How does economic roll forming work?
The variable and automatically equalising shaft spacing of the Multiformer® enables profile seals to be assembled particularly evenly.
The variable and automatically equalising shaft spacing of the Multiformer® enables profile seals to be assembled particularly evenly.
How can this be?
The drive in the press head of the Multiformer® is realized by several gear wheels arranged one behind the other.
These gear wheels are arranged in such a way that a movable gear is created, which divides the mechanical power of the drive unit into two counter-rotating working shafts.
The construction prevents high peak loads in the Multiformer® gear, which can be caused by differences in the thickness of the sheet metal flanges on the vehicle.
Air springs in the tensioning module ensure particularly even contact pressure on the bending rollers.
This means that the profile seal to be assembled is only subjected to the forces required for optimum shaping of the strength support, which guarantees even and gentle assembly.
Needs-based development and construction
Needs-based development and construction
Variable shaft spacing
Thanks to the variable shaft spacing of 24 to 35 mm, many profile seals can be covered. This often makes it possible to use relatively large bending rollers.
This improves the rolling behavior. Even anti-friction coated profile seals can be processed with the special design of the Multiformer®.
The air suspension makes it possible to open or close the press head with the bending rollers depending on the position of the hand lever. It is therefore possible to fit the profile seal with the opened press head and damage is avoided.
Three different switch-on and switch-off variants are available to enable optimum positioning of the Multiformer® on the profile seal.
The gear in the press head ensures that the working shafts remain parallel even with different flange thicknesses. The effective area or the pressure point of the bending rollers on the profile seal remains constant.
An assembly device that covers everything
An assembly device that covers everything
Multiformer® (variable)
One gear for all shaft spacings
Conventional (rigid)
An extra gear is required for each shaft spacing
Narrow gear housing
The Multiformer® is characterized by a particularly narrow gear housing. The small drive-through width in the assembly area results from the drive technology arranged in the working direction and makes it possible to pass through narrow spaces. The symmetrical design of the press head allows the same clearance for both directions.
The narrow design has a positive effect on the installation sequence of add-on parts. These include gas springs and their pivot pins, door hinges, dashboards and fastening rails.
Press head front view
Press head sectional view
Constant contact force
The contact force of the bending rollers is infinitely adjustable via the built-in pressure regulator. In combination with the air springs, the contact force is regulated and maintained evenly, even with different sheet metal flanges and shaft distances. The contact force is controlled in such a way that it acts evenly and as little as possible on the profile seal in order to achieve maximum pull-off forces. This setting is reproducible and can be easily checked from the outside.
Fast assembly
The assembly speed can be adjusted from the outside at any time without tools. By turning the throttle wheel, the speed of the air motor can be changed and thus the speed adjusted. The set value is readable on a graduated dial.
Variable shaft spacing of 24 to 35 mm
Small drive-through width
Adjustable contact pressure from 10 to 100 N
4.5 m of door seal fitted in 8 s
The Multiformer® is driven by a compressed air vane motor. This motor differs from electric motors in several ways and offers specific advantages.
Vane motor - structure and function
Image source: www.atlascopco.com
In short, the vane air motor in the Multiformer® uses the expansion of compressed air to generate a rotary motion, creating an efficient and powerful drive. This principle enables the direct conversion of pressure energy into mechanical movement, which makes the vane air motor particularly suitable for applications where robustness and reliability are required.
A vane motor converts gas pressure into rotary motion. It consists of two main parts: the stator and the rotor. The stator is a cylindrical housing with openings for the air to enter and exit. The rotor, a shaft, is positioned eccentrically within the stator and has longitudinal slots for the vanes.
These vanes are moving parts in the rotor that are inserted into the slots. They divide the space between the stator and rotor into several chambers. These chambers change size as the rotor turns: they become smaller as they approach the air inlet opening and larger as they move towards the outlet opening.
Air enters the motor at the narrowest point between the vanes, expands as it turns the rotor and escapes through the exhaust port when the space between the vanes is at its largest. Additional outlet openings help to expel any remaining air.
