Table of Contents
Advertisement
Quick Links
OPERATOR'S MANUAL
ROTARY DRAW BENDER
MODEL: RDB-150 & RDB-150-AS
Baileigh Industrial, Inc.
P.O. Box 531
Manitowoc, WI 54221-0531
Phone: 920.684.4990
Fax: 920.684.3944
sales@baileighindustrial.com
REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC.
IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss
caused by an omission or error in this Operator's Manual, resulting from accident, negligence, or other occurrence.
Rev. 03/2015
© 2015 Baileigh Industrial, Inc.
Advertisement
Table of Contents
Related Manuals for Baileigh Industrial RDB-150
Summary of Contents for Baileigh Industrial RDB-150
- Page 1 REPRODUCTION OF THIS MANUAL IN ANY FORM WITHOUT WRITTEN APPROVAL OF BAILEIGH INDUSTRIAL, INC. IS PROHIBITED. Baileigh Industrial, Inc. does not assume and hereby disclaims any liability for any damage or loss caused by an omission or error in this Operator’s Manual, resulting from accident, negligence, or other occurrence.
-
Page 2: Table Of Contents
Bending With Square Dies ..................31 Square Tooling Setup ....................31 Large Size Square ..................... 32 LUBRICATION AND MAINTENANCE ................33 RDB-150 ELECTRICAL SCHEMATIC ................34 RDB-150-AS ELECTRICAL SCHEMATIC ..............35 HYDRAULIC DIAGRAM ....................36 TROUBLESHOOTING ....................37 TABLES, CHARTS, & DIAGRAMS ................39 Diagram 1 ........................ - Page 3 Main Tube and Cylinders Assembly Parts Diagram ..........45 Swing Arm Assembly Parts Diagram ................. 46 Degree Dials Parts Diagram ..................47 Main Tube Assembly Parts Diagram ................. 48 Cart Assembly Parts Diagram ................... 49 Parts List ........................50...
-
Page 4: Thank You & Warranty
THANK YOU & WARRANTY Thank you for your purchase of a machine from Baileigh Industrial. We hope that you find it productive and useful to you for a long time to come. Inspection & Acceptance. Buyer shall inspect all Goods within ten (10) days after receipt thereof. Buyer’s payment shall constitute final acceptance of the Goods and shall act as a waiver of the Buyer’s rights to inspect or... - Page 5 • A 30% re-stocking fee applies to all returns. Baileigh Industrial makes every effort to ensure that our posted specifications, images, pricing and product availability are as correct and timely as possible. We apologize for any discrepancies that may occur. Baileigh Industrial reserves the right to make any and all changes deemed necessary in the course of business including but not limited to pricing, product specifications, quantities, and product availability.
-
Page 6: Introduction
After receiving your equipment remove the protective container. Do a complete visual inspection, and if damage is noted, photograph it for insurance claims and contact your carrier at once, requesting inspection. Also contact Baileigh Industrial and inform them of the unexpected occurrence. Temporarily suspend installation. -
Page 7: Safety Instructions
IMPORTANT PLEASE READ THIS OPERATORS MANUAL CAREFULLY It contains important safety information, instructions, and necessary operating procedures. The continual observance of these procedures will help increase your production and extend the life of the equipment. SAFETY INSTRUCTIONS LEARN TO RECOGNIZE SAFETY INFORMATION This is the safety alert symbol. - Page 8 SAVE THESE INSTRUCTIONS. Refer to them often and use them to instruct others. PROTECT EYES Wear safety glasses or suitable eye protection when working on or around machinery. PROTECT AGAINST NOISE Prolonged exposure to loud noise can cause impairment or loss of hearing.
- Page 9 KEEP CLEAR OF MOVING OBJECTS Always be aware of the position of the material and the swing area in which the material will travel. The material will swing with significant force. This swing area will create pinch points and the force of the material movement may cause serious bodily injuries.
-
Page 10: Safety Precautions
SAFETY PRECAUTIONS Metal working can be dangerous if safe and proper operating procedures are not followed. As with all machinery, there are certain hazards involved with the operation of the product. Using the machine with respect and caution will considerably lessen the possibility of personal injury. However, if normal safety precautions are overlooked or ignored, personal injury to the operator may result. - Page 11 11. Do not overreach. Maintain proper footing and balance at all times. DO NOT reach over or across a running machine. 12. Stay alert. Watch what you are doing and use common sense. DO NOT operate any tool or machine when you are tired. 13.
