Lujabetoni invests in new cage welding machines for manufacturing driven piles
Lujabetoni invests in new cage welding machines for manufacturing driven piles Lujabetoni, a major driven pile manufacturer in Finland, has systematically developed new solutions in recent years. The “Luja-pienpaalu” product developed and patented by Lujabetoni breaks with the myth of heavy concrete piles: driven piles that produce virtually no waste, and their lightweight driving equipment causes no significant vibrations. mbk Maschinenbau, a German family-owned company, has been on the market for 60 years and is one of the leading manufacturers of cage welding machines for the concrete industry. The mbk product portfolio is renowned for its high quality, reliability, durability and robust design. Machines manufactured by mbk feature very high productivity and flexibility in daily work, as well as simple handling and low manpower requirements in their operations. mbk always maintains a focus on the entire product life cycle, so that its very well-organised after-sales service and fast, reliable spare parts deliveries ensure that the equipment has very little downtime in the rare event of a malfunction. Lujabetoni’s first mbk welding machine for pile reinforcement was commissioned at the Haapajärvi production facility in 2001. In 2004, investment was made in a corresponding machine at the Pernaja production facility. According to Kaj-Mikael Weissman, Lujabetoni supervisor in Pernaja, the second machine showed wear after 15 years of operation and no longer lived up to expectations. Juha Kinnunen, director of the concrete product line at Lujabetoni, added that the increasing fragility of the old machine and the cost of spare parts made the case for a complete replacement. Jorma Ilkka, the factory manager in Pernaja, also saw the new machine as an opportunity to substantially increase pile production efficiency through smoother product changeovers and higher output rates. Another important point for Lujabetoni was the automation of the small pile diameters, which allows them to be produced about 50 % faster. Image 1: VSM-053-V cage welding machine for manufacturing reinforcement cages for driven piles Image 2: The new machine installed at Lujabetoni in Haapajärvi Reliability was important The machine’s adaptability was also important for Lujabetoni so that reinforcement can be produced according to high quality standards for all the types of piles available on the Finnish market. The crucial factor in the decision-making process was to see a similar machine in action in production in Sweden and to hear about the users ‘experiences. According to Kinnunen and Ilkka, mbk was “not the cheapest of the suppliers compared, but reliability, quality and after-sales service spoke in its favour”. The welding angle is automatically set and secured, enabling short product changeover times that, according to Kaj-Mikael Weissman, require only a fraction of the time in comparison with the old machine. Welding parameters and data are stored directly with the product in the programme. The service life of wear parts has been extended, for example, by equipping the welding and contact rollers with a metal carbon instead of a sliding contact lubricated with copper grease. With this means of electric power transmission, it is no longer necessary to lubricate the machine with copper grease several times a week, which saves on maintenance time and keeps the machine clean. The latest generation VSM machines feature less downtime, cleaner operations, or fewer wear parts and are safer and easier to maintain. In addition, problem solving is faster with mbk ‘s support via the LAN network. And since all drive and control units are state-of-the-art, spare parts availability is also guaranteed. Image 3: Processing the welded cages was adapted to customers’ logistics. Successful delivery The delivery process went very well. The agreed deadlines were met and the machine was replaced in three weeks, even faster than expected. Lujabetoni was very satisfied with the induction and the operator training was also particularly praised. According to Weissman and Ilkka, the new machine can produce 25 to 30 % more pile metres per day and the whole working day can be utilised for manufacturing reinforcement without any time loss. The users ‘positive experiences also include the machine ‘s ease of operation, speed, the high quality of the reinforcement produced and low noise level during production. In the meantime, Lujabetoni has also replaced the second mbk welding machine from 2001 in Haapajärvi with a new mbk welding machine and is looking forward to further cooperation with mbk. Image 4: Jorma Ilkka and Juha Kinnunen from Lujabetoni observe a test run at mbk Image 5: The new machine installed at Lujabetoni in Pernaja with the first cages produced
Welding machines, plants and automation for the construction and concrete industry
Welding machines, plants and automation for the construction and concrete industry In 1961, Georg Pfender decided to become self-employed and set up his own small mechanical turning shop – initially at his home in a garage. What started in a small way soon got around and more and more companies began to trust Pfender’s quality and inventiveness. A parallel development represented a milestone for the company: in the 1960s, the reinforced concrete pipe came onto the market. As a result, the first cage welding machine from Pfender was created and became a signpost for the next decades. The name Pfender was becoming increasingly well-known, even beyond Germany’s borders. In wise foresight that there might be difficulties with the pronunciation of the name Pfender, the name was changed. Georg Pfender Maschinenbau became today’s mbk Maschinenbau. That the abbreviation mbk would one day become synonymous with cage welding machines for numerous customers in many parts of the world – Georg Pfender would probably never have dreamed of that. As the product portfolio grew, so did the space needed in production. The move took place, bringing mbk to its current headquarters. Courage, diligence and inventiveness – three qualities that are essential to build such a business. In the years that followed, the company was continuously expanded, the machines and systems were constantly developed further and the product and service quality was optimised. Since 2011, the company has been managed by Mario Pfender in the third generation. With the right mix of technical and business understanding, respect for the past and the passion not to stand still in the future but to look ahead, the trained mechatronics engineer and graduate industrial engineer brings something to the table that has once again raised mbk to a higher level. After all, it is necessary to keep reinventing oneself and to continue optimising processes in order to survive in a market that is becoming more and more complex. Quality – made in GermanyToday, 11 years after the third generation took the helm, mbk can look back on over 60 years of company history. The company now has subsidiaries in the USA and Russia and employs around 110 people worldwide. Over 1,200 machines have now been installed in more than 60 countries. mbk offers its customers quality Made in Germany, ensured by qualified specialist staff, by a state-of-the-art design and development department that works to current standards, by the latest generation of machinery and, last but not least, by ISO 9001 certification. And so, through technical finesse, know-how, years of experience and very high quality standards, mbk has developed from a small craft business in