TECHNICAL ARTICLE:

Introduction

Specialists in the metal tube-manufacturing sector, Tube Tech Machinery, Italy, supply end-users with complete and customised systems for each phase of tube production, including laser technology. The company produces systems for tube manufacture, including cutting, straightening, threading, facing and chamfering plants, as well as a variety of other machinery for manufacturing plants in the different sectors related to tube production and finishing.

In particular the Brescia-based company, which belongs to the Castellini Group, supplies complete plants for tube machining, with particular emphasis on in-line or stand-alone laser cutting machines for work pieces with a diameter ranging from 20-610mm and lengths up to 16m.

These plants are supplied with 3D head and optimum performances, an important feature as three-dimensional systems permit the working not only of tubes with standard sections but also profiles. As far as traditional machines are concerned, the end-users of the systems produced by Tube Tech Machinery are essentially tube plants that increasingly require user friendly, highly productive and fully automatic systems.

Due to their experience in the field of machine tool manufacturing, the company has realised solutions characterised by important technological achievements. For instance, automatic tool changeover is one specific benefit introducing innovative criteria to the tube-manufacturing field, unknown prior to this development. The recent acquisition of the trade mark Restellini, a well know company in the sector, has further consolidated the corporate know-how and has enabled Tube Tech Machinery to be a global supplier for its customers: from coil-unwinding to in-line laser cutting and complete finishing.

Tube Tech’s Speedfly5 in-line laser cutting machine

Speedfly5: International Patent for In-Line Laser Cutting

Tube Tech Machinery believes it has developed the first machine in the world for the in-line laser cutting of stainless steel tubes. The model, branded Speedfly5, is a qualified international patent, and includes the most important concepts of laser technology for machine tools.

The simultaneous use of linear motors and laser tools enables the achievement of very high dynamics because the tube-feeding axis can reach 120m/min with 2.5g accelerations. In this process the laser tool allows highly accurate operations with perfect finishing, without having to re-machine the tube after the cutting phase. In addition, it assures adequate working conditions from the environmental viewpoint, considering the dual absence of noise and waste to be disposed. It also guarantees safe working conditions because no tool change is required.

This machine executes cuts up to a diameter of 219mm, with round, square, rectangular or oval sections. The company has also developed the software equipping this machine in cooperation with the University in Brescia, Italy and due to the fundamental support by Siemens, it benefits substantially from this design synergy.

FL600 3D: High Accuracy Laser Systemfor Different Profiles

In addition to large size tube manufacturers, the end-users of laser applications are medium-to-big carpentry factories working on structural jobs, cutting centres, automotive applications, and handling. Tube Tech Machinery has also developed a laser system that is designed to reach high accuracy levels, using different profiles, to obtain more and more complex couplings. The FL600 3D achieves the goals of accuracy, cutting quality and fast execution.

At the heart of the plant is a three-dimensional system permitting work at any point of the area. The movement along the five interpolating axes, with ball re-circulating screws and linear motors, assures high dynamics and performances of the whole plant.

FL600 3D laser cutting system

The machine is equipped with devices able to detect errors in the piece geometry. Four self-centring spindles, driven by synchronised hydraulic cylinders, assure the movements of the piece along the machining axis.

Feed and rotation, by means of rack with hardened and ground helical teeth, is enabled by brushless motors coupled to precision epicyclic reduction gears. Spindles are designed to permit the machining of different sections and diameters without retooling. The floating system is an integrated solution that allows compensation for the variations of piece straightness while machining.

An innovative solution in the laser-cutting field, it permits accurate operations even if abnormal and irregular shapes are present in the tube, preventing dangerous mechanical stress on the spindles. The plant is automatically managed by two NC – one for the handling area and the other for the laser machining part – while a third NC manages and supervises the laser source.

FL200 3D: An Efficient Partner

As a partner to the FL 600 3D, Tube Tech Machinery has designed the FL 200 3D, which offers a working field range from Ø15-220mm. The FL 200 3D can load any kind of profile; a tube loading system lifts the tube from a bundle with automatically rewinding belts and automatic adjustment to the tube diameter.

The structure accommodates three independent manipulators, which allow the mandrel feeding of both the tube loaded from a bundle and tube and profiles loaded from a chain. The loading system from the chain also allows the loading of open section profiles. It is composed of chains equipped with V supports.

FL200 3D laser head

The chain feed speed automatically adjusts to the tube diameter and weight. The chains are designed to slide on wheels in order to prevent noise and wearing. The plant is provided with an intelligent discharge system for the machined parts.

FL200 3D

Particular care is concentrated on the management of the finished pieces, which are handled differently according to length, dimension, quantity and type of machining. The ‘intelligent’ discharge enhances the system’s productivity, besides considerably reducing the dead time of the finished part stocking. For long pieces, the system is equipped with containing and supporting devices for all kinds of tube and profiles. The philosophy of all Tube Tech’s machines is for complete autonomy and labour-free production.

The machinery is equipped with two mandrels. The mobile mandrel is made up of a solid structure where four sliding and self-centring jaws are accommodated, adjusting to diameters ranging from 15-220mm, without any tool replacement being required.

Rendering FL600 3D

A tempered and rectified precision helical toothed rack activates the mandrel, which is in its turn operated by a brush-less motor and a precision reducer with slack recovery system.
The extraction system, with piping accommodated inside the mandrel, sucks up smoke and cutting dust, so as to guarantee a totally clean working environment.

The fixed mandrel is made up of a solid structure accommodating four idle rolls, which are self-centring and adjustable to diameters ranging from 15-220mm without any tool replacement being required.

FL600 3D Sphera

The FL 200 3D is equipped with a 3D laser head that, coupled with highly dynamic motors and high quality transducers, combines maximum speed with absolute precision. The 3D laser-cutting head can orientate the beam in any direction within a semi-sphere. Torque-direct drive motors operate the head movements without any mechanical transmission.
The exact distance between the nozzle and the cut surface is controlled by a capacitive sensor, which adjusts the machine axis in real time.

Laser cut

Particular care is reserved to the optical path, where high efficiency mirrors are fitted. The system pressurisation and integrated cooling guarantees the maximum working precision.

For construction of the mechanical parts particular care was taken in choosing first class and latest generation components, for maximum reliability: Tube Tech Machinery systems are a product of the most innovative technology presently available, and are conceived to guarantee maximum flexibility, productivity and value of investment.