FOCUS ON COIL PROCESSING
HVAC casing sizes.
HVAC casing blank length requirement. assembly process. A series size for a coil punching process( 5tn coil) is typically around 300 pieces to be run in buffer storage to feed a bending line,” confirmed Pivatic.
A company’ s products tend to have few product families with tens of size variables for the casings. These variables are parameterised and determined through the size and number of electrical devices inside, such as the blower motor size. The material used is typically under 2mm-thick mild steel that is pre-painted for the direct follow-up process of assembly. The process is required to be material-friendly.
HVAC casing punch features.
Punching
The challenges for punching are the size variables, knockouts, embossing, corner notches and large openings. These characteristics require a flexible punching solution, and a high production volume calls for an efficient solution.
Bending
“ The challenges for bending are mainly related to the large part size or the production methods. As the casing acts as the frame for the rest of the parts, it is usually a single metal sheet bent to consist of the sides and back of the unit. The size variables in casings requires this blank to be up to 3000mm / 118” long,” Pivatic told ISMR.
“ The bending forms are simple and mostly up-only, but the box bending( to bend up the sides) needs a large opening in the bending machine for part removal. The high-volume demand is usually not met by single bending machines in a continuous process. The followup assembly process is usually set up one phase at a time, as the output time needs to be equivalent or faster than the direct feed from the bending process,” it continued.
Solution for HVAC casings
Pivatic has developed several solutions for automatic production of large casings-type parts. The most common applications are for the HVAC units, refrigerator bodies or office drawer cabinets. The seasonal demand for casings in the HVAC industry is met with line solutions dedicated for casings, specifically tailored to customer product families.
PIvatic offers punching lines for blanks and for coils in conjunction with bending lines that can be integrated to the assembly process.
“ Depending upon the product design, a single automatic production line can produce up to 2000 casings per eight hours, or 500,000 casings per year in single-shift production. The future product model changes in five to ten years can usually be tackled with software or tooling updates, so the long lifecycle of our solutions( over 20 years) can continue to adapt to the changing environment,” highlighted Pivatic.
Both the punching line and the bending line are designed and programmed to produce the chosen few product families, with or without parameterised parts. All of the casing sizes are tested in acceptance test production before the line delivery and installation. Pivatic line solutions can process pre-painted mild steel as all line modules are chosen or designed to be material-friendly.
To meet the challenges for punching, Pivatic offers flexible punching stations with Thick Turret tooling, press tool stations and dedicated C-frame punching stations. A suitable combination of these technologies is made according to the customer budget, output requirement and variance in product designs.
“ The starting point is typically a single flexible punching station or several dedicated C-frame punching stations. The driving technology has traditionally been press toollines for blanks, but a coil punching line offers better cost-per-part. A flexible punching solution is also capable of producing other parts for HVAC units such as blower decks and end plates, most probably by the coilnesting method,” added Pivatic.
To meet the challenges for bending, Pivatic offers automated bending lines. A cycle time down to 14 seconds per casing is achieved by integrating a single bending unit for each side of the sides to be bent. For more complicated bends, a standard PivaBend unit can be replaced with a MPB unit.
“ Our bending units can handle up to 2mm / 0.078” mild steel and box bending of up to 1mm / 0.039” mild steel with no height limitation of the side bends. Thicker material than this can be bent with height limitation of up to 700mm / 27.5,” concluded the manufacturer. n
Air conditioning systems. https:// pivatic. com / en /
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