Baileigh RDB-050, Operator'S Manual

Page 1: ...OPERATOR S MANUAL ROTARY DRAW BENDER MODEL RDB 050 B8000 2015 Baileigh Industrial Inc ...

Page 2: ...DING SPRINGBACK 17 MATERIAL SELECTION 17 MATERIAL LAYOUT 18 PIPE AND TUBE BENDING DIAGRAMS 19 BENDING GLOSSARY 20 BENDING SUGGESTIONS 21 Aluminum Bending 21 Heavy Wall DOM tubing 21 LUBRICATION AND MAINTENANCE 22 TABLES CHARTS DIAGRAMS 23 Table 1 Standard Pipe Sizes and Schedules 23 Table 2 ARC LENGTH TABLE 24 Diagram 1 25 Diagram2 26 STAND ASSEMBLY PARTS DIAGRAM 27 Stand Assembly Parts List 27 TO...

Page 3: ...rrect installation guidelines Description of the functional parts of the machine Capacity charts Set up and start up instructions Machine operation Scheduled maintenance Parts lists GENERAL NOTES After receiving your equipment remove the protective container Do a complete visual inspection and if damage is noted photograph it for insurance claims and contact your carrier at once requesting inspect...

Page 4: ...safety alert symbol DANGER identifies a hazard or unsafe practice that will result in severe Injury or Death Safety signs with signal word DANGER or WARNING are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety messages in this manual IMPORTANT PLEASE READ THIS OPERATORS MANUAL CAREFULLY It contains important safety inform...

Page 5: ...nged exposure to loud noise can cause impairment or loss of hearing Wear suitable hearing protective devices such as ear muffs or earplugs to protect against objectionable or uncomfortable loud noises BEWARE OF CRUSH HAZARD NEVER place your hands fingers or any part of your body in the die area of this machine Be aware of the area on either side of the dies for crush points created by material mov...

Page 6: ...and caution will considerably lessen the possibility of personal injury However if normal safety precautions are overlooked or ignored personal injury to the operator may result Safety equipment such as guards hold downs safety glasses dust masks and hearing protection can reduce your potential for injury But even the best guard won t make up for poor judgment carelessness or inattention Always us...

Page 7: ... you are producing metal filings 11 Do not overreach Maintain proper footing and balance at all times DO NOT reach over or across a running machine 12 Stay alert Watch what you are doing and use common sense DO NOT operate any tool or machine when you are tired 13 Check for damaged parts Before using any tool or machine carefully check any part that appears damaged Check for alignment and binding ...

Page 8: ... technical support department can be reached at sales machineryhouse com au listing support and the model number in the subject line Tech Support handles questions on machine setup schematics warranty issues and individual parts needs other than die sets and blades List the model number serial number and contact name and phone number as well as a brief description of the nature of the contact in t...

Page 9: ...y damage painted surfaces Follow manufacturer s label instructions when using any type of cleaning product After cleaning wipe unpainted metal surfaces with a light coating of quality oil or grease for protection WARNING SUFFOCATION HAZARD Immediately discard any plastic bags and packing materials to eliminate choking and suffocation hazards to children and animals If any parts are missing do not ...

Page 10: ...o that all the supporting feet are taking the weight of the machine and no rocking is taking place INSTALLATION IMPORTANT Consider the following when looking for a suitable location to place the machine Overall weight of the machine Weight of material being processed Sizes of material to be processed through the machine Space needed for auxiliary stands work tables or other machinery Clearance fro...

Page 11: ...ock and the operator The floor should also be a level surface If the unit wobbles or rocks once in place be sure to eliminate by using shims WORKING CLEARANCES Take into consideration the size of the material to be processed Make sure that you allow enough space for you to operate the machine freely POWER SUPPLY PLACEMENT The power supply should be located close enough to the machine so that the p...

Page 12: ...pringback lever into the latch plate and re install and tighten the pivot bolt 4 Connect the latch spring 5 Read through the remainder of the manual and become familiar with the die installation and settings as well as normal operation 6 Position the machine as desired following the installation guidelines WARNING For your own safety DO NOT connect the machine to the power source until the machine...

Page 13: ...11 11 GETTING TO KNOW YOUR MACHINE I B C E G D F H A ...

Page 14: ...s been carefully built of high quality materials and designed to give many years of efficient service The simplicity of design and minimum effort required to operate the machine contributes towards meeting schedules and producing greater profits The RDB 050 is a manually powered Rotary Draw bending machine To bend material a bending die and hook sleeve are required The material is hooked by the ho...