the Allgäu region into a structured industrial company and, above all, one of the leading manufacturers of welding machines and equipment for the construction and concrete industries. The order of the day: automationIn addition to the welding machines for the production of concrete pipe reinforcements, the product portfolio has been continuously supplemented over time by a wide range of cage welding machines for driven and drilled pile production, mesh girder and mesh welding machines as well as wire straightening and cutting systems together with a wide selection of matching accessories . And more topical than ever: individually adaptable automation solutions characterised by very high performance with low manpower requirements – from simple automation accessories to fully automated production lines. Optimisation is a maxim that determines the daily production routine of many industrial companies. And it is precisely this requirement that mbk serves with its latest solutions, which are equipped with modern machine control along with remote maintenance and up-to-date software solutions. Another step on the way to a successful future. At the bauma again in 2022mbk has been an integral part of the bauma for 30 years now. This year, the mbk team will once again be present at booth 112 in hall B1, will come up with interesting innovations and will be available to answer any questions. In addition to various further developments in the machine portfolio, the main focus this year is on a completely new control generation for the machines, including new remote maintenance solutions. This offers completely new possibilities and takes into account emerging topics such as predictive maintenance. In addition, mbk will again be offering factory tours in Kisslegg with a shuttle service due to the close proximity to Munich. During the bauma, interested customers will be able to see, among other things, a mesh welding machine, a machine for processing lattice girders and various cage welding machines in test operation. If you are interested, please contact the mbk team in advance.
Allgäu Solidarity – New Wire Straightening and Cutting Machine for Böck Bau
Allgäu Solidarity – New Wire Straightening and Cutting Machine for Böck Bau Hans Böck GmbH & Co. KG, a company from Sonthofen, Allgäu, Germany, has been carrying out challenging projects in structural, civil and specialist foundation engineering for 75 years now. The construction company owes its good name in southern Germany primarily to its enthusiasm for innovation. This is surely also one of the reasons why cooperation with the mbk mechanical engineering company from Kisslegg, Allgäu, works so well: two companies from Allgäu with the same commitment to quality and a very similar philosophy. Since very recently, Böck Bau high-quality precast concrete elements have been produced, among other things, with a DRA-M – a wire straightening and cutting system for straightening, cutting and bending reinforcement wire from a coil. The DRA-M not only excels in robustness and precision but above all with its high degree of customisation possibilities. “The quality and precision of reinforcement processing, excellent communication with mbk, competent and prompt customer support with the resulting very minimal downtimes, as well as mbk’s in-house spare parts production,” explains Managing Director Andreas Böck, “are decisive advantages that will positively influence our everyday production in the future.” Utilising precast concrete elements is highly efficient thanks to their great structural, energetic, economic and visual advantages. That is why their production must run just as efficiently in a factory and always deliver the same quality. This is assured, among other things, by mbk’s in-house laboratory and by the Materials Testing Office for Building Structures, Solid Construction Department, at the Technical University of Munich. With the DRA-M from mbk, all the prerequisites for the needed efficiency and quality are also in place. The Böck team of specialists can now respond quickly and flexibly to individual requests, both in terms of production technology and scheduling, and offer a one-stop supply of all prefabricated elements that may be required. “A huge advantage of the new machine is its precision with bar lengths and double bends. This ensures consistently high reinforcement quality. Switching between hot and cold rolled material also works very well. The machine is also very robustly built, which we hope will give it a long service life. And what our employees like most about it is the clearly arranged control panel,” adds Andreas Böck enthusiastically. The DRA-M ensures smooth workflow with its five straightening rotors for wire diameters from 6 to 14 mm (six rotors up to 16 mm wire diameter are optionally available), a production length of 500 to 8,500 mm (optionally available up to 14,000 mm) and a straightening speed that can be controlled up to140 m/min. The machine is equipped with motor-driven decoilers incorporating an adjustable decoiler attachment for an inside coil diameter of 370 to 900 mm and up to a max of 1,200 mm on the outside. The maximum coil weight is 3,000 kg, but this can also be increased to 5,000 kg as an option. Other machine features include a more stable production process because of the synchronisation between wire reels, wire feed unit and rotor straightening unit, as well as high wear resistance thanks to straightening rotors with carbide straightening elements. The double bender for producing Z bends (bending shape 4) at both wire ends is perfectly tailored to meet the needs of precast concrete experts. With 70,000 square metres of floors per year, this is an exceptionally useful option. After straightening and bending, a wire discharge unit on both sides allows wire to be discharged into the existing conveyor systems. The front discharge unit is utilised to supply the pallet circulation system with wires. The wire discharge unit on the rear side is used to supply material for the special tables. If required, spacers from the integrated sorting and feeding system can also be loaded onto the wires during the straightening process. The machine is integrated into the customer’s specific master computer system (data transfer from the PC directly to the machine) via the control system LAN connection. This also permits a time-saving connection to the mbk service team for remote diagnosis. Last but not least, the DRA-M has been integrated into local conditions and a safety concept worked out and implemented for the overall system (wire straightening machine including existing conveying technologies and interfaces to other existing systems). Once the machine is up and running, the highly qualified mbk team also makes sure that it stays that way in the future. “The cooperation with mbk has been and is very good. We have competent specialists as contact persons for all issues. Our concerns were addressed individually even at the planning phase so that we received a straightening and cutting system that was precisely adapted to our needs. During the installation stage, we had very well-trained and committed technicians at our disposal, so that downtime during the changeover process was kept to a minimum. They have so far reacted promptly and purposefully to our enquiries in ongoing operations as well.” Precision, technical expertise, a wealth of ideas, high quality standards – all of this sets both Allgäu companies apart in equal measure. And these are the reasons why they will continue to play a leading role in manufacturing precast concrete elements in the future.
