Flexible automation for the manufacture of reinforcement elements

Flexible automation for the manufacture of reinforcement elements Industrial robots have been established for years as a proven solution for the automation of welding processes. They offer high speed and precision, resulting in improved welding quality. Another advantage of industrial robots is their ability to handle heavy and unwieldy parts. However, these robots require high investment costs and extensive programming skills. They are therefore often too complex for the production of small batch sizes, for use in small and medium-sized companies or for special applications such as the welding of reinforcements. In comparison, welding cobots are much easier to programme. Their low investment costs enable rapid amortisation, which makes them particularly attractive for smaller manufacturing companies. However, one disadvantage of standard welding cobots compared to industrial robots is often their limited radius of action and working area. With the new mbk welding cobot, however, this disadvantage is a thing of the past. DSM-L (Line)The DSM-L (Line) model was specially developed for the manufacture of long reinforcement elements and is suitable for a wide target group – from small steel companies to precast concrete plants. “The DSM-L can process components up to eight metres in length, which was previously only possible with industrial robots. We thus offer a unique solution on the market,” says Mario Pfender, Managing Director of mbk. The cobot travels on an eight metre long linear axis and thus covers the entire working area. In addition to the robot, the welding power source, the wire supply, the welding fume extraction system and the torch cleaning station also move. The integrated 3D welding table has an impressive size of 8400 x 1395 mm. Very high safety at full performanceSafety is the top priority at mbk. Protective welding walls around the welding cell protect the operator from electric arcs and eye damage. Laser scanners monitor the working area and ensure that the cobot stops immediately if an operator gets too close to the working area. These safety precautions make it possible to achieve the maximum movement speeds of an industrial robot without jeopardising safety. Simple operation and flexible programmingThe mbk Cobot impresses with its user-friendly interface. The software was specially developed and optimised for the cobot and the welding process. The multifunctional handle serves as an interface between the robot and the operator. Teaching involves manually moving the welding torch to the desired welding spots. Start, end and intermediate points are saved at the touch of a button. Whether you are an experienced programmer or a beginner – professional welding programmes can be created in just a few minutes. The entire process can be simulated before the actual welding so that the operator can make adjustments if necessary. Efficient work in alternating operationAnother highlight of the mbk Cobot DSM-L is its special design, which enables efficient work in alternating operation. The workspace can be divided into two areas by a partition wall. This arrangement creates space for two working areas, so that the operator can set up or clamp workpieces on one area while the cobot is already welding on the other. This significantly increases productivity. Welding is a demanding, physically strenuous activity that requires a high level of concentration. The cobot relieves employees of tiring routine tasks and reduces physical strain at the same time. An optional single-axis manipulator with counter bearing enables the precise positioning of workpieces weighing up to 2,000 kg in the optimum welding position, eliminating the need for laborious reclamping. The manipulator and robot axes work simultaneously, resulting in greater efficiency and speed during welding. The result is precise spot welds of consistently high quality. Other models and versionsIn addition to the DSM-L, there are also the DSM-H (House) and DSM-T (Table) models, which are each tailored to smaller component dimensions and their specific requirements and applications. mbk – Partner for innovative manufacturing solutionsWith the new mbk Cobot DSM-L and other advanced technologies, mbk is setting new standards in automated production. The company stands for quality, innovation and customised solutions that sustainably increase productivity and efficiency in the manufacturing industry. mbk is not only aimed at small and medium-sized companies, but also offers user-friendly automation solutions to large companies.

