25 March 2008
AddisonMckee tube bending technologies provide 30% reduction in cycle time for European truck exhaust manufacturer

As 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.

As a recent case in point, the Preston, UK, division of the world-leading tube bending and end-forming technology specialists has supplied two brand new all-electric DataBend™ tube benders for use by a premier European truck manufacturer. Of greatest note, however, was the high level of efficiency that the new machines were able to achieve.

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 DB150ESRB 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™ DB150ESRB 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.

About AddisonMckee

2008 winners of Managing Automation magazine's Progressive Manufacturing 50 Awards – a prestigious award based on an organization’s ability to use information and automation technologies to transform its business and create a sustainable competitive advantage – AddisonMckee is globally renowned for the design, manufacture and supply of some of the world's finest tube bending and end forming technologies - for increasingly complex automotive, aviation, truck and shipbuilding requirements.

In addition, AddisonMckee also offers highly innovative muffler and catalytic converter assembly solutions, hydraulic press machinery, tube inspection systems, plant automation and complete workcell integration.

In addition to these capabilities, a whole range of tooling and accessory options are also provided, as are comprehensive maintenance and service contracts, training and education programs and financial services. Where applicable, AddisonMckee is also able to offer customers the opportunity of machine rebuilds, refurbishment, upgrades and trade-ins.

From its state-of-the-art manufacturing centers in the USA, United Kingdom, Canada and China, AddisonMckee is committed to providing rapid solutions to market and also regularly assists clients in product prototyping, parts development, small production runs and pre-production sample development.

AddisonMckee is principally owned by WHI Capital Partners (WHICP), a Chicago-based private equity group that invests in middle market, industry-leading companies with solid financial fundamentals and proven management teams. WHICP is an affiliate of William Harris Investors, Inc., a family-based asset management firm founded by Irving B. Harris in 1987.

For further information please contact:

Rachel Thomas – BHL Marketing
E-mail: rachel@bhlmarketing.com
Tel: +44 (0) 1244 851850
Fax: +44 (0) 1244 851888

Christian Rogiers – AddisonMckee
E-mail: crogiers@addisonmckee.com
Tel: +1 513 228 7076
Fax: +1 513 228 7226