This master’s thesis deals with design of a hydraulics bending machine. Bending machine will be used primarily for bending reinforcement bars in the shape of stapes. It consists of bending, sliding and chute system, which are located in the machine frame. Drive of each system is provided by a rotary and two linear hydraulic motors. Then there is described a hydraulic system and selection of its most important parts. Work is supplemented by visual documentation in the form of images of individual systems were processed in a CAD system Inventor 2010

This study developed a reinforced steel rod bending machine for rods with diameters of up to 8 mm and annealed wire cutter for up to 5 kg for replacing manual intervention required to bend rods in reinforced concrete columns. This study aims to reduce the physical effort that could lead to occupational diseases, such as tenosynovitis, bursitis, muscle disorders. Clamp manufacturing possesses great risk for workers, who are exposed to injuries while using different cutting devices, such as grinders and electric saws. They also face potential problems such as muscular fatigue due to the nonergonomic and repetitive work positions. The proposed machine features a mechanical dragging and bending systems and manual shears. Additionally, the proposed machine has been designed theoretically and its effectiveness has been assessed through simulations conducted using the SolidWorks CAD software. A bending machine prototype for producing clamps is developed and its machine productivity is measured. Using this machine, approximately 300 clamps can be bent per hour without possessing any risk to the worker.

Den här rapporten är en del av ett examensarbete på 22,5 högskolepoäng inom högskoleingenjörsprogrammet i innovationsteknik och design och utförs vid Karlstads universitet under vårterminen 2017. Examensarbetet utförs på uppdrag av Rejlers AB som är ett svenskt teknikkonsultbolag. Rejlers har under två års tid tillverkat och testat en prototyp för bockning av ståldetaljer. Prototypen i sin nuvarande form anpassar automatiskt ståldetaljen efter slutanvändarens behov, genom inkrementell formning. När ståldetaljer med stort tvärsnitt bockas uppstår problem i form av plastisk deformation av komponenter i maskinen. Projektet grundar sig i att Rejlers nu har inlett projekteringen av nästa version av prototypen, för att implementera förbättringsförslag som uppkommit vid testkörning och lösa problemet med deformation av maskinens komponenter. Syftet med arbetet är att skapa underlag för detaljkonstruktion och dimensionering av prototyp nummer två. Problemet löses genom att tillämpa produktutvecklingsprocessen och leverera ett konceptuellt lösningsförslag i form av en layoutkonstruktion. I layoutkonstruktionen integreras kritiska komponenter på ett skalbart sätt, så att framtida arbete med dimensionering och detaljkonstruktion underlättas. / This report is part of a thesis of 22.5 ECTS for a Degree of Bachelor of Science in Innovation and Design Engineering at Karlstad University during the 2017 spring semester. The thesis is carried out on behalf of Rejlers AB, a Swedish technology consultancy. Rejlers has manufactured and tested a prototype for two years for bending steel parts. The prototype in its current form automatically adjusts the steel part to the end user's needs, by incremental shaping. When steel parts with a large cross-section are bent, problems arise in the form of plastic deformation of components in the machine. The project is based on the fact that Rejlers has now started the design of the next version of the prototype, to implement improvement proposals that occurred during the test run and solve the problem of deforming components in the machine. The purpose of the work is to create the basis for detail design and dimensioning of prototype number two. The problem is solved by applying the product development process and delivering a conceptual solution in the form of a layout design. In the layout design, critical components are integrated in a scalable way, so that future work on dimensioning and detailing is facilitated.

This work describes the design of a dedicated three-rolls hydraulic bending for Hardox 500 without the possibility of bending sheet metal for the manufacture of pipes. The work will analyze the problem of proposed three-rolls bending, bending technology and creating of the pre-bending, the design of the adjusting hydraulic servo-cylinder, planetary gearboxes with hydraulic motors to drive the bottom rollers, a partial draft of the hydraulic circuit and the complete frame structure of bending machine with its covers.