Difer Impianti becomes part of the mbk group

Difer Impianti becomes part of the mbk group The mbk group is growing and integrating the Italian pile cage welding machine manufacturer Difer Impianti. Founded in 2007 by Leo Ferrari, the company specializes in the development and manufacture of its own piling machines. The machines on offer cover the entire range of sizes up to 3 m in diameter, including an extensive portfolio of accessories. mbk Maschinenbau develops and sells customized solutions for the concrete, construction and precast industries. The third-generation family-owned company has been active in the field of reinforcement welding machines for over sixty years and is one of the world’s leading companies in the industry. Machines for processing reinforcing steel as well as customer-specific special machines round off the product range. Difer Impianti and mbk are united by a very similar corporate philosophy of offering customers a high-quality, reliable and durable product. Combined with strong customer orientation and focus on after-sales service. “After decades of dedication to the design and marketing of piling machines that have improved the production of foundation piles around the world, the time has come for me to retire. It is with great pleasure that I have sold my company Difer Impianti to Mario Pfender of mbk, safe in the knowledge that he will be able to continue it with great success,” says Leo Ferrari. Mario Pfender, Managing Partner at mbk comments: “I am looking forward to the new challenge and the opportunities we have together. The Difer gas shielded arc welding machines complement mbk’s resistance welding machines perfectly. Together we are able to cover almost all requirements in the field of cage welding machines for bored pile cages. With the gas-shielded arc welding machines, the resistance welding machines and the patented Dual Weld Option (which combines both technologies in one machine), we offer a range that no other supplier can match.” Both companies benefit from their respective experience in this segment and want to utilize synergies in the future, not only in the areas of sales and service. Stefano Gabrielli, Technical Director at Difer Impianti, adds: “After 20 years of experience in the reinforced steel machinery sector, particularly with the pile cage machines, I’m thrilled to embark in this new chapter with MBK and our new CEO, Mario Pfender. This is a huge opportunity for both Difer Impianti and myself, and I can’t wait to see how we can further strengthen our company for the future. The journey continues, and I’m excited for what lies ahead!”

Customised solutions for the modernisation and optimization of production facilities

Customised solutions for the modernisation and optimization of production facilities Customised solutions for the modernisation and optimization of production facilities The renowned company mbk Maschinenbau in Kisslegg is increasingly establishing itself as a preferred partner for customer-specific solutions in the modernisation and optimisation of production systems. Through dedicated collaboration with customers and continuous expansion of the product portfolio, mbk is able to precisely identify and realise individual requirements. The modernisation and optimisation of existing production facilities is one of the focal points of the corporate strategy. Supported by the company’s practice-focused development and design departments, this area is increasingly taking centre stage. Customers benefit from the many years of experience and the customer- and solution-orientated approach that is one of the company’s guiding principles. A very good example of mbk’s innovative strength is the newly developed product family of the mbk DRA wire straightening and cutting machine. The DRA family offers solutions for different requirements in various versions: DRA C features Rotor straightener with one rotor, fixed measuring stop and upright cutters. A cost-effective solution, particularly suited to jobs where the investment cost is paramount, without sacrificing quality. Image 1: Wire straightening and cutting machine DRA-C DRA E features Rotor straightener with a rotor, length measurement by a measuring wheel and optional stationary or flying cutter. This variant is particularly suitable for tasks where a high-quality solution with simultaneous flexibility is required. Image 2: Wire straightening and cutting machine DRA-E DRA M features Rotor straightener with up to six rotors, either stationary or flying cutters. This option offers very high performance and quality with great flexibility. This is an extremely worthwhile option, especially for customers who want to overcome capacity and quality bottlenecks in existing circulation systems. Image 3: Wire straightening and cutting machine DRA-20-M for wires up to 20 mm Another special feature of the DRA M series is the possibility of equipping it with a double bender, which considerably expands the range of applications and flexibility. This facilitates use in new investments and retrofits in precast plants and reinforcement bending companies. Other automation solutions include possibilities for placing the wires on a circulation pallet or picking units. Image 4: DRA-M wire straightening and cutting machine with integrated double bender mbk supports customers in all project phases – from the initial idea through project planning and technical implementation to commissioning and after-sales, directly on site in the customer’s existing infrastructure. The contemporary implementation, modernisation and optimisation of advanced transport, logistics and automation solutions, safety concepts and software connections are also part of mbk Maschinenbau’s holistic concept of customer-oriented solutions.