Compact, light and powerful
Compared to electric motors with the same power, compressed air motors are much smaller and lighter. The ratio of installation space is 1:6 and the ratio of weight is 1:4, meaning that the compressed air motor has a much higher power density.
Speed is infinitely adjustable
The speed of an compressed air motor can be infinitely adjusted by throttling the supply or exhaust air. In our Multiformer® we use an exhaust air throttle; this increases the effective torque in low speed ranges.
Torque increases with the load
The performance of a compressed air motor changes only slightly over a wide speed range. If the speed drops due to an increasing load, the torque increases.
Robust
Compressed air motors are insensitive to heat and vibration. Their reliability under extreme operating conditions is unique. The design and construction ensure trouble-free operation with low maintenance requirements.
No electrical danger
No electrical supply lines or components are required; only compressed air drives the Multiformer® and its control unit. An electrical hazard can therefore be ruled out.
Resilient
Compressed air motors can be overloaded to a standstill without damage. Even when constantly starting and stopping, they do not run hot.
Operating conditions
Care should be taken to ensure that clean and lightly lubricated compressed air is always used, ideally with an operating pressure of 6.3 - 7.0 bar at the tapping point. A lower operating pressure is often sufficient. Example: with a working pressure of 4 bar, an operating pressure of 5 bar is ok.
Electromagnetic compatibility (EMC)
As no electronics are installed in the compressed air motor, it has a high level of electromagnetic compatibility. Therefore, other devices are not disturbed by unwanted electrical or electromagnetic effects, nor can the Multiformer® be disturbed by other devices.
Even after the generation change of a vehicle model, an adapted Multiformer® can continue to be used.
Even after the generation change of a vehicle model, an adapted Multiformer® can continue to be used.
Modular components
Thanks to the modular design of the Multiformer®, customer-specific extensions and adjustments can be implemented quickly. The Multiformer® is individually manufactured or configured according to your requirements so that you always get the best possible result for your vehicle. Here are a few examples:
Straight/angular unit
The Multiformer® is available in two versions: straight and angled. The version is selected depending on the assembly situation and the desired handling.
The tensioning module
When using one of the four different tensioning modules, the pressure force when rolling on or the shaft distance can be precisely adapted to your assembly situation. The tensioning module can be exchanged in just a few simple steps.
The bending rollers
The bending rollers are an essential component for the quality of the seal assembly. They can be replaced quickly and without disassembling the Multiformer®.
The pressure rollers
With the help of the pressure rollers, the profile seal is pressed onto the body flange and the running behavior is influenced during the roll forming process.
The pressure roller holder
The pressure roller holder is available in different versions to optimally press the seal onto the vehicle body flange using the pressure roller. If required, an additional pressure or guide roller can be mounted on the side.
The gear stage
There are three gear stages to choose from: slow, normal and fast. Gear stage "normal" is the most frequently installed variant and covers most applications.
The drive shafts
The drive shafts differ in length and therefore influence the position of the bending rollers in relation to the pressure roller. Due to the special design, the bending rollers can be replaced if necessary without disassembling the Multiformer®.
Other outstanding features of the Multiformer®
Other outstanding features of the Multiformer®
Easy handling by using the hand lever as the only operating element.
The rotating bending rollers drive the roll forming device, allowing the operator to guide the device with minimal effort.
The high reliability of the Multiformer® results from its design, which prevents the occurrence of peak loads. This is particularly evident during continuous use in difficult assembly situations.
Long service life and therefore low maintenance requirements, for example the gear wheels of the gear in the press head are designed for over 20,000 operating hours
Low air consumption thanks to precise adjustment of power requirement and speed/gear combination.
No electrical components are required for the Multiformer® to function.
Summary
Adaptation of the Multiformer® to the assembly situation
Compensation of different sheet flange thicknesses
Infinitely adjustable contact pressure
Uniform contact force
Control of the contact force by checking the working pressure
Pneumatic opening and closing of the press head
Start and stop the drive by operating the hand lever
Simple handling
Hand lever as the only operating element
Strikingly narrow gear housing