Straightening and cutting of reinforcing wire off the coil
Straightening and cutting of reinforcing wire off the coil The area of application of the DRA-10-C wire straightening and cutting machine from mbk with a wire diameter range of 4-10 mm and a max. straightening length of 4 m is primarily in the concrete pipe production for the manufacture and supply of longitudinal wires for the reinforcement cages, especially in connection with the cage welding machines from the mbk series ISM, ESM and BSM. However, the DRA-C is also interesting for manufacturers of other precast concrete elements or also reinforcing steel processing companies in order to straighten and cut wires of different lengths off the wire coil for further processing. Recent optimisations of mbk’s rotor straightening technology and corresponding program/software updates have also been incorporated into the DRA-C, further improving straightening results and accuracies to allow very small tolerances for reinforcement in concrete pipes, precast elements and for rebar producers. ReelThe reel carries the spooled wire material, which is available in various coil sizes. The standard reel for this machine carries coils of up to 3 tonnes in weight and is equipped with a pneumatically operated locking brake and wire sensing for quick detection of wire ends. Optionally, the straightening machine can also be equipped with a motor-driven version as well as a variant for 5-tonne coils in order to reduce the time required for coil changes. Feed unitThe standard scope of supply of the DRA-C includes a feed unit that gently pulls the inserted wire from the reel and guides it to or through the straightening rotor. The feed unit, whose contact pressure is generated pneumatically, is easily adjustable and can thus handle all predefined wire sizes. Rotor straightening unitThe DRA-C straightens the wires according to the rotor principle with straightening jaws/straightening nozzles, in which hard metal jaws rotate very quickly around the unwound wire. The straightening jaws describe a wire-specific, empirically determined curve and achieve a very good straightening result. The feed speed and rotor speed are also coordinated accordingly. Stationary cutterThe DRA-C has a high-speed cutter, which was specially developed for this application. It is adapted to the corresponding wire diameters to ensure fast, safe cutting speeds. During this time, the feed motor and rotor motor run at virtually unthrottled speed. Wire dischargeThe wire discharge system, which ejects to the operator’s side as standard, also carries the length measuring system. This system is easily adjustable and convinces with its repeatability. There is a discharge area adapted to possible wire lengths, in which wires can be collected and bundled or simply removed. The wire discharge is positioned after the cutter and adjusted in height to the machine. Control with PLCA simple and clear operating console with touch display allows the operator to communicate with the machine and make all necessary entries. The DRA-C controller is based on B&R’s current platform, and all components such as PLC, visualization, safety technology and drives come from a single source. In the case of service and spare parts, the systems can also be attended to quickly and reliably in the future. In addition, these control components are available worldwide in the event of a malfunction. Further areas of applicationAs a relatively simple machine, the DRA-C is tailored to the above-mentioned areas of application. For other or larger wire diameter ranges as well as longer wire lengths, mbk’s product range includes the single-rotor straightening systems type DRA-E as well as the multi-rotor systems type DRAM, which can also be combined with automation solutions or directly integrated into the downstream processes or machines.