-
Page 12: Technical Specifications
TECHNICAL SPECIFICATIONS Maximum Center Line Radius (CLR)* 8" (203mm) Minimum Center Line Radius (CLR)* .5" (12.7mm) Minimum OD .25" (6.35mm) Mild Steel Pipe (Schedule 40) Based on a maximum material tensile strength 2" (50.8mm) of 60000 PSI Aluminum Pipe (Schedule 40) 2"... -
Page 13: Unpacking And Checking Contents
UNPACKING AND CHECKING CONTENTS Your Baileigh machine is shipped complete in one crate. Separate all parts from the packing material and check each item carefully. Make certain all items are accounted for before discarding any packing material. WARNING: SUFFOCATION HAZARD! Immediately discard any plastic bags and packing materials to eliminate choking and suffocation hazards to children and animals. -
Page 14: Transporting And Lifting
TRANSPORTING AND LIFTING CAUTION: Lifting and carrying operations should be carried out by skilled workers, such as a truck operator. Make sure the machine is well balanced. Choose a location that will keep the machine free from vibration and dust from other machinery. -
Page 15: Assembly And Set Up
• Keep the floor free of oil and make sure it is not slippery. • Remove scrap and waste materials regularly, and make sure the work area is free from obstructing objects. • If long lengths of material are to be fed into the machine, make sure that they will not extend into any aisles. -
Page 16: Getting To Know Your Machine
GETTING TO KNOW YOUR MACHINE... -
Page 17: General Design Description
GENERAL DESIGN DESCRIPTION You have made a practical choice in purchasing the RDB-150 Hydraulic Bending Machine. It has been carefully built of high quality materials and designed to give many years of efficient service. -
Page 18: Electrical
ELECTRICAL CAUTION: HAVE ELECTRICAL UTILITIES CONNECTED TO MACHINE BY A CERTIFIED ELECTRICIAN! Check if the available power supply is the same as listed on the machine nameplate. WARNING: Make sure the grounding wire (green) is properly connected to avoid electric shock. DO NOT switch the position of the green grounding wire if any electrical plug wires are switched during hookup. - Page 19 • Improper connection of the equipment-grounding conductor can result in risk of electric shock. The conductor with insulation having an outer surface that is green with or without yellow stripes is the equipment-grounding conductor. If repair or replacement of the electric cord or plug is necessary, do not connect the equipment-grounding conductor to a live terminal.
-
Page 20: Operation
OPERATION CAUTION: Always wear proper eye protection with side shields, safety footwear, and leather gloves to protect from burrs and sharp edges. CAUTION: Keep hands and fingers clear of the dies and swing arms. Stand to the front of the machine to avoid getting hit with the material during the bending process. -
Page 21: Die Selection And Installation
Bronze Counter Die Insert “0” Mark Note: Pipe and Tube are not the same, (see table 1) for nominal pipe sizes. All BAILEIGH INDUSTRIAL dies are color coded to avoid confusion between pipe and tube (see table 2). IMPORTANT: Damaged or worn tooling should be replaced before attempting to bend material. - Page 22 Spindle Die Drive Pins 1/2-13 Tapped holes for bolting down dies Center Pin Hitch Pin Positioning Bolts 4. To install the counter die, remove the hitch pin and insert the counter die in the opening in the counter die mount until the 3/4” holes line up. 5.
- Page 23 Incorrect Counterdie Position Too far away from die Touching die Correct Counter Die Position Approximately 1/8” (3mm) away IMPORTANT: Be sure the long end of the counter die points away from the hook arm, or to the right of machine.
-
Page 24: Material Insertion
Material Insertion 1. Once the die set is properly installed, the material that matches the die can be inserted (I.E. 1-1/4”tube would go into a die mark D-1250T-R***). 2. Open the counter die quick release assembly and insert the material past the hook arm. The start of bend mark is engraved with an “O”... - Page 25 Bending Using Main Degree Wheel 1. After the material is installed, bending can take place. 2. Turn on the power switch 3. Keep hands away from the bending zone. 4. Press the right foot pedal switch to rotate the die forward. Keeping the foot pedal activated, visually watch the degree dial (A).
