Scarborough, February 11, 2009 --- Unison has developed an all-electric end-former machine for automating refurbishment of automotive steering rack mechanisms. The machine uses programmable servomotors to drive the end-forming dies into position, and provides a much more flexible and efficient means of handling the process than traditional manual and hydraulic methods, which involve changing dies between different forming operations. In fact, Re-Go Autoparts, the specialist steering component remanufacturing company that has taken delivery of the first machine, reports that the entire end-forming process has been reduced from 2 to 3 minutes to less than 10 seconds - a radical productivity improvement of around 1500%!

Re-Go Autoparts Ltd has acquired an enviable reputation for remanufacturing very high quality components for automotive power steering systems, under the Lenco trade name. Founded some 30 years ago as an automotive spares supplier, the company has grown to become one of Europe's leading suppliers of steering racks, steering boxes and steering pumps to vehicle repair and servicing organisations and specialist parts distributors. Nowadays, Re-Go Autoparts employs more than 50 people and operates two facilities; its headquarters and steering rack and pinion manufacturing plant are based in Tonbridge, Kent, and it has a large dispatch warehouse and logistics centre in Wevelgem, Belgium, where it also manufactures steering pumps.

Re-Go Autoparts is a recent convert to the versatility of all-electric tube bending technology. About a year ago the company sought a new tube bending system, and after thoroughly researching the market, decided that Unison's all-electric approach offered the most flexible solution, which in the long run was likely to prove far more cost-effective than traditional manual or hydraulic systems. It subsequently invested in a multi-stack version of one of Unison's 16 mm Breeze tube bending machines, which is used to produce a variety of small complex parts, such as hydraulic brake pipes and power steering tubes.

According to Gary Martin, one of Re-Go Autoparts' Directors, "Our experience with the Unison tube bending machine proved extremely positive, and we very quickly became fans of digital control. The machine's programmability enables us to accommodate small production batches without incurring the delays associated with changing tool sets on traditional tube bending machines, and its accuracy and repeatability help ensure product quality. However, even with the best will in the world, we found it difficult to subsequently form the ends of tubes accurately - especially on some of the more sophisticated parts that we produce - without spending a considerable amount of time on the process. Which is why, when we caught sight of a prototype of Unison's new end-former machine during a visit to their facility, we promptly expressed interest in purchasing a custom-built version."

Unison's new end-former machine is a fully-integrated three-axis system, housed in a compact standalone cabinet. It provides software-controlled four-stage end forming, by automatically flaring, compressing and reducing the ends of the steel tube, ranging from 6 to 10 mm, used in vehicle steering racks. The motive power for the machine's main drive is provided by a Baldor servomotor. The four stages and clamp are actuated by SMC pneumatic cylinders, all connected to a Baldor MintDrive intelligent drive with a built-in motion controller. Overall machine control is handled by a PLC, with all user input commands and operational status feedback provided by a Baldor HMI panel.

The all-electric end-former machine offers numerous advantages over conventional hydraulic end formers - it is quick and easy to set up, and is much more energy efficient, quieter and faster. Furthermore, the machine's use of closed-loop servomotor control ensures excellent end forming accuracy and repeatability. The first machine was installed at Re-Go Autoparts' facility in Tonbridge in November 2008, and its performance has even surpassed the company's already high expectations. To quote Gary Martin again, "Quite apart from experiencing a dramatic improvement in productivity, we are now able to put the finishing touches to our products by creating very high quality tube ends, synonymous with the Lenco trade name. The machine is also proving very easy to use - so much so, in fact, that we can now fabricate complex variants of steering rack tubes which previously proved impossible."