60 years of welding machines and systems for the construction and concrete industries
60 years of welding machines and systems for the construction and concrete industries In 1961, Georg Pfender, who was employed as a factory fitter at Rinninger, a local concrete producer, decided to set up his own small mechanical lathe shop – initially from a garage at his home. Exactly 60 years ago, this industrious craftsman from Allgäu, Germany, started turning components for companies in the surrounding area. What started small soon gathered momentum and increasingly more companies began to trust in Pfender’s quality and inventiveness. He bought a plot of land from a farmer and erected a hall there. At this site, he mainly manufactured welded structures, machines and other equipment. At the end of the 60s, the company changed its name to Georg Pfender Maschinenbau. A parallel development taking place at that time marked a milestone for the company. Reinforced concrete pipes came onto the market in the 1960s. Although there were already machines for producing the reinforcements, they were still quite complex and expensive. This motivated Rinninger, the concrete producer, to commission Georg Pfender Maschinenbau to construct such a machine. As a result, the first reinforcement welding machine from Pfender was built and became a trailblazer for the next decades. The name Pfender became increasingly well-known, even beyond the borders of Germany. The small artisanal business from Allgäu had suddenly turned into an internationally active company. After the first welding machines had been sold throughout Europe at the beginning of the 1970s, another significant step in the company’s history was taken in 1981. The first machine departed the Allgäu region for the USA, paving the way for a successful future overseas. A further change of name ensued in wise foresight that there could possibly be difficulties with the pronunciation of the name Pfender. Georg Pfender Maschinenbau became today’s mbk Maschinenbau. Georg Pfender would never have dreamt that this abbreviation would one day become synonymous with cage welding machines in the USA. As the product portfolio grew, so did the space needed for production. The company’s next move brought mbk to the place of its current headquarters. Courage, diligence and inventiveness – these three qualities are essential in building up such a company. And Albert Pfender, who followed in his father’s impressive footsteps in 1985, also possessed these three qualities. For a quarter of a century, this master mechanical engineer guided mbk in its second generation. He invested his entire time, energy and all his heart and soul in continuously expanding the company, in constantly developing its systems and machines still further and in optimising product and service quality. In 2011, his son, Mario Pfender, joined the management team and, as a trained mechatronics technician with studies in industrial engineering, he brought that something along that would once again raise mbk to a higher level: the right mix of technical and entrepreneurial understanding, respect for the past yet the passion not to stand still, but to always look ahead to the future. It is imperative to constantly reinvent oneself and optimise processes still further in order to survive in a market that is becoming ever more complex. Quality “Made in Germany” Today, 10 years after the third generation took the helm, mbk can look back on 60 years of company history. The company now has subsidiaries in the USA and Russia and employs around 100 people. More than 1,200 machines have been installed in over 60 countries. mbk offers its customers quality “Made in Germany”, assured by qualified specialist staff, by a state-of-the-art design and development department working to the latest standards, by a machine pool of the latest generation and, last but not least, by ISO 9001 certification. Whereas Georg Pfender initially drew the designs for his constructions on a workbench with chalk, today strategically thought-out processes and management control are on the agenda. And so, by dint of technical finesse, expertise, years of experience and very high quality standards, mbk has developed from a small artisanal business in the Allgäu region into a structured industrial company and, more importantly, into one of the leading manufacturers of welding machines and systems for the construction and concrete industries. Currently on the agenda: automation In addition to welding machines for producing concrete pipe reinforcements, mbk’s product portfolio has been continuously supplemented over time by a wide range of cage welding machines for driven and drilled pile production, lattice girder and mesh welding machines as well as wire straightening and cutting systems, together with a wide selection of matching accessories. And most recently: individually customisable automation solutions featuring very high performance but with low manpower requirements – from simple automation accessories up to fully automated production lines. Optimisation is a maxim that determines the daily production routine of many industrial companies. And it is precisely this requirement that mbk serves with its latest solutions, which are equipped with modern machine control along with remote maintenance and up-to-date software solutions. Another step on the way to a successful future.
Automation is the future
Automation is the future It is always just a matter of being one step ahead. To have solutions ready when a market indicates that the times demand something new. With the BSM, mbk has an innovative cage welding machine in its programme, which ensures streamlined and economic everyday production with various, individually adaptable automation solutions. Highest quality standards, maximum output, minimum manpower, trouble-free integration into spatial and existing production-relevant conditions, low maintenance requirements and short response times in case of service – these are the common demands made by customers of a machine manufacturer.It is the daily routine for mbk – and the ambition to always offer a little more. The versatile possibilities for individualisation of the machines achieve an enormous savings potential in terms of material and the production process. Tailor-made automation solutions are an essential part of the everyday business of mbk Maschinenbau GmbH. mbk develops, designs and implements modern concepts for the rebar, precast concrete, manhole and concrete pipe industry at its headquarters in Kisslegg: the BSM cage welding machine is available with different automation solutions due to its innovative technology and modular design. The BSM cage welding machine has long been tried and tested for the production of reinforcement cages for the manhole and concrete pipe industry. BSM technology and its wide range of applications have become an integral part of everyday production for many customers. With the BSM cage welding machine, reinforcement cages can be produced in the following designs: round (straight or with spigot and bell / socket), double cages (outer and inner cage) one behind the other, oval, egg shape, open shape or special shapes such as round-oval-round (ROR). Eight different sizes are currently available, the producible cage diameters range from 220 – 5,200 mm, depending on the machine type. For the cage lengths to be produced, dimensions of up to 7,000 mm apply, other lengths are possible on request. Reliability, stability and durability, low maintenance and energy costs combined with high productivity are the core features of this cage welding machine. Strictest production tolerances for exact and straight cages and their compatibility with any standard make the BSM highly suitable for everyday use. Companies are under constant pressure to improve their day-to-day production. Adapted automation solutions are predestined to optimise the value chain of a company. mbk provides interesting automation solutions for the BSM and BSM-ROR cage welding machines. These range from simple automation accessories to fully automatic production lines with buffer solutions and transfer of the reinforcement to the downstream pipe machine: Wire straightening and cutting machine (DRA) for the production of longitudinal wires The DRA family ranges from simple single wire straightening and cutting machines in various gradings (DRA-C and DRA-E) to the new multiple wire straightening and cutting machine, DRA-M. The facilities for straightening, cutting and bending reinforcement wire from a coil cover wire diameters in the range of 4 to 20 mm. The automatic wire change in the DRA-M, equipped with up to 6 rotors for different wire diameters, ensures a smooth workflow. Production lengths up to max. 14 m and straightening speeds up to 140 m/min are possible and numerous optional additional features such as automatic connection to the cage welding machines make the production process noticeably easier. Automatic longitudinal wire feeding with wire from the bundle or from the coil The feeding of the longitudinal wires for the cage can be automated, either from the bundle (ALZ-B) or directly from the coil (ALZ-C). These variants are fed individually, bar by bar, and also allow the loading of non-round products (oval, egg shape, etc.). The new version of the type ALZ-M automatic longitudinal wire feeder opens up new dimensions in terms of cage output: the new feeding system allows all of the longitudinal wires required for the cage to be inserted – fully automatically – in one step for all the cage diameters that can be manufactured by the machine. The basic version of the longitudinal wire feeder works with pre-lengthened longitudinal wires from the magazine, which can be filled with up to one tonne of material. Alternatively, the design and combination with an integrated wire straightening and cutting machine, which works directly from the coil, is also possible here. Multiple winding wire guide with automatic and quick wire change Automatic winding wire shears This allows automatic cutting of the winding wire after the welding process. Adequate solutions are also available for the removal and handling of the manufactured products. In addition to simple and electro-hydraulically adjustable cage removal carriages, different versions are available for automated handling of the cages: Cage removal devices (KEG) for removing and setting down the reinforcement. Different versions cover a wide range of requirements, from just one to several set-down positions, as well as the loading of buffer and conveyor belts Cage removal and joining devices (KFG) for removing, setting down and joining double reinforcements (outer and inner cage). With this version, too, several set-down positions and the loading of buffer and conveyor belts are possible. Buffer solutions for intermediate buffering of reinforcements. Transport solutions for safe transfer of the reinforcement to the downstream pipe machine. The machine control system and the software solutions offered are also all state-of-the-art. The connection of the machine software to the office workstation not only allows production lists to be generated and evaluated in the office. It is also easy to log all machine parameters and settings, and to save and evaluate production data. Through hotline solutions for the secure transmission of image-controlled customer support with completely new and innovative systems for efficient maintenance and repair with Augmented Reality and Assisted Reality, mbk is also at the forefront when it comes to the service practised. These individually adaptable automation solutions are a step into the future, where top performance and competitiveness will play an even more important role. And a partner who has the appropriate spirit of innovation, decades of experience, a good deal of know-how and a great deal of social competence is a
Cage welding machines for driven and bored piles, columns and beams
Cage welding machines for driven and bored piles, columns and beams When ground conditions are difficult and a firm foundation has to be created, this is the time for pile foundations and bored piles.There is also great demand for precast driven concrete piles, ranging from simple halls to extremely complex constructions. Reinforcements in a wide range of dimensions form the basis for all these driven and bored piles, columns and beams. When special designs and gigantic dimensions are required, one name is at the forefront of the industry: mbk Maschinenbau GmbH has long been known as a system solution partner. Individual concepts with added value are created with a high level of technical know-how, a great deal of experience, immense innovative power and the ability to fully engage with the concerns of the customers. For the production of round and square reinforcements for driven and bored piles, columns and beams, mbk has cage welding machines with different specifications in its product range. ASM cage welding machine The ASM cage welding machine, which was designed for the flexible production of reinforcement for driven and bored piles, columns and girders, is capable of producing cages with an outer diameter of up to 2,100 mm (depending on the number of longitudinal wires and wire combinations) and a maximum length of 24,000 mm. The longitudinal wire diameter is 12 – 25 mm (optionally 12 – 32 mm), the diameter for winding wire is 6 – 12 mm (optionally 6 – 16 mm). Various welding processes are possible with the ASM: resistance welding, single and multiple inert-gas welding and the patented DualWeld – the flexible, dual welding concept that combines the advantages of both systems. With DualWeld it is possible to change between the welding processes or to weld in parallel. A straightening unit for winding wire, a hydraulic cage support, winding wire reels with or without drive, various longitudinal wire diameters and asynchronous divisions in one cage are all components of the ASM. The LAN/WLAN connection, a touch screen with colour display and the setting of the reinforcement cage and welding data via stored programs are standard. The LSM, VSM-S and VSM-V cage welding machines were