- Page 26 Using the auto stop feature – if equipped, (Setting the automatic stop position) The cylinders must be fully retracted and the main (top) degree dial must read “0”deg before setting the lower degree dial. Note: Do not adjust the micro switch mounting bracket; this is preset from the factory.
- Page 27 Material Removal 1. After reaching the desired angle, the material needs to be removed. 2. Press the reverse (left) foot pedal. Both the die and the counter die will retract simultaneously. Run in reverse until all bending pressure is released from the bend. Activating the quick release lever 3.
-
Page 28: Material Insertion Limitations
Material Insertion Limitations Left Right • The left figure shows the recommended minimum / correct amount of material remaining to be fully supported in plastic slide. • The right figure shows the maximum amount the material can be pulled through the counterdie. -
Page 29: Bending More Than 180 Degrees
Bending More than 180 Degrees • This machine is capable of bending more than 180 degrees. Contact Baileigh Industrial about your application. o It will require a password to make the machine go past 200 degrees. o Requires special tooling to allow removal of bent part. If standard tooling is used, the material will be locked onto the die. - Page 30 • Another program available is BEND-TECH which is a program specifically designed for tube bending and will give you all of the required data to make a part. This software is available from Baileigh Industrial. • Bending with a rotary draw bender requires determining the start of bend point which will line up with the “0”...
-
Page 31: Pipe And Tube Bending Diagrams
PIPE AND TUBE BENDING DIAGRAMS L = Arc length (outside) R = Rise (inside) D = Tube outside diameter t = Tube wall thickness a = First bend arc angle H = Height of offset b = Second bend arc angle L = Length of offset A = First tangent R1 = First radius... -
Page 32: Bending Glossary
BENDING GLOSSARY Arc Length The length of material along the centerline of the tubing Distance in inches from the center of curvature to the centerline Centerline Radius (CLR) axis of the tube bending or pipe bending bends. Abbreviated as CLR. See Tube Bending and Pipe Bending Diagram Angle in degrees to which the tube/pipe bends are formed (i.e. -
Page 33: Bending Suggestions
• If using BAILEIGH INDUSTRIAL’s standard counterdie is not producing desired results, roller counter dies are also available. • BAILEIGH INDUSTRIAL has both steel rollers as well as plastic rollers. Plastic rollers are used primarily for polished aluminum. Steel rollers would be used for non-polished materials. -
Page 34: Heavy Wall Dom Tubing
• Use a piece of two sided coarse emery cloth in between the hook arm and the material, this works very well. • In only this application, high pressure grease applied to the DIE GROOVE also helps. • BAILEIGH INDUSTRIAL can make special clamps to hold material in place. Bending With Square Dies • Die Parts... -
Page 35: Large Size Square
If the square material slips in the hook arm, use the supplied clamp and bolts to hold in place. BAILEIGH INDUSTRIAL offer crush bend dies to form a concave crease on the inside of square bends to reduce the possibility of wrinkling. -
Page 36: Lubrication And Maintenance
1/2 full, fill to the top with AW-46 hydraulic fluid. Hydraulic fluid and the filter should be changed when the filter gauge reads “Change Filter”. • Check periodically for leaks. If a leak is detected, consult Baileigh Industrial. • There are four grease zerks on the machine, at the main spindle pivots. Grease these zerks every month with only two pumps from a standard grease gun. -
Page 37: Rdb-150 Electrical Schematic
RDB-150 ELECTRICAL SCHEMATIC... -
Page 38: Rdb-150-As Electrical Schematic
RDB-150-AS ELECTRICAL SCHEMATIC... -
Page 39: Hydraulic Diagram
HYDRAULIC DIAGRAM... -
Page 40: Troubleshooting
TROUBLESHOOTING WARNING: Make sure the electrical disconnect is OFF before working on the machine. Problem Solution Cylinders not retracting all the Do the dry run sequence as outlined in section 8 of the way or not in sequence manual under operation Check to make sure the autostop dial has the micro switch roller riding on the outside of the perimeter of the dial. - Page 41 Too much lube on material and is transferring to the bend die clean the bend die with degreaser. The counter die should be lubed only Material slips in the hookarm The material may need to be clamped Wrong material for the die set If the bend dies are not bolted down properly the drive pins Spindle drive pins are damaged will get damaged.
