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March/April '08 |
AddisonMckee tube bending technologies provide 30% reduction in cycle time for European truck exhaust manufacturerAs the drive for greater manufacturing accuracy and enhanced materials efficiency increasingly becomes a focus of the global automotive industry, AddisonMckee has been showing a considerable number of vehicle manufacturers and exhaust component OEMs how significant cost reductions can be made by investing in the latest tube and end-forming technologies.
The first model supplied by AddisonMckee, a DataBend™ DB150 ESRB (E - all-electric, S - stack, R - multi-radius, B - boost) will be used for the precision manufacture of numerous short-run, large-diameter exhaust components at the truck manufacturing facility. The second, smaller, model also supplied - a DataBend™ DB20 ESRD (E - all-electric, S - stack, R - multi-radius, D - dual) - will be used for the creation of smaller components, including brake lines and air-conditioning tubing. Selected for its 'dual' capability, this model enables both left- and right-hand tubular components to be bent using the same bending head. Accuracy and repeatability As part of their brief to AddisonMckee regarding the supply of the larger DB150 model, the customer required a machine that would be capable of providing accurate, repeatable bending of large diameter stainless steel exhaust tubes at thin wall and tight radii, with short straights between bends. At the same time, it was specified that the model supplied should also be sufficiently flexible to produce multiple component types without re-tooling. 30% quicker component-to-component time To justify their investment in new tube-bending machinery, the truck manufacturer also stipulated that their new exhaust tube bender should be 30% quicker per manufacturing cycle than the competitor machine it would replace. AddisonMckee set-up like-for-like manufacturing trials and this figure was achieved, with the additional benefit of the renowned component accuracy and repeatability that investment in AddisonMckee technology brings.
Industry-wide reputation Rapidly gaining a place as the preferred tube bending solution amongst truck exhaust manufacturers, the technology employed in AddisonMckee’s DB150 ESRB model has been developed especially to significantly reduce tube scrap and considerably improve process cycle time at larger tube diameters on tight multi-radii. Eco choice A high-technology 'green' model that eliminates all hydraulic functions yet retains speed, power and flexibility, the DataBend™ DB150 ESRB machine is a rigid, clean, quiet unit with automatic repeatable slide setting for tool change. Minimized tooling changeovers A tooling height of 450mm (17¾ in) enables the use of multi-radius and compounded tooling. Alternatively, the bender will accommodate tooling set-ups designed to minimize tooling changeovers - an absolute necessity in an environment such as a modern truck manufacturing facility where exhaust system components can differ considerably from truck to truck. Dual-boost system At the same time, an electric carriage boost of 15Kn a dual-boost system allows a boost as close as possible to the tangent point of the tooling, enabling the maximum amount of available tube to be pushed into the tooling area in order to reduce costly scrap. Component research In addition to providing significantly quicker component-to-component manufacturing time, whilst generating considerably less waste material, AddisonMckee also worked directly with the customer to assist in the re-development of some exhaust components. This has involved the reduction of various cutting and welding procedures in favor of the greater use of single piece tubing, a process potentially offering less resistance to exhaust gas airflow. Intensive training To enable shop floor maintenance staff to 'fully support' the new DB150 and DB20 machines themselves, following commissioning AddisonMckee also provided intensive training on each model. During this three-week program, a senior AddisonMckee training officer was sent to the manufacturing plant to ensure complete knowledge transfer for both machines. Healthy European business Comments AddisonMckee Export Sales Director, Graham Wood, "At a time when economic influences in the American automotive market, in particular, are impacting on sales to numerous machinery manufacturers and component suppliers, it is refreshing to report healthy business from Europe. "With its ability for short production runs and fast tool changeovers, multi- radius capability, in line boost with second boost to tangent option and high axis resolution for improved repeatability," he continued, "the DataBend™ DB150 is helping manufacturers to achieve new efficiencies and create the exhaust components necessary to meet the most stringent of emission requirements. |
Stock machines for sale! Click here for a complete listing. Call for further details or to purchase.________________________________________________ |
Product Focus - DataBend DB150 ESRBThe AddisonMckee DataBend™ 150 ESRB machine is a 150mm (6") high-performance variable stack boost bending machine designed for maximum productivity demanded by today’s industry.
The machine comes standard with the following features:
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Touch Screen Control for ease and speed of operation
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