C Marshall Fabrication Machinery, Inc.

AR530 – The Largest Angle Roll Ever Built

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The MG Factory

The MG Factory

AR 530 is the new section bending machine manufactured by MG SRL, Italy that completes the already large range of models of plate and section bending rolls the company can take pride in its 54 years of life. The AR530 is the biggest section bending machine ever built; it is a giant 29.5′ x 29.5′, almost 26′ high, 340 tons, 220 HP with 1900 ton torque. The AR530 can bend standard and special profiles; Ts and channels, beams, round and square tubes and pipes. Wide flange beams up to 40″ can be bent the hard way!

A Guinness World Record!

It has been commissioned by an Italian company called Tromba Maurizio S.n.c. Tromba Maurizio S.n.c., located in Verona, is is very experienced in gargantuan bending for large building construction such as the Innsbruck Ski Jump, the Mestre Hospital and the Johannesburg 2010 Soccer World Championship Stadium. “Another important job we have made is the backbone of the Italian Genova – Ventimiglia tunnel for the high speed train,” says Mr. Maurizio Tromba, co-owner of the company together with Mr. Andrea, Mr. Nicola Tromba, and Mrs. Lauretta Binato. “We built about 1800 Tons of beams with sections from 7″ to 8.6”. All made on MG machines, 15 hours a day for 14 months production! This has definitely been a machine testing.”

Tromba Maurizio S.n.c., established in 1967 for the fabrication of flanges used for the closing of heater hatches, has made prominent technological innovations through the years responding to the demand of the market for the deformation of always bigger elements. After constant investments, they own now several MG branded bending machines; a complete fleet among which model AR 360 was the largest capacity one, outclassed today by AR 530, the largest capacity ever. “With the AR 360, even if big,” Mr. Tromba goes on, “we could not satisfy some of the new market requests demanding larger sections bending, due to the machine’s physical limits. Now, with AR 530, we will be able to compete on a new market segment.”

“We produce over 300 machines, produced and started up every year,” states Massimo Roccia, who is the co-owner of MG SRL together with Mr. Francesco Barca and Mr. Giorgio Giraudo. “This is an innovative project we have added to our already differentiated range of products. It has been a challenge lasting for two years, from the initial project to the final test and I can say it will count us among the best industrial solutions in the world.” MG SRL is a flexible company always ready to pursue new solutions. MG offers its machines all over the world. It focuses on the constant attention to the customer’s needs and offers products targeted precisely to each client’s requirements.

A cooperation based on trust

It’s rather interesting that in Italian the word trust is translated with “fiducia” that comes directly from the Latin word “fides”. The second meaning of fides is “rope”. And it is truly a figurative rope that ties these two companies together in this case. Anyone who climbs mountains knows how important it is to be tied to the rest of the group. The cooperation between Tromba and MG has been going on since 2002 and this new big machine, AR530, has been realized thanks to mutual research and support between the two companies. “This comparison,” Mr. Tromba continues, “definitely conveys how our relationship with MG is. We have always been MG customers and have always found in MG people listening to our requirements and being attentive to our needs, able to give us the answers to new performance demands.” “This rope is not only between us and our customers,” adds Massimo Roccia, “it involves our suppliers, as well. It is the success of a close-knit team of workers aiming for the same goal. Everyone has contributed with ideas, projects, and technological know-how in order to build this machine.”

Guinness features

AR 530 stands out for its modular design in order to best optimize the assembly of the machine. Its design makes it also easy for packaging and freight handling. The main frame is made of very strong electro-welded steel, on which two modules of respectively 54 and 64 Tons are assembled. This machine has been built following the unique manufacturing tenets which are typical for MG, such as the planetary movement of the bending rolls, which, thanks to the hydraulic cylinders, reduces frictions to a minimum and can be considered an anti-deflection system. In fact, the planetary approach of the two bending rolls towards the main shaft, which is fixed in the center, allows a perfect bending with very short flat edges. The hydraulic side guides have a tri-dimensional movement. Therefore the bending rolls will adapt to the profile and follow it completely in the curve forming. “Our Direct Drive system,” says Massimo Roccia, “which has replaced all low-efficiency components such as belts or chains with a direct axis driving, allows the entire machine’s torque to go into the bending and does not lose torque between the various gears.”

The three double pre-bending motorized rolls allow the assembling of dies up to 43″ diameter, and are keyed to 21″ diameter shafts. The force of the two side shafts is 950 tons each, able to generate a total thrust of 1900 tons on the piece to be deformed, with 50.000 Kgm torque in rotation, thanks to the two hydraulic coaxial epicyclic motor-gear boxes. All components have a sealed permanent lubrication, which is another specialty of MG manufacturing principles, lasting for the life of the machine. “AR 530 is unique not only for its features but also for the electronic,” Massimo Roccia points out. “It is controlled by the CNC Touch Command EVO. This particular CNC control is made of two units; one is positioned on the electrical cabinet, the other one is on the control console. The two-units-CNC works wirelessly in protocol 802.11 on a real time operative system. It is not simply a PLC controller but an application with dedicated cards monitoring the bending cycle in real time.”