Mesh welding machine for precast slabs, double and solid walls

Mesh welding machine for precast slabs, double and solid walls The mesh welding machine developed by mbk Maschinenbau GmbH is a cutting-edge solution for producing precast slabs with in-situ topping, double and solid walls. This machine incorporates technical innovations such as a mesh conveyor system that allows for different depositing positions and stack formation according to the pallet layout. It offers flexibility in providing meshes based on customer requirements and ensures just-in-time placement on the pallet. mbk, headquartered in Kisslegg, Germany, specializes in efficient and reliable solutions for the construction, concrete, and precast industry. Their highly skilled team integrates customer needs and requirements into modern production environments, responding to market changes with innovative approaches and designs. Efficient and intelligent reinforcement production is crucial for highly automated precast production of walls, double walls, and precast slabs with in-situ topping. The meshes produced by mbk find applications in building construction, residential and industrial construction, particularly in precast concrete elements with recesses for window and door openings, walls, and ceiling recesses. The flexible mesh welding machine, MSM-M, directly welds reinforcing steel meshes according to individual CAD drawing specifications. It can produce mesh widths ranging from Image 1: MSM-M welding portal with 6 or 9 welding heads possible Image 2: DRA-16-M: longitudinal and transverse wire transfer to the welding portal 500 mm to a maximum of 3,500 mm and mesh lengths ranging from 1,000 mm to 8,000 mm. Smaller and larger sizes are also available. For automatic loading of longitudinal and transverse wires, mbk utilizes the DRA-M multiple rotor straightening and cutting machine. It handles standard wire diameters from 6 mm to 16 mm, adjustable up to 5 mm to 20 mm. The longitudinal reinforcement is transferred automatically from the DRA-M to the welding unit of the mesh welding machine, while the transverse reinforcement lengths are assembled by the DRA-M and transferred as required. Image 3: Mesh extraction from the welding portal Image 4: Mesh transport with mesh stacking unit on chain cross conveyor Once the mesh is completed, it is automatically labeled with text and/or barcode, and a mesh conveyor system enables further processing through a fully automated traverse. The mesh is transported for further processing to the bending beam for Z-bending or directly to the stacking position. In the subsequent circulation plant, the mesh is deposited and stacked according to the master computer specifications. The MSM-M mesh welding machine from mbk ensures everyday suitability, cost-effectiveness, and low maintenance requirements. It can be tailored to meet specific production requirements, offering different performance levels and automation accessories. The plant layout is flexible and adaptable to local conditions. Special and standard meshes can be produced for series and end stirrup production. Image 5: Plant overview: MSM-M with mesh conveyor and Z-bending unit (BF4) To produce precast slabs, the machine is equipped with a mesh bending station for frontal Z-bending of the bar overhangs. The automated traverse allows the produced slabs to be deposited on an additional stacking pallet for external use in structural precast elements and construction site additions. mbk’s strength lies in developing and implementing individual, modern, and future-oriented solutions based on customer needs. They also prioritize professional spare parts and maintenance services. These qualities have earned mbk Maschinenbau GmbH a strong reputation worldwide, as they value customer relationships and their impact on market shares.

