volume reduction is key.
The SPC 1500-3000 PT/VC machine provides a clean operation using plasma or oxyfuel to perform the programmed cuts and is capable of ink, punch, and plasma marking depending on the application. Difficult-to-cut holes such as hillside holes, saddle set-in holes and hole set-in for pressure connections are cut quickly and easily with the weld prep performed by the patented Autofocus Robot incorporated into the machine.
Additionally, by automating the vessel cutting process, production time is reduced which can, in turn, reduce on-site labor costs by as much as 30%. This is good news for shops that are experiencing skilled labor shortages. The machine is simple to learn and easy to use, freeing up personnel to perform other operations such as nozzle fitting and welding.
“The SPC 1500-3000 PT/VC machine provides accurate and clean cutting, virtually eliminating secondary operations such as grinding that can result in worker injuries and downtime,” said Brandon Welch, HGG area sales manager, U.S. “Custom features such as powered and non-powered support systems, rollers and extra options on the machine like the pre-heater for thick-walled profiles help to speed up process time and physical labor to cut holes manually on large vessel pieces.”
Industry First: AI, Machine Learning Computer Vision for Arc Welding of Pipe
Novarc Technologies Inc. (North Vancouver, BC, Canada), a full-stack robotics company specializing in the design and manufacturing of cobots and computer vision AI for automated welding applications, has launched NovEye Autonomy (Gen 2), a real-time vision processing system that constantly improves weld quality based on data collection and model enhancement to fully automate the pipe welding process while maximizing productivity and delivering the highest quality welds.
“NovEye Autonomy (Gen 2) is an industry-first as we have developed the intelligence to fully-automate the welding process,” said Soroush Karimzadeh, CEO of Novarc. “This is an accomplishment that has resulted from years of data collected through machine learning, and we are extremely excited to be able to offer this solution to the industry.”
NovEye Autonomy (Gen 2) is the only AI machine learning real-time vision processing system that constantly improves welds based on data collection and model enhancement. NovEye Autonomy gets smarter as it continuously improves through a terabyte-scale library of welding videos, ensuring unmatched precision and reliability.
The software is embedded in the control system of the cobot and controls the weld pool in exactly the same way a human welder would, allowing the boring, repetitive welds to be delegated to the robot. The autonomous welding process enables uninterrupted welding due to NovEye Autonomy (Gen 2’s) multi-pass and multi-layer autonomous welding system, which is able to handle real-world pipe fitting inconsistencies like HiLo and varying root gaps. NovEye Autonomy (Gen 2) can immediately detect and adapt welding parameters to maintain weld integrity.
Fabricators and contract manufacturers worldwide are held to strict standards to provide sophisticated welds for industries such as aerospace, food and beverage, mining, energy, pharmaceutical, shipbuilding, chemical processing, and water treatment and desalination. All of these industries stand to benefit from NovEye Autonomy (Gen 2), which enables high quality welds with zero operator intervention, maximizing productivity and minimizing errors.
Also, the system can easily integrate into existing manufacturing processes of customers across a range of industries. The Spool Welding Robot, which is the hardware component of NovEye Autonomy, is designed with a very small footprint, but a very long reach, enabling it to fit in almost all fabrication shops, and easing the adoption of automation.
Automation is a very big milestone for the welding industry, dramatically reducing human exposure to all welding hazards as it positions the operator several meters away from the welding arc and noxious welding fumes. With NovEye Autonomy (Gen 2), operators can program the weld, and observe the weld away from the arc, reducing the risk of exposure to dangerous fumes and radiant heat. Also, muscle fatigue is reduced as the welding process is fully automated: ultimately, a win-win for the welder and the pipe shop, delivering X-ray quality welds, every time, with zero operator intervention.
The new system is the result of years of data collected from Novarc’s fleet of SWRs at customer sites in North America, Europe, the Middle East and Australia, and has undergone extensive internal and external testing to ensure all of the features are performing and the weld quality meets ASME standard to ensure unmatched precision and reliability.
Combination Bench and Pipe Vise is 70% Stronger than Competition
Palmgren’s (Naperville, IL) Combination Bench and Pipe Vise is 70% stronger than competing u-shaped vises. It features a super strong power tunnel with a straight-line pull to guarantee that its lifetime spindle and nut will never wear out. The spindle and nut are housed in square tube casting for protection from dust, chips and moisture resulting in lifetime lubrication. The precision fit of the slide bar eliminates side play and jaw wobble even when clamping with open jaws. The vise comes with the Palmgren lifetime warranty and is available in three models with jaw widths of 5”, 6” and 8”.
New Automated Unloading System for Laser Tube Cutting
TRUMPF Inc. (Farmington, CT) announced a new automated unloading system for its laser tube cutting machines. Laser tube cutting machines equipped with the “automated unloading interface with longitudinal belt conveyor” can automatically convey cut tubes to an automation system, which then sorts the parts or delivers them to the next production step for further processing. The automation solution, which is designed to prevent errors and reduce the operator’s workload, is available for TRUMPF’s 5000 and 7000 series TruLaser Tube laser-cutting machines.
“This new automation technology is another example of how TRUMPF provides solutions that address the real-world requirements of companies in the metal fabrication industry,” said TRUMPF Inc. Executive Vice President Burke Doar. “Laser tube cutting involves a high operator workload, which can be very challenging for many companies. Our solution helps companies tackle the shortage of skilled workers while also improving capacity utilization. The result is higher productivity and greater competitiveness.”
Compared to many other technologies, laser tube cutting requires significant operator involvement. TruLaser Tube machines are highly productive, which means a production worker needs to be available at regular intervals to remove and sort the cut tubes. With skilled staff in short supply, it can be hard for fabricators to find someone to carry out this task. In addition, the cut tubes tend to be large and unwieldy, so workers are often reluctant to take on this job. TRUMPF’s automated unloading system helps solve this dilemma.
In machines equipped with the new solution, the laser cut tubes are automatically deposited on a belt conveyor. The conveyor transports the parts to the automation system’s safety enclosure. Here, the parts are retrieved by a separate machine known as an integrator, which could be a robot or some other handling device. TRUMPF uses integrators from well-known partners, such as Starmatik and Transfluid, for part retrieval and handling.
None of the automation obstructs or limits the open concept of the laser-cutting machine: users are still free to unload parts manually, an option that continues to be particularly advantageous for small batch sizes and intermediate products. TRUMPF’s automated unloading system also features a digital interface that transfers all relevant information about the parts to the integrator. TRUMPF’s Programming Tube software makes this data available to the integrator automatically via the TruLaser Tube’s digital interface. This data makes the next stage simpler, for example by enabling the Starmatik robot to sort cut parts or convey them directly to the next step in the process without having to teach individual positions. This digitalization solution also saves time and reduces the possibility of errors.
TRUMPF’s automated unloading system is a particularly good choice for medium and high-volume manufacturers, as well as for job shops that handle orders of various sizes. Typical applications include furniture, fitness machines and agricultural machinery.
TRUMPF’s automated unloading system is the final link in the chain that enables every step in the tube fabrication process to be automated, including laser tube cutting. The company’s automated loading system, which enables raw material to be taken directly from storage and automatically loaded into the machine, has already been on the market for some time. TRUMPF can also help users to automate their tube-bending and welding processes. To achieve these advances in the tube-processing chain, TRUMPF works with well-known industry partners, including Starmatik, Transfluid and STOPA.
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