developed for the production of round and square reinforcements for driven and bored piles, columns and beams. LSM, VSM-S and VSM-V cage welding machines The LSM is available in two sizes (084 and 150) and two types (R/S: R = round, S = round and square).For square cages of LSM type S, the outside flank length ranges from 90 to 1,108 mm, depending on the wire combinations. The outer cage diameter for round cages is between 170 and 1,570 mm, depending on the number of longitudinal wires and wire combinations. Standardised cage lengths can be realised in the range from 3,000 to 24,000 mm; other lengths are of course available on request. The longitudinal wire diameter is 8 – 25 mm (optionally 8 – 32 mm), the diameter for winding wire is 5 – 10 mm (optionally 5 – 16 mm). LSM-C cage welding machine The cage welding machine of the type LSM-C is predestined to produce round and conical reinforcements for masts, driven and bored piles, columns and beams. It is also available in two sizes. The outer cage diameter for round cages is max. 1,500 mm, depending on the number of longitudinal wires and wire combinations. Standardised cage lengths can be realised in the range from 3,000 to 24,000 mm; other lengths are of course available on request. The longitudinal wire diameter is 8 – 12 mm, the diameter for winding wire is 5 – 8 mm. With the cage welding machines from the LSM series, no consumption of inert gas and electrodes is necessary. The ergonomic handling on the wire and cage side makes working noticeably easier. Winding wire cutters with and without drive as well as electric wire cutters ensure an efficient production process. The electronic welding point control achieves a very high welding capacity and welding quality – the precise dosage of the welding power, the contact pressure and the length of the respective welding impulses achieve very good results.The possibility of setting reinforcement cage and welding data via stored programs is a great help in everyday production. The programmable winding wire pitch also ensures high variability. Easy handling and programming is guaranteed by the use of touch panels and IPC/PLC control. The LAN/WLAN connection is part of a modern production process. The LSM can also be optionally equipped with the DualWeld, the flexible, dual welding concept. The VMS-S and VMS-V cage welding machines impress with their very high production rates. VMS-S cage welding machine The VMS-S is distinguished by a number of features such as the performance package for higher welding and production capacities or the coil winder for winding standard coils onto LSM series coils. For square cages of VSM type S, the outside flank length ranges from 94 to 450 mm, depending on the wire combinations. The outer cage diameter for round cages is between 132 and 636 mm, depending on the number of longitudinal wires and wire combinations. The number of longitudinal wires is defined by replacement discs (variable). The maximum standard length of the cages is 3,000 – 24,000 mm and can be individually determined on request. The quick-change system for different cage geometries (round, triangular, square, etc.) supports economical work. Very high flexibility underpins efficient production. This is made possible by the quick changeover of the machine to other geometries. VSM-V cage welding machine The VSM-V cage welding machine is used for the production of square reinforcements for driven and bored piles, columns and beams. It only differs from the VSM-S in the manufacturing dimensions, the characteristics are identical. For square cages of VSM type V, the outside flank length ranges from 111 to 422 mm, depending on the wire combinations. Cage lengths as for the VSM-S, i.e. 3,000 – 24,000 mm, including the possibility of individualisation. 4 longitudinal wires, optionally double wire in the corner.
Benefits for the manhole and concrete pipe industry
Benefits for the manhole and concrete pipe industry The requirements of the concrete industry are increasing.mbk Maschinenbau GmbH usually succeeds in developing machine concepts in advance that ensure rational and economical everyday production. Solutions with added value are created on 10,000 m2 at the headquarters in Kisslegg. In addition to top quality and a high degree of individualisation of the machines, mbk also focuses on achieving the highest possible savings potential in terms of material and production processes. This is achieved, among other things, through tailor-made automation solutions, which play a significant role at mbk. For the production of various manhole and concrete pipe reinforcements, mbk has cage welding machines with a wide range of specifications in its range. ROR cage welding machine with variable spread When round concrete components are produced (e.g. for wastewater piping systems), round concrete elements are inserted into the mould during pipe production. Since concrete is enormously pressure resistant but not resistant to strain or bending, different stress ranges arise in a concrete pipe – depending on the installation condition – which must be supported differently. As it was not possible until recently to produce reinforcement cages with different geometric shapes (e.g. round-oval-round) on one machine, two round cages with different diameters were used. With one reinforcement cage the tensile stresses in a certain pipe area were absorbed and with the second cage the stresses in another area, which are usually offset by 90°, were absorbed. The result was not only disproportionately higher costs (and masses) for the respective products, but also a noticeable additional expenditure in terms of time and handling. mbk’s know-how was in demand and the BSM-ROR was born – a cage welding machine with which cages with variable, interlocking geometry can be produced. In the production process, reinforcement cages flow smoothly from one shape to another shape and then back again (e.g. round-oval-round). The tensile stresses, which are offset by 90° in different diameter ranges, are only absorbed by one reinforcement cage. Responsible for this is the development of a spreading system in which the linear movement of a spreading drive is divided into different linear movements of the individual slides, each holding a longitudinal wire. A special challenge was also the hydraulic control system of two hydraulic drives, some in synchronous and some in counter-rotating operation. Oval reinforcements were, of course, already known and corresponded to the current state of the art. However, pipes with oval reinforcement as central elements have no support in the connecting elements of the pipes (socket and bell). These connecting elements must be round for reasons of tightness. Thus, round reinforcements at the ends of the pipes are indispensable for a stable, fatigue-resistant and tight concrete pipe. The BSM-ROR is mbk’s answer to the demands of an innovative market and offers economic advantages such as enormous material and time savings, handling and maintenance benefits as well as a significant added value for the environment: Saving of