Efficient automation solutions for the concrete pipe industry

Efficient automation solutions for the concrete pipe industry The main objective is to stay one step ahead and provide solutions as soon as the market signals new requirements. The BSM is an innovative cage welding machine made by mbk that has been continuously refined. It offers various customisable automation solutions to ensure efficient and economical day-to-day production. These customisable automation solutions are an important step towards the future, where excellence and competitiveness play an even greater role. Customers attach great importance to high quality, maximum performance and low staff costs. Easy integration into existing production environments, low maintenance requirements and fast response times in the event of service are equally important. A machine manufacturer must meet these requirements. Considerable savings in materials and manufacturing processes can be achieved due to the versatile customisation options of the machines. Customised automation solutions are an integral part of mbk Maschinenbau GmbH’s everyday business. The company develops, designs and implements modern concepts for the reinforcing steel, precast concrete, manhole and concrete pipe industries at its headquarters in Kisslegg. The BSM cage welding machine features innovative technology and modular design and offers various automation solutions. The proven BSM cage welding machine is becoming increasingly important in the manhole and concrete pipe industry. It is used to produce reinforcement cages in various designs, such as round cages (straight or with spigot end and bell/ socket), double cages (outer and inner cage) arranged alternately behind each other, oval, egg-shaped, maul-shaped or even special shapes such as round-oval-round (ROR) or oval-oval-oval (OOO). Depending on the machine type, eight different sizes are currently available. The cage diameters that can be produced range from 220 to 5,200 mm. Image 1: High speed cage welding machine BSM-190-R Image 2: BSM-190-R with automatic longitudinal wire feeder (ALZ-M) Image 3: Automatic longitudinal wire feeder (ALZ-M) with integrated wire straightening and cutting machine The fully automated BSM-190-R cage welding machine can produce cages with lengths of up to 7,000 mm. Other lengths are possible on request. This machine excels in reliability, stability and longevity. According to the manufacturer, the machine offers high productivity at low maintenance and energy costs. Due to their precise manufacturing tolerances, very accurate and straight cages are produced. The BSM also complies with various standards and is therefore particularly suitable for daily use. Companies are under constant pressure to improve their production processes. Customised automation solutions can help to optimise the value chain. mbk offers interesting automation solutions for the BSM cage welding machine. 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) The wire straightening and cutting machine (DRA) is used for the production of longitudinal wires. There are different versions of the DRA, from simple single straightening and cutting machines (DRA-C and DRA-E) to multiple wire straightening and cutting machines (DRA-M). These plants can straighten, cut and bend reinforcing wire with diameters from 4 to 20 mm. Optional additional features such as the automatic connection to the cage welding machines further facilitate the production process. Automatic longitudinal wire feeding An automatic longitudinal wire feeder can automatically feed the longitudinal wires for the cage. This is done either with pre-cut longitudinal wires from a magazine that can be filled with up to one tonne of material (type ALZ-B) or alternatively via an integrated wire straightening and cutting machine directly from the coil (type ALZ-C). The longitudinal bars are fed individually and one after the other, which means that these variants also permit the placement of non-round products such as ovals or egg shapes. The latest version of the automatic longitudinal wire feeder (type ALZ-M, patented) allows feeding of all required longitudinal wires in one step, fully automatically and independent of the cage diameters that can be produced. The wires are already inserted during cage removal, which reduces the machine downtimes in the production process to a minimum. Automatic winding wire changing system The automatic winding wire change system (type AWDW, patented) allows changing between up to five different wire diameters. It consists of winding wire reels for the different diameters and a wire changing unit with an automatic wire Image 4: BSM-190-R with automatic longitudinal wire feed (ALZ-M) and winding wire changing system (AWDW) cutter and feed unit. The automatic wire cutter cuts the wire during cage production, which further reduces the cycle time compared to conventional cutters. The feed unit guides the next active wire up to the welding roller to make it available for the production of the following cage. The welding carriage is further equipped with an automatic adjustment of the welding and contact roller for automatic adjustment of the welding roller stroke and compensation of different wire thicknesses and wear. With the winding wire change system, inner and outer cages can be produced alternately with optimised wire diameters. Also, cages can be serially provided in different sizes, for example for pipe machines that alternately produce different pipe diameters. Cage removal device and cage removal and joining device After the production of the cage, there are various solutions for their automated removal and handling. The cage removal device (KEG) is available in various designs for removing and depositing reinforcement. Image 5: Cage removal robot (KFG) in operation at the customer’s site Image 6: Cage removal with cage feeding function (KFG) It meets a wide range of requirements, from a single to multiple parking positions. Depending on the stage of expansion, it also offers the loading of buffer and conveyor belts. The cage removal and joining device (KFG) is also used to remove, place and join double reinforcements (outer and inner cage). Like the KEG system, it features several set-down positions and the loading of buffer and conveyor belts. With transport and buffer solutions, reinforcement can be buffered and safely transferred to the pipe machine. This compensates for different cycle times and the cage welding machine can produce continuously, even if the cages are removed

