Automatic straightening machines - for various applications

Do you straighten short or long, round or profiled parts? Are you looking for the right machine for your straightening process? MAE has developed two solutions: the M-AH and ASV automatic straightening machines. With this series you can straighten your workpieces efficiently and with 0.01 mm accuracy.

Properties

  • Pressing forces: 15 - 25,000 kN
  • Workpiece lengths: 40 - 30.000 mm
  • Unit weights:  5 grams to 20 tons
  • Straightening accuracy: up to 0,01 mm
  • M-AH automatic straightening machine - for round and profiled components

M-AH – the global market leader in automatic straightening machines. You can straighten round and flat parts, as well as workpieces with complex geometries precisely to your application.

  • Directive forces: 2 - 1.600 kN
  • Workpiece lengths: 30 - 3.000 mm
  • Cross-section: 2 - 300 mm
  • Straightening accuracy: up to 0,01 mm

 

Structure of the machine:

The specific requirements of your straightening process are taken into account: 

  • Robust, simple, durable design through patented swiveling lever principle with rotating, maintenance-free embedded ram.
  • Very stable thanks to closed frame structure
  • Quickly convertible
  • Exceptional access
  • Ideal for manual and automatic loading
  • Low space requirement thanks for compact design
  • Straight workpiece handling, therefore ideal for integration into production lines

 

Cam disc gears with variable transmission:
the core of the M-AH electromechanical drive unit. MAE has optimized the force-displacement behavior of the patented, rotating ram movement for the straightening process. You benefit from favorable cycle times and straightening sequences.

Performance data:

  • Repeatable positioning accuracy under 0,001 mm
  • Dynamic movements through low inertiaOptimale Sicherheit durch Gegengewichtskonzept

  • Optimum safety thanks to counterweight concept

You can straighten a wide range of workpieces with straightening machines from the M-AH series.

 

M-AH systems are used in the following sectors in particular:
automotive, tools and standard components, textile machines, electric machines

  • ASV automatic straightening machine - the automatic straightening machine for long parts

The largest straightening machine in the world. Expressly adapted to the requirements of manufacturers of long parts. ASV - the patented MAE series

  • Directive forces: up to 25,000 kN
  • Workpiece lengths: up to 30.000 mm
  • Cross-section: up to 800 mm
  • New type of conversion concept: also suitable for small batch sizes
  • For curve straightening and pressure straightening

 

Structure of the machine:
ram, straightening table and anvils: the compact, C-shaped straightening head, which you can move behind the workpiece, supports all elements. The straightening table is integrated into the machine, so the flux remains in the C-frame.

Benefits for you:

  • Low space requirement
  • Minimal conversion requirements
  • Low energy costs
  • Minimal tool costs

You can straighten various large-scale parts with the ASV:

ASV systems are used in the following sectors in particular:
automotive, rail, steel industry, oil and gas production.

  • 3D straightening – standard concept for custom applications
3D straightening
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Do you straighten complex applications? MAE has developed various modular standard concepts for such cases. This delivers an efficient solution, tailored exactly to your specific straightening task:

  • Directive forces: up to 1.000 kN
  • Workpiece lengths: up to 2.000 mm
  • Straightening accuracy: up to 0,05 mm
  • Modular concept
  • Flexible adjustment to various straightening requirements

Structure of the machine:
machine table, electromechanical straightening unit, non-contact measuring, variable straightening position, integrated conveyor technology. The systems are particularly suitable to straightening welded parts (gear stick or chassis components) and cast iron parts (structural parts or chassis components).

3D straightening systems are used in car manufacturing in particular.

  • RICOS – the high-performance straightening controller
RICOS
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The straightening computer is hugely important for the performance of automatic straightening machines: the software for the RICOS straightening controller undergoes constant redevelopment. RICOS is already impressive as a standard configuration. MAE systems have a high-performance computer architecture with separate processors for straightening sequence and visualization, as well as a field bus connection between machines and SPS. You can enjoy optimal ergonomics with the large-scale TFT touch display and the windows user interface.