steel resources (45%), energy saving, reduction of traffic volume. BSM cage welding machine The BSM cage welding machine for the production of reinforcement cages for the manhole and concrete pipe industry is also available in the following versions: round (with bell socket), double cages one behind the other, oval (round, with bell socket), oval, egg shape, open shape or in special shapes. The BSM is available in eight sizes, the producible cage diameters ranging from 220 – 1,700 mm to 900 – 5,200 mm, depending on the machine type. The cage lengths range from 2,000 – 7,000 mm, other lengths are available on request. The BSM is very reliable and durable. In addition to a stable design, it is distinguished by high productivity, flexibility and low maintenance and energy costs. Changes of dimension at the push of a button and link programs for inner and outer cages. Strictest production tolerances for exact and straight cages and their compatibility with any standard make the BSM highly suitable for everyday use. Numerous additional features guarantee stable production processes. A wide range of optional automation solutions improve the daily production routine. BSM Automation The automation solutions for the BSM and BSM-ROR cage welding machines range from simple automation accessories to fully automatic production lines with buffer solutions and transfer of the reinforcement to the pipe machine.A wire straightening and cutting machine is used to produce longitudinal wires. Wrap wire decoiler with and without drive, multiple winding wire guides for quick wire change. The automatic longitudinal wire feed with wire from the bundle or from the coil. The automatic wire wrap cutter is also part of an automation solution. Appropriate aids are available for handling the manufactured products, such as a cage removal carriage and cage removal devices. Removal, placement, positioning and joining of reinforcements and double reinforcements by means of cage removal and joining devices. Buffer solutions optimise the storage of reinforcements.Modern transport facilities were designed in order to ensure the safe transfer of the reinforcement to the pipe machine.Various software solutions such as machine software for office connection, production lists in the office, recording of all machine parameters, settings and production data simplify and accelerate the production performance noticeably. ISM cage welding machine The ISM cage welding machine was designed to produce reinforcement cages flexibly and economically. Like all mbk machines, the ISM meets all requirements for reliability, durability, energy saving and low maintenance. With the ISM, cages in the round version (with bell socket) can be produced in the following diameters (depending on the machine type):220 – 1,400 mm (140)220 – 1,900 mm (190)330 – 2,500 mm (250)660 – 4,500 mm (450) Cage lengths can be realised from 2,000 – 3,000 mm, other lengths are available on request.ISM also stands for strictest production tolerances and guarantees the production of exact and straight cages. The scope of delivery includes wrap wire decoilers up to 3 t as well as a switch-off ramp with monitoring for wrap wire decoilers. A wire deflector as well as wire guiding stands, a cage removal
Further developed mesh welding machine for precast slabs with in-situ topping and solid walls
Further developed mesh welding machine for precast slabs with in-situ topping and solid walls As a system solution partner, mbk Maschinenbau GmbH’s product range also includes a modern mesh welding machine for the production of precast slabs with in situ topping concrete with Z-bending (BF4) and meshes with recesses for solid walls (double walls) as well as special and standard meshes. The line is equipped with technical innovations such as a mesh conveyor system for different depositing positions and stack formation according to the pallet layout. In addition, the reinforcement welding machine MSM-M capable of providing the meshes flexibly – according to customer requirements – and to place them on the pallet just-in-time. mbk develops, designs and implements efficient and reliable solutions for the construction, concrete and precast industry with a highly expertise development and technical team at its headquarters in Kisslegg, Germany, located on a site of circa 10,000 m2. In addition to know-how and experience, innovative strength also means integrating the needs and requirements of customers into a modern production environment. mbk reacts to the changes in the market with new, contemporary approaches (and designs). A highly automated precast production of precast walls, double walls and slabs requires efficient and intelligent reinforcement production. The main area of application of the meshes produced is in precast concrete elements for building construction, residential and industrial construction. In particular, the automated production of reinforcement meshes for the manufacture of precast concrete elements with recesses for window and door openings, for walls and recesses for ceilings is becoming increasingly important. The flexible mesh welding machine MSM-M welds reinforcing steel meshes directly from the coil – set to individual CAD drawing specifications. The mesh width that can be produced on the machine shown is in the range of 500 mm to max. 3,500 mm, depending on the requirements. The mesh length ranges from 1,000 mm to 8,000 mm. Since the system is manufactured to customer specifications, larger dimensions, both in length and width, are also possible. mbk’s DRA-M multiple rotor straightening and cutting machine is used for the automatic loading of the longitudinal and transverse wires for flexible mesh production from the coil. The standard wire diameters to be processed range from 6 mm to 16 mm and can optionally be be adjusted from 5 mm to 20 mm. In this version, the wires are fed in via 5-tonne reels, alternatively 3-tonne reels can be used. The longitudinal reinforcement is transferred fully automatically directly from the DRA-M rotor straightening and cutting machine to the welding unit of the mesh welding machine. The grid size of the longitudinal reinforcement is 25 mm.The automatic provision of the additional reinforcement by means of DRA-M on a separate run-off carriage is another useful accessory function. The required lengths of the transverse reinforcement are assembled with the DRA-M and then fully automatically transferred to the welding unit of the mesh welding machine as required. The minimum distance between the cross wires is 35 mm and can be adjusted with no upper limit. Once the mesh is finished, it is automatically labelled with text and/or barcode as required, the information required for this coming directly from the host computer. A mesh conveyor system enables further processing via a fully automated traverse. The mesh is transported automatically – depending on the application – for further processing to the bending beam for Z-bending the end bars (BF4) or directly to the stacking position. In the subsequent circulation plant, the mesh is deposited and