Tube Folding Machines for Microchannel Tubes
The new trend in tube profiling.
Folded microchannel tubes.
Folded microchannel tubes are inexorably taking hold in heat exchanger development. Compared to extruded profiles, they offer the same strength data but significant advantages in terms of the product design possibilities. Where only standard profiles have been available to date, today the most varied geometries are made possible with the use of the new technology.
Schöler is sufficiently familiar with this topic. The first concepts for the manufacture of thin-walled, dimensionally stable hollow bodies were patented to the innovators of today's multi-chamber tubes as early as 1950. The developments over the past decades have resulted in production facilities which, due to their moderate investment costs, make their own in-house production realistic. For our customers this means less dependence on suppliers resulting in significantly more flexible "just-in sequence"-production.
Highlights of the RFL tube folding machines.
The RFL tube folding machines are regarded as the world's first process-capable production solution for the 24/7 production of folded multi-chamber tubes under industrial conditions. Schöler machines are known for such highlights as the compact and ergonomic design, the modular design, the proven swap body technology as well as an intuitive HMI user guidance - all of these highlights are of course also to be found in this machine series.
The deformation - and chip-free cutting of the multi chamber tube is considered worldwide as an exclusive and unique selling proposition of our machines. This is achieved by a newly developed cutting device, which in principle is based on the foundations of the well-known and proven Schölerboard technology. This technology, in its movements, has been specifically designed to meet the requirements of the new process.
In the production process of 2- or 3-part multi chamber tubes, topics such as integrated degreasing, inner and outer fluxing as well as automated packaging are also order of the day. Schöler has a solution for each of these topics - just ask us!
Efficient roller set construction. The key to success.
Every tube profile is unique. Therefore, a reliable process for construction of roller sets is the key to success and it enables every order to be fulfilled quickly and efficiently.
Schöler’s engineers have these key skills at their disposal. A complex three-stage process of simulation guarantees a reliable machining and construction process will be achieved on each and every roll set.
Critical reshaping steps can be localized during the construction phase, so that corrective action can be taken at the relevant time. In addition, detailed information regarding the diffusion of stress in the profile gives early data about the results that can be expected when the production process is carried out. This saves time and reduces the development costs to a minimum.
Tube forming pattern design
A rapid and accurate assessment of the tube forming pattern carried out at the start of the roller set construction will ensure that the best possible distribution of stress is achieved. Pre-simulation and consideration of the material behaviour enables our engineers to effectively split up the requisite shaping steps.
Time-consuming laborious tasks are eliminated by finding solutions through utilization of modern software thus enabling our design engineers to concentrate entirely on designing the shaping concept.
3D - Profile roller modeling
Using 3D CAD software from Pro-ENGINEER, the modelling profile data for each station can be imported and verified.
All roller profiles will then be generated automatically on the basis of a parametric reference system. Potential collision ranges will have already been detected and eliminated during the construction phase. The drawings and parts lists will also be generated automatically, saving time and labour.
After design and construction of the profile rollers is complete the results can be fully verfied and checked with the help of finite-element-simulation.
Having already received very detailed information about the stress ratios in the profile and the critical shaping steps during construction via the FEM simulating software, the developer can take corrective action if necessary. Extended shaping steps can also be simulated without any problem, like dimpling or cutting the tube into lengths for example.