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

NEW: DualWeld – flexible, dual welding concept for reinforcement cage welding machines

NEW: DualWeld – flexible, dual welding concept for reinforcement cage welding machines Mbk Maschinenbau is renowned for bringing revolutionary developments to the market offering its customers interesting opportunities to secure a share in today’s fast-moving market by means of innovative production methods.Now the company from Kisslegg has introduced a welding concept that combines the advantages of resistance welding and inert gas shielded arc welding: the Dual Weld process, which is unique in the industry in this form. The aim of this combined welding technology is to continuously weld using both welding processes and to seamlessly flex and incorporate the advantages offered by both processes directly in the production process as and when required. This enables welding to be performed in certain phases or component sections both with maximum strength and at high speed. It is also possible to work with both processes at the same time in specific work steeps or on particular components. mbk’s focus is always on the needs of the customer. With their requirements for automation, flexibility and quality the customer challenges the status quo and drives future-oriented developments. The requirement at hand was to develop a high-speed cage welding machine for bored foundation piles that combined the advantages of both welding processes. As component geometries are constantly being optimised in structural design it is often necessary to provide reinforcement for concrete elements with a filigree appearance and relatively thin longitudinal diameters of 8 – 25 mm and solid components with very thick longitudinal diameters of 25 – 45 mm. Fast-rotating resistance welding machines are used for manufacturing the long reinforcement cages necessary for foundation piles, columns and beams as a result of their superior efficiency. This method allows longitudinal wires up to a diameter of 25 mm to be firmly welded together with cross wires up to a diameter of 12 mm. Resistance welding is only suitable to a limited extent for reinforcement cages with a longitudinal wire diameter > 25 mm, because the amount of energy required to fuse the thick wires firmly and permanently cannot be applied in the short welding sequence. At a particular point the inert gas shielded arc welding process becomes more efficient than resistance welding. This process has the advantage that significantly greater wire thicknesses (longitudinal wire diameter 25 – 45 mm with winding wire diameter up to 14 mm) can also be welded without difficulty. The benefits of integrating both welding processes is a challenge that mbk has successfully addressed with the combined DualWeld welding concept. The new welding unit exhibits a high level of time saving potential and welding quality compared to current machines. It is able to adjust and react to changing diameters, axial welding positions and angles without any problems and decide which welding process is used for any particular welding spot. This is made possible by the innovative dual welding technology and intelligent control system. The new technology also satisfies the high demands in automation, working speed, repeat accuracy of the welding process and process reliability even where contamination is present. DualWeld is already patent pending.mbk currently offers both LSM and ASM with the new dual welding concept. The cage welding machine LSM 150 was designed for the production of round and square reinforcement for both driven piles and drilled piles, columns and beams and ensures a constant daily production routine for companies processing reinforcing steel as well as in concrete and precast plants. The LSM 150’s high speed (up to 5 times faster than the classic inert gas shielded arc welding process) and the high-speed welding performance of the LSM have been achieved to date with electronic spot-welding control. The control allows precise metering of the welding power, the contact pressure and the duration of the respective welding pulse. This is possible without consuming inert gas and electrodes. The new optional DualWeld welding concept has provided the LSM further performance optimisation and greater flexibility in terms of diameter range, welding and cage stability.The basic LSM cage welding machine is still available with conventional welding technology. A range of welding processes are available with the ASM cage welding machine, which was developed for the flexible manufacture of reinforcements with a varying number of longitudinal wires for driven and drilled piles, columns and masts; manual inert gas shielded arc welding, single and multiple inert gas welding robots and resistance welding. The ASM cage welding machine is now also available with the new dual welding technology DualWeld. As with the LSM, the ASM cage welding machine is still available with the conventional welding technology. mbk offers automation solutions for all of their machines. This ranges from the automatic cutting of the longitudinal wire from the coil through to the removal and further processing of the finished reinforcement cage. The advantages are clearly obvious: The mbk DualWeld technology reduces the amount of space and resources required by the processing plant. The output of cages with smaller wire diameters is up to 5 times higher than with the classic inert gas technology. Reinforcement cages manufactured with this process are stronger. This enables efficiencies such as the omission of some of the stiffening rings, resulting in significant time savings. Both techniques can be used for cages with larger wire diameters. This development will bring about increased flexibility, which will become increasingly important in the future. DualWeld is an investment in the future in which the requirements for optimised production processes will continue to increase. https://youtu.be/jigkhNkhycE By loading the video, you agree to YouTube’s privacy policy.Learn more Load video Always unblock YouTube

