This project was for the design and manufacture of a bespoke tube bending machine to bend rectangular hollow section and channel section of varying sizes up to a maximum of 100mmx50mm for use in the production of car trailers.

The tube is bent around a machined former whilst being supported on either side by shoulder pins. To accommodate different section sizes spacer plates are added to the machined former and different size shoulder pins are fitted. All the specific tooling pieces are stamped up with the size of the section to be produced.

Limit switches are fitted to control both the extend and return stroke of the hydraulic cylinder. Control of the extend stroke ensures an accurate and repeatable bend in the tube, whilst control of the return stroke keeps the stroke length to a minimum and ensures a quicker cycle time. The switch strikers are bolted to an aluminium extrusion fitted with a graduated scale. This ensures quick and accurate adjustments. An additional section of aluminium extrusion (not shown) provides a length stop.

The machine was designed in conjunction with a hydraulics company. This enabled the machine frame and hydraulic pack to be sized so that the pack could slide easily into the machine framework resulting in a compact footprint.

The control system was of a compact design  mounted in a panel bolted to the side of the machine frame. The sequence of operations was controlled by a Telemechanique Zelio PLC. The tube bender is operated by a foot switch.

On completion the machine was supplied with a full documentation package, including mechanical and electrical drawings, parts lists, risk assessment and manual in both hard copy and on CD Rom.