Cage welding machine for the production of reinforcement square pile

Cage welding machine for the production of reinforcement square pile C L Pile Sdn Bhd is a reputable manufacturer of Quality Reinforced Precast Concrete Square Piles. The company was incorporated in Malaysia in the 1990s and start with the aim of management commitment and term cooperation effort, in order to optimize both productivity with quality and equipment life cycle, and maximize infrastructures effectiveness with cost effective control. The piles are manufactured in various sizes ranging from 125mm x 125mm to 450mm x 450mm and with various length 3.000 mm to 12.000 mm length, customize length can be made according to requirement as well – thus providing options to suit different working loads and depth of penetration and hence with minimum resources wastage. In order to meet the market, C L Pile produces both Reinforced Concrete Square pile and Prestressed Square pile. C L Pile’s product has been cooperated in many of the major projects and used extensively in highrise buildings, commercial buildings, mall, port, bridges, reservoirs, retaining walls, schools, residences and shop lots. They are not only supplying piles in Malaysia, but also exporting to Singapore and Indonesia, such as projects at Malaysian Johor Port/PTP, the development of luxury real estate and various independent Chinese schools in Malaysia, as well as Changi Airport and the Tuas Mega Port project in Singapore. Image 1 & 2: C L Pile Sdn Bhd in Johor Bahru Image 3 & 4: Driven piles produced in different dimensions RSM cage welding machine To produce round and square reinforcements for driven and bored piles (with or without cone end), columns and beams, that is what the cage welding machine RSM stands for in the -V and -S versions. For square cages (type RSM-V), the flank length on the outside ranges from 92 to 422 mm, depending on the wire combinations. The number of longitudinal wires is four, with optional double wires in the corner. In the round version (type RSM-S), round columns and micropiles with an outer cage diameter between 130 and 596 mm can also be manufactured. Cage lengths are possible from 3 to 18 m, with other sizes also available on request. The RSM can convince with many features, such as a very high variability in the freely programmable winding wire pitch (also multiple production of short cages in a long cage programmable), the production of cages with tip (cone end) by means of pre-bent longitudinal wires or the possibility of double wires in the corner. Due to the economical resistance welding technology, the RSM also eliminates the consumption of shielding gas and electrodes. The cage welding machine also convinces many users with its simple handling, with the setting of the reinforcement cage and welding data via saved programmes, low maintenance requirements and the LAN/WLAN connection for uncomplicated remote maintenance. Image 5: mbk cage welding machine RSM-V at C L Pile’s plant for high quality and efficient reinforcement for driven piles