stacked at the respective positions for further processing – as in the pallet layout – according to the master computer specifications. This further development of the MSM-M mesh welding machine from mbk also meets the requirements of everyday suitability and within budget. With the usual stable and solid construction made in Kisslegg and low maintenance requirements, mbk guarantees efficient production processes. The production capacity of the MSM-M corresponds to the production requirements of the customer’s pallet circulation system and is dependent on the layout and recesses. The MSM-M is developed and built in different performance levels and with various accessories for automation according to individual customer requirements. The plant layout is flexible and can be adapted to local conditions. In this MSM-M mbk implements stacking for buffering in the reverse order: The meshes are prepared for production in different stacks in the areas assigned by the master computer. The stacks of meshes are then provided just in time for the circulation plant by means of a chain conveyor. For series and end stirrup production there is also the possibility of producing special and standard meshes. The equipment of the plant with a mesh bending station for frontal Z-bending (BF4) of the bar overhangs is predetermined for the production of precast slabs with in situ concrete topping. The automated traverse allows the produced boards to be deposited for external purposes on an additional stacking pallet. These can then be used for other purposes such as structural precast elements and additions for the construction site. The strength of mbk lies in the development and realisation of individual, modern and future-oriented solutions according to the actual situation of the customer and the respective requirements profile. Our professional spare parts and maintenance service is also one of the company’s focal points. At mbk Maschinenbau GmbH these qualities are part of our ethos and customers all over the world appreciate this.Because, even in a world dominated by technology, values shape customer relationships (strong connections) determine how market shares develop. https://youtu.be/1mgbCBe9CzI By loading the video, you agree to YouTube’s privacy policy.Learn more Load video Always unblock YouTube
mbk is to launch a new wire straightening and cutting machine with double bender – the DRA-16-M
mbk is to launch a new wire straightening and cutting machine with double bender – the DRA-16-M Right on time for wire 2020, mbk will present its new product, the DRA-16-M, a new wire straightening and cutting machine for straightening, cutting and bending reinforcement wire from coil – offering many advantages. The new wire straightening and cutting machine for the straightening, cutting and bending of reinforcement wire from the coil is designed to have a highly positive effect on a tight production schedule. 6/8/10/12/14/16 mm wire diameters belong to its wide processing spectrum, 6 rotors ensure a smooth workflow. The maximum production length is 14,000 mm, the minimum production length is 500 mm and the straightening speed can be controlled up to 140 m/min. The DRA-16-M is available in a right-hand version as standard, in other words, the machine is loaded with wire from the right-hand side of the control panel. Production direction from right to left, rod removal on the left side. The machine has been equipped with clockwise rotating reels with adjustable reel attachment for an inner coil diameter of 370 – 900 mm and an outer coil diameter of max. 1,200 mm. The coil weight is 3,000 kg, but can be supplied with 5,000 kg if required.The feed unit is synchronised with the rotor alignment unit, which ensures a stable production process. Straightening rotors are equipped with carbide straightening elements, which among other advantages, provides excellent wear resistance as well as reduced maintenance time. The stationary cutter is also part of a stable, precise and economical production process. A flying cutter is also available as an option. The standard version of the DRA-16-M also includes the wire discharge of the cut reinforcement on the operator’s side for reinforcement operations. Wire lengths of 1 m and more can be bundled, wire lengths of less than 1 m are allowed to drop freely, e.g. into a cage. A distinctive aspect regarding this new design is, among other things, that the version with wire discharge on both sides is also available as an option. The double bender for the production of the Z-bend (BF4) for precast concrete and element slab production is an additional useful option. Consequently, this additional feature can be used to accommodate and satisfy a wide range of customer situations and demands. The IPS control and Soft PLC provide for the stable processes of the DRA-16-M. The machine does not require hydraulics, which is also reflected in lower maintenance requirements. Furthermore, this machine of course complies with all technical and safety specifications according to CE conformity. To ensure that customers are provided with the most effective solution in all situations, mbk is launching an extensive range of accessories for all new developments – including for the DRA-16-M. In addition to double-sided wire ejection (as mentioned above), a LAN connection and a double bender for Z-bending (BF4) are available as options for the DRA-16-M. The definition/precise specification of the interfaces from the host computer or for the wire transfer (interface 1 for the loading of the circulation system, interface 2 for the loading of the production such as double wall solid wall and slab) can also be optionally implemented. The necessary and safe operation has to be guaranteed, as the machine is not only delivered as a stand-alone unit, but also works together with existing circulation systems. The definition/accurate determination of the interfaces and safety technology – which is also possible as an option – is a crucial factor. mbk also offers additional features in the field of sorting technology for reinforcement spacers: The optimised sorting technology is integrated into the machine both mechanically and with regard to the control system. Sorting technology such as the sorting container and feed rails have been improved, the spacer gun has been reworked, adapted to different spacer diameters and further developed. The wire straightening and cutting machine with double bender – DRA-16-M – represents a new development from mbk that will make everyday production easier for many companies.Looking into the future with foresight and guaranteeing security of investment – a highly qualified team is available to customers for after sales service and support.The technology from mbk Maschinenbau GmbH, which is founded on precision and a high level of individualisation, offers the best conditions for economic efficiency and consequently contributes significantly to modern economic life. https://youtu.be/xgoiqS6FLbU By loading the video, you agree to YouTube’s privacy policy.Learn more Load video Always unblock YouTube