-
Page 42: Tables, Charts, & Diagrams
TABLES, CHARTS, & DIAGRAMS Table 1 Standard Pipe Sizes and Schedules PIPE O.D. Pipe Schedules and Wall Thickness SIZES XX STRONG 0.405 0.400 0.050 0.068 0.095 0.540 0.500 0.070 0.088 0.119 0.675 0.500 0.070 0.091 0.126 0.840 0.700 0.080 0.109 0.147 0.188 0.294... - Page 43 Table 3 ARC LENGTH TABLE EXAMPLE: Arc Length = Constant x Bend Radius. Example: 90deg bend with 6” clr EXAMPLE: 1.575 (from table) x 6” (clr) = 9.45” (Arc Length) For bends more than 90deg, Constants can be added together. Degrees Constant Degrees...
- Page 44 Table 4 Counter Die Placement Chart 1" THICK 1.5" THICK 2" THICK (Centerline COUNTERDIES COUNTERDIES COUNTERDIES Radius) #N/A #N/A SILVER HOLE# 1 #N/A SILVER HOLE# 1 GOLD HOLE# 1 SILVER HOLE# 1 GOLD HOLE# 1 SILVER HOLE# 2 GOLD HOLE# 1 SILVER HOLE# 2 GOLD HOLE #2 SILVER HOLE# 2...
-
Page 45: Diagram 1
Diagram 1... -
Page 46: Diagram2
Diagram2... -
Page 47: Parts Diagram
PARTS DIAGRAM Power Unit and Cart Assembly Parts Diagram... -
Page 48: Main Tube And Cylinders Assembly Parts Diagram
Main Tube and Cylinders Assembly Parts Diagram... -
Page 49: Swing Arm Assembly Parts Diagram
Swing Arm Assembly Parts Diagram... -
Page 50: Degree Dials Parts Diagram
Degree Dials Parts Diagram... -
Page 51: Main Tube Assembly Parts Diagram
Main Tube Assembly Parts Diagram Item Part Number Description Qty. M150-6A013 Main Tube Imperial 3/8-16 x .75 SHCS M150-7A015 Flanged Sleeve Bushing PP-0294 Flanged Sleeve Bearing .25-28 GREASE ZERK Straight Grease Zerk... -
Page 52: Cart Assembly Parts Diagram
Cart Assembly Parts Diagram Item Part Number Description Qty. M150-5A014 Upright, Base PP-0035 1" Set Screw Collar PP-0064 8" Rubber Wheel PP-0043 1.0 ID x 1.1875 OD x 0.75 Lg Bushing PP-0048 4.0 Inch Caster Imperial 3/8-16 x 1 Carriage Bolt Imperial 3/8 Flatwasher Imperial... -
Page 53: Parts List
Parts List Item Part Number Description Qty. Power Unit Assembly M150 Power Unit Assembly Imperial 5/16 Flat Washer Imperial 5/16 Lockwasher M175-6A016 Riser M150-6A035 Cross Bar Imperial 3/8 Flatwasher Imperial 3/8 Lockwasher M150-5A006 Main Tube Assembly PP-1430 17mm Hex Key PP-1494 20 Mm Set Screw Collar PP-0403... - Page 54 Item Part Number Description Qty. ME-M150-5A016 Pivot Assembly (Metric) M20 X 2.5 X 160 SHCS M20 X 2.5 X 45 SHCS ME-M175-7A005 Spindle M175-7A004 Cylinder Pin (Long) PP-0035 1" Set Screw Collar ME-M150-6A020 Pointer Block (Metric) M6 X 1.0 X 25 SHCS M150-6A029 Auto Stop Sticker...
- Page 55 NOTES...
- Page 56 , WI 54220 UFEK RIVE ANITOWOC : 920. 684. 4990 F : 920. 684. 3944 HONE www.baileigh.com BAILEIGH INDUSTRIAL, INC. 1455 S. C , CA 91761 AMPUS VENUE NTARIO : 920. 684. 4990 F : 920. 684. 3944 HONE BAILEIGH INDUSTRIAL LTD. U...