Flexible mesh welding machine MSM-M – setting trends

Flexible mesh welding machine MSM-M – setting trends At our headquarters in Kisslegg, Germany a highly experienced development and technology team, develops, designs and implements efficient and reliable reinforcement mesh welding machines for the construction, concrete and precast industries on an area of around 10,000 m2 . Known in the industry as a global player and system solution partner with a high level of individualisation, mbk Maschinenbau GmbH has been inspiring its customers with technical innovations and future-oriented systems since the company was founded in 1961.mbk Maschinenbau GmbH has successfully established itself as one of the leading manufacturers for innovative machine concepts that enable state-of-the-art manufacturing processes and markets welding machines and equipment for the construction and concrete industries in over 60 countries worldwide. Alongside know-how and experience, innovative capability also means recognising the current trends and reacting accordingly to the demands of a modern market. The automatic production of CAD-based reinforcement meshes for the manufacture of precast concrete elements with recesses for window and door openings is becoming increasingly significant. mbk recognised this trend and reacted with the flexible mesh welding machine MSM-M. This mesh welding machine welds reinforcing steel meshes directly from the coil – in accordance with individual specifications. The width of the mesh that can be produced ranges from 400 mm to max. 4,000 mm, depending on the requirements. The mesh length ranges from 1,000 mm – 14,000 mm, larger dimensions are possible on request. This new mesh welding machine is currently available in five sizes. The newly developed multiple rotor straightening and cutting machine DRA-M is used for automatic loading of the longitudinal and cross wires for flexible mesh production from the coil.The wire diameters processed range from 6 mm to 16 mm, as an option also from 5 mm to 20 mm. The longitudinal reinforcement is placed directly from the rotor straightening and cutting machine DRA-M in the desired mesh position on a mobile transport table. A fully automatic transport and transfer to the welding unit of the mesh welding machine follows from there. The grid size for the longitudinal reinforcement is 25 mm, the respective reinforcement bar diameter is decisive for the distance. The cross reinforcement is also placed in the required lengths in the correct sequence on an additional transport table, which is likewise mobile. The cut cross bars are then transported to the welding unit, where they are individually fed from below to the longitudinal reinforcement. The minimum distance between the cross wires is fixed at 50 mm, but is optionally infinitely variable. An impressive range of accessories for automation makes it possible to add useful features such as mesh handling, mesh deposit for “stand-alone” systems or in following circulation systems as well as for further processing in downstream bending stations. This flexible MSM-M mesh welding machine from mbk is an innovation on the market that satisfies all requirements for suitability for everyday use and cost-effectiveness. The robust design and low maintenance requirements guarantee efficient production processes. An uncomplicated and free exchange of information within a precast concrete plant is ensured by the connection to the Unitechnik CAD-CAM interface, LAN and WLAN connections offer the best conditions for fast and uncomplicated help in the event of a malfunction as well as simple and professional production planning through the use of various updates. The MSM-M average production output is approximately 200 m2/h. However, this depends on the mesh coverage and the recesses. A higher throughput can of course be achieved on request. One of mbk’s major strengths is its ability to develop and implement modern, future-oriented solutions that are tailored to the actual situation of the customer and the requirement profile. The professional and well-developed after-sales service – a key company focus – ensures that all machines and systems developed and built operate smoothly, well after commissioning, and that customers are able to benefit from a complication-free, economical day-to-day work flow. For mbk such aspects are a matter of course.This is something that customers all over the world have come to appreciate.Even in a world dominated by technology, it is values that shape customer relationships (strong connections!) and decide 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

New high performance cage welding machine for Pretensados Nacionales S. A. delivered to Costa Rica

