Order number: 6005

The Arch- and Ring-Bending Machine GEBR 605 is an universal bending machine enabling the rolling of round and square tubes as well as most of the current sections into arches and rings.
All three bending shafts are driven by an electrical vario-drive. The rotation speed of the bending shafts can be selected infinitely variable between 5 and 13 rpm. Owing to the 3-shafts drive all kinds of rolling can be done with smooth faced bending rolls.
The bending shafts are installed in a triangular position. The both front shafts are stationary, the intermediate one is movable. The feed motion of the movable bending shaft is made by a 10-t-hydraulic cylinder. The oil flow of the hydraulic system is manually adjustable in fine doses or controlled automatically by the GLASER-Position Control GPS-2.
In automatic function the adjustable bending shaft is controlled by the GLASER-Position Control GPS-2. The position of the adjustable bending shaft is registered by an absolute electronic measuring system and shown on a digital display.
By means of an additional Pitch Arm an accurate spiral rolling of the handrail tube for spiral staircases with solid or open newel is possible. For the measuring of the radius of the rolled tube and for the calculation of the pitch several technical devices are available, which are explained later on.
The handrails have to be differently rolled for left- or right-turning spiral staircases. For this reason the Pitch Arm is optionally mounted on the one or the other side of the bending machine.
The Arch- and Ring-Bending Machine GEBR 605 is mounted on a swiveling underframe and can, on demand, be easily moved to the equivalent space required for rolling of big work pieces.
The underframe stands on four heavy load rollers and can easily be moved. This feature allows to use the machine at the building site and in small workshops.

The standard type contains a set of split steel rolls for the bending of arches and rings from flat and square material, thick-walled square tube as well as some T-shaped and angle sections. The rolls can be opened step by step up to max. 40 mm. For round tubes special rolls with adequate diameters are supplied.
It is recommendable to use high strength plastic rolls for the rolling of stainless steel and brass tubes. In case of steel rolls steel particles could possibly be transferred onto the surface of the stainless steel tubes, which may promote future corrosion. By rolling with plastic rolls nearly any damage can be avoided.

GLASER-Position Control GPS-2
The GLASER-Position Control GPS-2 is designed for series production and for repeated rolling of single pieces. It comprises 10 program memories for the various adjustments of the third bending shaft. Each program memory stores max. 10 adjustments. The variance comparison of the movable bending shaft is indicated by large numerical displays. In case of hand rolling of the first work piece the individual values of the feed motion can be transferred by button to one of the 10 program memories (Iearning process). The values of the feed motion can be hand-noted in the single memories. Furthermore the values of the first learning function can be corrected.

Technical Data
Diameter of the bending shafts: 50 mm

Rotation speed:
infinitely variable between 5 and 13 revolutions per minute (rpm)

Voltage supply:
380-400 V three-phase current with loadable central conductor
(220-230 V), 16 A, 50 Hz.
Other voltage and frequency on demand.
Power consumption: about 3 kW

Paintwork:
Two-component varnish, blue

Dimensions: 860 x 1100 x 1100 mm

Weight: about 650 kg

Normally Arch- and Ring-Bending Machines are equipped with split standard steel rolls, by which most profiles of structural steel, such as flat iron, cross- and edgewise, T-shaped and angular iron, rectangular and square tubes, can be bent to arches and rings. Eventual deviations from the desired radius due to the material characteristics can be corrected by re-rolling or mechanical readjustment.

For the rolling of round tubes out of structural steel special rolls with respective profiles are applied avoiding an oval deformation of the tube cross-section during the rolling process. Also in this case eventual deviations from the desired radius due to the material characteristics can be corrected by re-rolling or mechanical readjustment. The rolling of handrails, underrails and cross bars out of stainless steel and brass for spiral staircases with solid and open newel makes high demands on an accurate execution. For this task the usual Arch- and Ring-Bending Machines have to be equipped with a Pitch Arm. Furthermore special mechanical and electronic measuring devices are available.

1. Pitch Arm
When rolling handrails, underrails and cross-bars for spiral staircases it is necessary to work out a certain pitch of the handrail, besides the arch. For this purpose a Pitch Arm is provided. The Pitch Arm is open on top so that the rolled material can easily be taken out. There is no problem even with a high pitch. Depending on the rolling of handrails for right- or left-turning staircases, the Pitch Arm is mounted either on the left or the right side of the machine. The position of the Pitch Arm is adjusted by a hand wheel and can be read on a digital display or a scale.

2. Plastic Rolls
It is recommendable to use high strength plastic rolls for the rolling of stainless steel- and brass-tubes. In case of steel rolls steel particles might eventually be transferred to the surface of the tubes, which may promote future corrosion. Rolling with plastic rolls avoids nearly any damage of the stainless steel- and brass-tubes.

3. The correction of a spiral arch is practically almost impossible
The correction of a spiral arch is almost impossible, for the reason that rolling of an arch by means of a Pitch Arm deforms the material in the third axis, which makes the spiral arch very hard to handle. The first rolling process is a defined rolling, the second one an undefined rolling. The solution of this problem is accurate rolling by GLASER's auxiliary technical attachments. Due to a Measurement Scheme where the staircase data are defined the desired arch with the respective pitch can perfectly be rolled.

4. Measuring of the bending radius
The radius of the rolled material is indirectly measured resp. calculated by a Radius Sliding Caliper as folIows: First the distance "chord - arch" is measured. Then the radius is read from a radii-table. This is applied to inside and outside radius. In addition to the radii-table GLASER developed a special Radii Calculation Program.

5. Measuring of the pitch in the rolling process
When rolling spirals the tube continuously twists. Before rolling the tube is divided into parts of e.g. 300 mm (control measurement). Then during the rolling process the twisting grade per control measurement is measured in angle degrees at the not yet rolled tube end with a Twisting Measuring Device. From the twisting grade per control measurement results the pitch of the rolled handrail.

6. The radius of a spiral arch
The radius of a spiral arch is larger than the radius of a plain arch due to the pitch. The dimensions, adjustment of the Radius Sliding Caliper as well as the actual radius, are calculated by the Spiral Calculation Program.

7. Spiral Calculation Program
Some years ago GLASER opened a bending centre where handrails, underrails and cross-bars for spiral staircases with open and solid newel as well as various frames are manufactured. The total production program is manufactured according to customer's requirements. Mathematics and technical experience are combined in a Spiral Calculation Program. Experience also induces the input of the different parameters. A Measurement Scheme (on the opposite) shows the floor height, the number of steps, the step width and the step radius. The calculated pitch height is compared with the value measured on site for controlling purposes. The Spiral Calculation Program additionally comprises two further calculation programs for the balustrade construction: a Radius Calculation Program and a Bar-Distance Calculation Program. The Radius Calculation Program has two functions: first it calculates the actual radius from the distance "chord-arch" measured by the Radius Sliding Caliper and on the other hand a desired radius is pre-set and the adjustment of the Radius Sliding Caliper is calculated. The Bar-Distance Calculation-Program determines the number of the necessary balusters calculated from the staircase data: length, angle and max. bar distance (e.g. 120mm width in the clear) and the clear distance between two bars. An even or odd number of balusters is optional.