Multi-Axis Forming Machine
Overview
This is a bespoke Stretch/Tension Forming machine designed to meet the client’s specific project requirements while also providing future-proofing for potential future projects. This flexibility is achieved through the use of type change clamp units and component form tools.
The Solution
Synergy’s experience with stretch forming, more accurately described as Tension Control Forming, has demonstrated the importance of proper clamping and preventing section slippage through the clamps. This led to the development of clamp indentations, which can be tailored to specific component geometries and may involve multi-axis actuation of the clamping surfaces.
To achieve the formation of components with complex 3D geometries, the machine was designed symmetrically about the centerline and includes a total of 10 servo-hydraulic axes. This combination of programmable axes allows the forming of both asymmetrical and symmetrical components with full 3D geometry, including bends and twists.
The servo-proportional system features Duplomatic actuators, integrated with Bosch Rexroth servo-proportional hydraulic valves. Simultaneous control of all axes is managed via a National Instruments CRio system and LabVIEW control software.
The Windows-based HMI (Human-Machine Interface) allows file storage customized to the client’s needs, assisting operations and maintenance personnel with:
- Component Drawings
- Tool Change Instructions (with videos)
- Component-specific quality notes and photos
The user-friendly operator interface and component-specific sequence programming are further enhanced with the following features:
- Teach Function: The axes are manually positioned via the HMI, and these positions are stored in the control system’s memory.
- Tabulation: The position of each axis, whether linear (mm) or angular (degrees), is defined in a tabulated form, with travel time between steps set in seconds.
- Program File Export: Sequence files defining machine movements can be exported as CSV files, allowing easy editing of axis positions and digital I/O conditions using Microsoft Excel on any laptop or PC.
Synergy, since its formation in 2009, has built upon decades of experience to support UK manufacturing through its tailored services and the provision of automation and manufacturing solutions of various scales. We provide everything from Low-Cost Automation (LCA) to fully automated turnkey production facilities.
Synergy leverages its cross-industry expertise to deliver bespoke solutions, focusing on simplification and reducing complexity. We implement the latest technologies only when appropriate, favoring simpler, more cost-effective solutions where possible. This is achieved by gaining a deep understanding of our clients’ technical skill sets, operating procedures, and broader business needs, not just their immediate requirements.
This approach fosters long-term relationships, allowing us to provide continued support across multiple areas of our clients’ businesses, including sales and business development. Whether through Low-Cost Automation or fully automated systems, we help clients achieve increased productivity, improved quality, labor savings, enhanced safety, and cost-efficient manufacturing.
To discuss your requirements and find out how Synergy can support your manufacturing needs, get in touch with us today.