New high performance cage welding machine for Pretensados Nacionales S. A. delivered to Costa Rica Reacting quickly and individually to the changing requirements of the construction, concrete and precast industry is part of everyday life at mbk. The manufacturer of wire cage welding machines from Kisslegg is known in more than 60 countries for the high quality of its machines and its pronounced customer orientation. Customers who have once decided in favour of a wire cage welding machine from mbk usually also decide in favour of mbk technology for the replacement or extension of the production process. This was also the case with Pretensados Nacionales, a company from Costa Rica for which mbk has already supplied and installed a wire cage welding machine. Pretensados Nacionales S.A. is a purely Costa Rican company founded in 1960 thanks to the vision and entrepreneurial spirit of Don Miguel Ángel González Camacho. The company focuses on the manufacture of non-reinforced concrete pipes according to ASTM C-14 specifications, reinforced concrete pipes according to ASTM C76, Class III, IV and V specifications, prestressed concrete poles for public lighting and power lines, prefabricated columns and concrete slabs for in- dustrial buildings, as well as elements and piles for docks, bridges and buildings. The company is one of the leading companies in Costa Rica, and convinces through high product quality and mature production processes. Miguel Ángel and Eloy Alberto González, the sons of Miguel Ángel González Camacho, who today continue to guide the company’s fortunes with innovative strength and entrepreneurial intuition, recall:“The connection to Germany and its technology accompanied our company history early on. Germany played an important role as early as the end of the 1950s, when the production of precast concrete parts began with concrete pipes, centrifuged piles and blocks: The concrete pipes were manufactured in individual steel moulds and these steel moulds came from Germany”. In 1977 the first machine (Pfeiffer brand) for the production of pipes – also from Germany – was imported. This was followed by the expansion of the product portfolio to include the production of poles for public lighting and electrical wiring. The prerequisite for this production was a pre-stressed centrifugal system – devices from Germany are also used for this process. To this day, the results stand for excellent quality and convincing aesthetics. Later, the Prenac precast system was developed, which en- closes houses and school buildings with columns and concrete slabs. The prefabricated system for Prenac school buildings is registered in the Department of National Buildings of the MOPT, the PROMECE Department and DIEE (Directorate of Education Infrastructure and Equipment of the Ministry of Education). In addition, the product range was expanded to include the production of concrete slabs and columns for industrial halls, as well as elements and piles for bridges, docks and buildings. “In 2007, we visited various concrete plants in Europe that had specialized in the production of concrete pipes. It quickly became clear that the machine, which was widespread, worked stably and efficiently, and had optimized manufacturing processes without any problems, came from mbk. The decision was made quickly and already in 2008 the first mbk machine was delivered and installed. It filled us with pride as it was also the first mbk wire cage welding machine in Costa Rica. Since then, we have produced all reinforcements exclusively with this machine. It ensures a stable daily production routine and is inexpensive in terms of maintenance. In the event of a malfunction, mbk as a service partner reacts quickly and without complications.” The market in Costa Rica is booming. This was and is an opportunity for the company to constantly increase its market share. “However, in order to cope with the increased volume of orders, we were forced to consider further investments, and since our existing mbk wire cage welding machine meets all our quality and production requirements, we decided in 2019 to purchase another mbk wire cage welding machine. The decision was made in favour of the BSM 360-O cage welding machine. It is equipped with the latest technology and is the largest of its type in Central America.”With the BSM 360-O, reinforcement cages for the manhole and concrete pipe industry can be manufactured with a round (with or without pallet), oval, egg or jaw form up to a diameter of 3,600 mm and a length of 3,000 mm. As a special feature, this machine was equipped with special performance packages for an even higher production output. In addition, a LAN/WLAN connection enables remote maintenance and teleservice from Germany. “We are partners in the country’s most important construction projects, e.g. Juan Santa Maria Airport, Puente Lindora extension, Garantías Sociales roundabout, Puente Virilla extension, Circunvalación San Jose project, school infrastructure and much more. Last year alone, we were involved in over 150 projects.”Quality is of great importance for the company and this also applies to the company’s internal behaviour in the event of maintenance. “We only use original spare and wearing parts from mbk and observe all maintenance intervals specified or recommended by the manufacturer.” This guarantees very high machine efficiency and maximum performance.“Since the company was founded, we have continuously strived to optimise manufacturing processes in order to offer our customers the best of all solutions at all times. With the BSM 360-O, reinforcement cages for the manhole and concrete pipe industry can be manufactured with a round (with or without pallet), oval, egg or jaw form up to a diameter of 3,600 mm and a length of 3,000 mm. Over the years we have tested many manufacturing processes and materials and have only ever been satisfied with the best. Only manufacturers who have the same high regard for quality and social competence as we do are given the chance to help shape the success of our company. In mbk we have found a partner who fully meets our requirements.” The success story of Pretensados Nacionales clearly shows how a partnership-based cooperation affects the win-win situation of all the companies involved, because everyone really