Cage welding machines with well-proven technology

Cage welding machines with well-proven technology Driven and bored piles form the basis of load-bearing foundations on construction sites. There is usually no way around them especially in difficult soil conditions. Precast concrete driven piles are a popular choice. mbk, as one of the leading manufacturers of welding machines and systems for the construction and precast concrete industries, also has innovative solutions for this application in its product portfolio. Reinforcements of the most varied dimensions are possible with the VSM series cage welding machines. These machines have been tried and tested over a long period of time and can thus guarantee stable production processes. This is primarily due to their high quality, reliability and durability – but also because of the numerous possibilities of customising them completely individually to relevant production requirements. mbk is passionate about its work, should special designs and dimensions outside the usual range be required, and ensures that (almost) every customer specification can be met with a high level of technical expertise, a wealth of experience and immense innovative power. Image 1: VSM-V cage welding machine Square cages – VSM-V cage welding machine The VSM-V cage welding machine is tailored to the production of square reinforcements for driven piles, and also columns and girders up to a maximum length of 24m. Flank lengths of 111 to 422 mm are possible depending on the wire diameter combination. Both single and double wires can be welded in the corner. The VSM, unlike the other types of mbk cage welding machines, works or welds on a stationary product. It means that, rather than the cage, the coil together with the winding wire and welding unit rotates around the product, resulting in more speed and stability for products with a square cross-section. The spool for the winding wire can either be wound directly in the machine or alternatively by means of a separate spool winder. This then allows very short changeover times in conjunction with additional spools when the winding wire runs out or needs to be changed to a different wire diameter. Image 2: The spool rotates around the product together with the winding wire and welding unit. The result – more speed and more stability for products with a square cross-section Image 3: Square, rectangular, round, triangular – the VSM-S cage welding machine Image 4: VSM-057-S cage welding machine from mbk The wire decoiler supplied for coils is equipped with an adjustable decoiler attachment, which allows different coil sizes to be accommodated and is designed for a max. coil weight of 3,000 kg. Square, rectangular, round, triangular – the VSM-S cage welding machine The VSM-S cage welding machine is the flexible version of the well-known VSM. In this design, adaptable interchangeable discs allow different cage geometries to be produced on one and the same machine, with flank lengths up to 450 mm or diameters/diagonals up to 636 mm depending on the wire diameter combination. The discs and thus cage geometry can be changed easily and rapidly by means of a quick-change system. This has more than proven its worth particularly in the case of frequent geometry changes, such as in steel reinforcement and precast production facilities. This flexibility makes the VSM-S interesting not only in manufacturing driven piles, but also for producing reinforcement for bored piles, precast concrete columns, beams and masts. Image 5: Automatic VSM-V with DRA-20-M Round cages can also be produced in lengths up to 24 m – with different cage diameters and also different spacings. Cage lengths of up to 14 m can be achieved when manufacturing rectangular cages. Processable wire diameters for all versions are 8 to 25 mm for the longitudinal wire and 5 to 8 mm for the winding wire. Practical add-ons – accessories and automation solutions for the VSM A comprehensive range of accessories is available for the VSM series, as well as automation solutions ranging from the simple automation of individual operations to fully automated production lines. This means that longitudinal wires can be prefabricated and automatically fed to the machine when connected to a wire straightening and cutting line, allowing different cage lengths with different wire diameters to be produced just in time. It also facilitates a high degree of flexibility in production, for example, when fulfilling structural specifications for customer orders. The fully automated changeover of all relevant systems to other product sizes is possible as is the integration of a longitudinal wire insertion device for welding cages with short longitudinal wire overhangs. After welding, cage handling equipment and stacking systems enable the automatic removal, intermediate storage, transport and positioning of finished products for further processing in downstream operations. Image 6: VSM-V with intermediate storage system including product positioning for removal Flexibility is enhanced significantly thanks to fully automated production processes. Outputs of up to 1,600 linear meters of driven pile cages are also possible in a single working shift. A bundling solution for packaging cages for shipping is also part of the extensive range of accessories for the VSM. All of these automation solutions both ensure savings on personnel in the manufacturing process and also allow staff to work ergonomically in day-to-day production operations. Specialised for over 60 years in manufacturing reinforcement welding machines mbk is a global player in the concrete, construction and precast industries with over 1,200 machines sold worldwide. Welding machines – now in the third generation – have been manufactured in Kisslegg since 1961 and are operating in more than 60 countries. Professional, technically advanced after-sales service also plays a significant role in the company’s day-to-day activities. Quality “Made in Germany”, assured by qualified personnel, a state of the art design and development department, new generation machinery and last but not least ISO 9001 certification.

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.