Page 15: ...r pull in speed 1 b 8 degrees per pull in speed 2 c 12 degrees per pull in speed 3 d Increasing speed increases pulling effort of the bending handle When the machine is in the home position engage the anti springback lever A Next engage the ratchet release lever B Without material in the machine Pull on the ratchet wheel clockwise You will hear a click every time the lever is cycled through one st...

Page 16: ...ck Die Selection IMPORTANT Damaged or worn tooling should be replaced before attempting to bend material This will ensure that bends are correct and provide a longer life to machine components 1 Before any bending can take place the proper die set must be chosen to match the material being bent Example 1 1 2 diameter tubing requires a die set marked 1 1 2 tube 2 Two different types of dies are ava...

Page 17: ...the centerline radius of the die and install the 3 4 hook pin There are two different hook sleeve holders One for whole number nominal CLR dies ie 4 0 clr and one for fractional 0 5 increment dies ie 4 5 clr 6 Choose a counter die that matches your bend die and install the 1 1 4 counter die pin so the gap between the die and the counter die is approximately 1 8 For dies under 3 5 clr the 3 4 die c...

Page 18: ...ing the bending die and hook sleeve will encourage slipping of material during the bend Follow the bending steps to bend the material to the desired degrees Material Insertion Limitations Using the Material Layout formula calculate the amount of material that will be pulled through the die Verify that the material is long enough to provide at least 80 coverage in the counter die at the end of the ...

Page 19: ... perfect 90 is obtained At that point document the actual machine degrees Full manual mode is the best place to do these tests Use the overbend amount and enter that value into the springback field MATERIAL SELECTION When selecting materials keep these instructions in mind Material must be clean and dry without oil Material should have a smooth surface so it processes easily Dimensional properties...

Page 20: ...is easiest For non symmetrical bends continuous one direction bending is best Another way to layout material is to draw them in a 2D computer software program like Auto Cad There are many free programs on the internet In a 2D program you will draw the parts centerline only with corresponding clr s Then you will be able to list individual segments of the bent part This data can be directly entered ...

Page 21: ...de D Tube outside diameter t Tube wall thickness a First bend arc angle H Height of offset b Second bend arc angle L Length of offset A First tangent R1 First radius B Straight between bends R2 Second radius C Second tangent t Tube Wall Thickness D Tube outside diameter ...

Page 22: ... required by the bending machine to form the bend Neutral Axis That portion of the pipe or tube that is neither in compression or tension O D Outside diameter in inches of the tube or pipe Out of Plane The deviation of the horizontal plane of a single pipe bend between its tangent points based on the theoretical center line of the pipe bend Ovality The distortion or flattening of pipe or tube from...

Page 23: ...um Steel rollers would be used for non polished materials Some aluminum will crack as it is being bent 6061 T6 is very hard and may need to be annealed or ordered in the T 0 condition Aluminum will age harden so if possible try to get freshly run material Heavy Wall DOM tubing If heavy wall materials are bent to a tight radius they can tend to slip in the hook arm causing a poor bend result below ...

Page 24: ...nted surfaces Note Proper maintenance can increase the life expectancy of your machine There are two grease zerks on the machine at the main spindle pivots Grease these zerks every month with only two pumps from a standard grease gun Check for any loose or worn parts WARNING Make sure the electrical disconnect is OFF before working on the machine Maintenance should be performed on a regular basis ...

Page 25: ... 540 0 500 0 070 0 088 0 119 3 8 0 675 0 500 0 070 0 091 0 126 1 2 0 840 0 700 0 080 0 109 0 147 0 188 0 294 3 4 1 050 0 700 0 080 0 113 0 154 0 219 0 308 1 1 315 0 700 0 110 0 133 0 179 0 250 0 358 1 1 4 1 660 0 700 0 110 0 140 0 191 0 250 0 382 1 1 2 1 900 0 700 0 110 0 145 0 200 0 281 0 400 2 2 375 0 700 0 110 0 154 0 218 0 344 0 436 2 1 2 2 875 0 800 0 120 0 203 0 276 0 375 0 552 ...

Page 26: ... 0 6631 68 1 1866 9 0 1571 39 0 6806 69 1 2041 10 0 1745 40 0 6980 70 1 2215 11 0 1920 41 0 7155 71 1 2390 12 0 2094 42 0 7329 72 1 2564 13 0 2269 43 0 7504 73 1 2739 14 0 2443 44 0 7678 74 1 2913 15 0 2618 45 0 7853 75 1 3088 16 0 2792 46 0 8027 76 1 3262 17 0 2967 47 0 8202 77 1 3437 18 0 3141 48 0 8376 78 1 3611 19 0 3316 49 0 8551 79 1 3786 20 0 3490 50 0 8725 80 1 3960 21 0 3665 51 0 8900 81 ...