The gears: your measurements

  • Measuring with ball calipers
    Would you like to measure gears? You can with the patented ball caliper equipment. This equipment is used predominantly for hypoid gears and small batches. This eliminates substantial costs for master gears.
  • Run-out compensation for master gears (LSK)
    Run-out errors for master gears: they can represent up to a third of required straightening accuracies. MAE compensates for these errors in master gears numerically using a patented software. The result: improved measuring accuracy and fewer unnecessary stresses on the workpiece.
  • Measuring with master gears
    Would you like to identify run-out errors and individual or total composite errors? RICOS delivers exact values when you use master gears for rolling and plug-in gears.
  • Trilos
    Trilos is the perfect way to measure geared workpieces during ongoing straightening processes. The laser measuring system and the software for measuring run-out accuracy are embedded in the RICOS controller. While the gear rotates, the angle on the flanks is determined precisely: in high resolution and high frequency.

 

The straightening sequence: basic functions

  • Self-learning stroke length controller
    Optimize cycle time and number of strokes, minimize stress on the workpiece, offset tool wear: with RICOS you can control your straightening process exactly as intended.
  • Fully-configurable straightening sequence
    With pre- and final straightening functions. You can straighten based on the whole length or individual sections.
  • Freely selectable reference base
    You have the choice: straighten based on the tips or on two initial selected starting points.
  • Batch statistics
    In addition to the standard existing workpiece statistics, would you like to obtain a specific evaluation of individual batches? RICOS delivers the statistics you want. Bending data is represented in histograms and tables. You can track the workpiece quality in detail before and after the straightening sequence.
  • Remote maintenance
    A direct link worldwide. MAE systems mean precision: the straightening controller, drive system and SPS are connected to the MAE service in Erkrath via a network connection or via mobile radio. Whether diagnostics or update, our experts can intervene directly.
  • Automatic measurement device capability test
    The accuracy of the measurement devices used in straightening machines must be verified regularly; this is the only way to guarantee the process capability.
RICOS automatically performs the measurements necessary for the measurement device capability test with all motion sequences and documents the results in accordance with the specifications of the automobile industry.
  • Detect form errors
    1000 measurement values per rotation, at all test points. So form errors such as ovalities or surface roughness are reliably detected. They are calculated, adherence to tolerances is checked and these errors are separated from run-out errors.

The software: RICOS highlights

  • Vectorial straightening - prevent cracks
    Should your workpiece only bend at selected measuring points? This can lead to cracks in sensitive components. RICOS lowers the crack quota: many sectors make use of RICOS for plastic deformation by axially shifting the straightening hammer or turning the workpiece.
  • Measure sections and inner contours contactlessly
    Checked inside and out: a laser scanner also sweeps complex profiles during the ongoing straightening process. And an optical measurement device reads the inner diameter of tube-shaped components continuously.
  • Run-out compensation for center pins (ZSK)
    Run-out errors caused by the part of the center pin actively dipping into the workpiece? Not with the RICOS. The controller detects and compensates for these errors with a patented procedure (ZSK). The wear is continuously offset with two reference sensors at the tips.
  • Varius: the variable straightening strategy
    Varius represents the variable straightening strategy with universal stress curve. So performance and accuracy continue to increase. Varius optimally reacts to all curves occurring in practice. The straightening strategy combines continuous straightening over the entire length with conventional 3-point and innovative 4-point straightening.
  • Pressure straightening
    In addition to normal bend straightening procedure, RICOS is also suitable for pressure straightening procedure. So you can straighten through-hardened or crack-sensitive components efficiently.
  • Section straightening
    Need to straighten round or full/semi-profile sectioned parts? All in the same system? You can with the RICOS controller!
  • Interactive straightening
    RICOS works "with foresight": The controller also considers the position and direction of neighboring stroke vectors when calculating the stroke. The result: reduced cycle times, less unnecessary stress.
  • Data export
    ASCII files, Microsoft-Excel®, QS-stat® or else an Ethernet coupling: RICOS transfers quality workpiece data in various formats to higher-level computer systems.

 

We're happy to answer your questions: sales@mae-group.com