The CNC Touch Command EVO, developed by MG subsidiary Software Company Delsy, whose leader is Mr. Daniele Albenga, is already known all over the world for its unlimited capacity of saving programs, its integrated 3D graphic, 15″ touch screen, and tripled calculating capacity compared to the old versions. Even when controlling the AR530, a monster size machine, it remains user friendly. Developed on Linux platform, allows the operator to CAD generate any bending shape with the input of a few parameters and to load them directly from a DXF file into unlimited libraries. A geometric laser control system allows the CNC to read three points of the bending radius allowing on-line correction, if needed. On a profile bending machine of such extraordinary dimensions the laser system allows the making of very big radii, up to 72’. “It’s the first time the wireless technology is applied on such type of machines,” Mr. Roccia proudly says. “No cables or connecting wires obstruct the operators in the working space while they are checking the machine production.” Last but not least, when this giant is placed on its site in Verona, the machine itself will rotate. It will be put into a 16′ deep pit on a rotating platform. During the bending cycle of particularly long beams, the machine can rotate on its axis to avoid any obstacles that may be on the way.

“We built a 40′ diameter pit,” Maurizio Tromba describes, “which is impressive indeed! Being able to move the machine like this we will always find the most optimal working space.”
AR 530 will be used to bend very large beams. It will be able to bend a 1 mt thick beam the hard way! Until now these kinds of beams had to be cut in the middle, bent, and then welded to form the original piece. “In the deformation phase of such striking profiles, it’s necessary to preserve the core and not to twist it. We can do that using our technology called Traction Tooling which allows the core to remain perfectly straight and intact for the whole length.” Thanks to this new machine, Tromba Maurizio S.n.c. will stand out on the market for large structures buildings, for example the new 2015 Milan Expo, and also participate on tenders for the 2020 Tokyo Olympic Games. The AR530 will be used to build the future skyscraper Oculus in Manhattan, USA, together with the adjoining 590′ tall seagull structure by the near metro station.

In order to transport the AR530 twelve trucks were used, two of them with police convoy for exceptional loading. “The market requests,” Mr. Roccia concludes, “seem to be evolving towards larger products. If this trend is confirmed in the next few years, MG will definitely need more space for the construction of big machines. I have to say that we all felt a sense of emptiness when the last part of the AR530 was shipped. You know, we had all gotten used to have this giant towering over us!”

Translation from “MG firma un nuovo Guinness World Record” written by Claudio Tacchella.
www.tacchella.altervista.org

Images of AR530

To dismount, and package and transport this giant, 12 trucks were necessary, two for exceptional freight.

To dismount, package and transport this giant, 12 trucks were necessary of which two were for exceptional freight.

The frame

The frame

AR 530 has a modular structure. The main frame is made with strong electro-welded steel

AR 530 has a modular structure. The main frame is made with strong electro-welded steel.

To dismount, and package and transport this giant, 12 trucks were necessary, two for exceptional freight.

To dismount, package and transport this giant, 12 trucks were necessary, of which two were for exceptional freight.

The machine will be put into a 5 mt deep pit on a turntable. This way, the machine can rotate on its axis during the bending cycle of large and long beams.

The machine will be put into a 5 mt deep pit on a turntable. This way the machine can rotate on its axis during the bending cycle of large and long beams.

The final result of this giant project is an example how great goals can be reached by a determined and passionate team.

The final result of this giant project is an example how great goals can be reached by a determined and passionate team.

With the Direct Drive solution all the machines torque goes into the bending, thus allowing energy saving.

With the Direct Drive solution all the machine’s torque goes into the bending, thus allowing energy saving.

The three motorized rolls that allow the assembling of dies 1100 mm in diameter are keyed to 540 mm diameter shafts.

The three motorized rolls that allow the assembling of dies 1100 mm in diameter are keyed to 540 mm diameter shafts.

933 smaller

The approach of forming rolls allows a perfect bending and shorter straight edges. The hydraulic side guides are of tri-dimensional movement to adapt to the different bending radii.

The approach of forming rolls allows a perfect bending and shorter straight edges. The hydraulic side guides are of tri-dimensional movement to adapt to the different bending radii.

From left: Mr. Massimo Roccia, co-owner of MG SRL and Mr. Maurizio Tromba, co-owner of the Tromba Maurizio S.n.c.

From left: Mr. Massimo Roccia, co-owner of MG SRL and Mr. Maurizio Tromba, co-owner of the Tromba Maurizio S.n.c.

It is the first time wireless technology is used on such a machine. Operators can easily move in the working space without having to avoid cables or wires.

It is the first time wireless technology is used on such a machine. Operators can easily move in the working space without having to avoid cables or wires.

 


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C Marshall Fabrication Machinery, Inc.