Page 27: ...25 25 Diagram 1 ...

Page 28: ...26 26 Diagram2 ...

Page 29: ...scription Qty 1 M050 6A002 Bottom Plate 1 2 AA 838 16 Sleeve Bushing 1 3 M050 5A005 Stand Weldment 1 4 LW 0 375 3 8 Lockwasher 4 5 0 375 16 x 1 00 HHCS 3 8 16 x1 Hex Head Cap Screw 4 6 0 250 20 x 1 00 SHCS 1 4 20 x 1 Socket Head Cap Screw 1 7 0 250 20 Hex Nut 18 4 20 Hex Nut 1 ...

Page 30: ...28 28 TOP FRAME ASSEMBLY PARTS DIAGRAM ...

Page 31: ... 6A025 Rectangular Spacer 1 12 1250 Snap Ring 1 1 4 Snap Ring External 1 13 1000 Snap Ring 1 Snap Ring External 1 14 1500 Snap Ring 1 1 2 Snap Ring External 1 15 LW 0 75 3 4 Split Ring Lockwasher 3 16 LW 0 625 5 8 Split Ring Lockwasher 3 17 0 75 10 x 6 50 HHCS 3 4 10 x 6 1 2 Hex Head Cap Screw 2 18 0 75 10 x 9 00 HHCS 3 4 10 x 9 Hex Head Cap Screw 1 19 0 625 11 x 1 50 HHCS 5 8 11 x 1 1 2 Hex Head ...

Page 32: ...30 30 RATCHET WHEEL ASSEMBLY PARTS DIAGRAM ...

Page 33: ...Hex Nut 1 15 M050 6A025 Rectangular Spacer 1 16 M100 6A019 Degree Sticker 1 17 M050 7A024 Lower Bushing 1 18 1000 Snap Ring 1 Snap Ring External 1 19 0750 Snap Ring 3 4 Snap Ring External 4 20 LW 0 75 3 4 Split Ring Lockwasher 1 21 M050 6A011 Latch Plate 1 22 0 750 10 x 9 00 HHCS 3 4 10 x 9 Hex Head Cap Screw 1 23 0 250 20 x 0 75 SHCS 1 4 20 x 3 4 Socket Head Cap Screw 2 24 0 625 11 x 1 50 HHCS 5 ...

Page 34: ...32 32 DRIVE LEVER ASSEMBLY PARTS DIAGRAM ...

Page 35: ... 1 14 FL 75 4 Flanged Sleeve Bushing 8 15 M050 7A024 Lower Bushing 1 16 M050 7A007 Thrust Washer 1 8 4 17 AA 838 16 Sleeve Bushing 2 18 M050 7A026 Special Hex Nut 1 20 FF 838 1 Flanged Sleeve Bushing 1 21 AA 838 25 Sleeve Bushing 1 22 M050 7A025 Lower Pivot Sleeve 1 23 0750 Snap Ring 3 4 Snap Ring External 6 24 0625 Snap Ring 5 8 Snap Ring External 2 25 0 313 18 x 1 00 HHCS 5 16 18 x 1 Hex Head Ca...

Page 36: ...34 34 Distributed By SYDNEY 02 9860 9111 MELBOURNE 03 9212 4422 BRISBANE 07 3715 2200 PERTH 08 9373 9999 ...

Page 37: ...n the off position before re connecting 14 Use correct amperage extension cords Undersized extension cords overheat and lose power Replace extension cords if they become damaged 15 Keep machine well maintained Keep blades sharp and clean for best and safest performance Follow instructions when lubricating and changing accessories 16 Keep machine well guarded Make sure guards on machine are in plac...

Page 38: ...o be carefully monitored during use is the rotational area of the formers 8 Understand the machines controls Make sure you understand the use and operation of all controls 9 Overloading Pipe Tube Bender Do not over load the machine by using material which exceeds the rated capacity 10 Avoiding Entanglement Pipe Tube Bender guards must be used at all times Tie up long hair and use the correct hair ...

Page 39: ...t of your body between moving formers and material Do not exceed maximum capacity Keep hand away from moving parts Wear safety boots MEDIUM OR PUNCTURING OTHER HAZARDS EYES B C E CRUSHING Item Hazard Assessment STRIKING PLANT SAFETY PROGRAM No Hazard Identification Safety officer Authorised and signed by This program is based upon the Safe Work Australia Code of Practice Managing Risks of Plant in...