Review of bending machine SGA-1: design, models, characteristics

Machine for bending reinforcement SGA-1. Photo by PromStroyMash From the moment man learned to process metals and create various structures from them, the problem of expanding the scale of production became acute. Today, the metalworking industry offers us many equipment options for fast and convenient work in enterprises. The main task of such machines is not only to improve the quality of the final product, but also to speed up the work process and improve conditions for the machine operator .
Let's take a closer look at this type of machine, such as mechanisms for bending fittings and pipes, namely SGA-1. Let's analyze its pros and cons, advantages (in comparison with similar devices), operating modes, components and consumables that are used in working with metal. We will also consider the technical characteristics and list which factories produce these machines and whether it is worth buying used equipment.

Advantages of the bar bending machine

Considering the active development of scientific and technological progress, you need to understand that most of the innovations produced by manufacturers around the world are modifications of simple mechanisms that were discovered more than a century ago.

A logical question immediately arises : is it as rational to use machines for bending fittings and pipes as manufacturers claim?
In order to answer this question, you need to turn to statistics on production volumes before 1915, because it was at that moment that automatic and semi-automatic machines for bending metals began to be introduced on a large scale. It’s hard to believe, but until this moment, metal products were bent by hand, and sometimes, in order to process a reinforcement bar, the efforts of 3 or even 4 people were required.

This leads to the first advantage, namely acceleration of the work process and increase in production volumes.

If the machine is so efficient, then it must have some kind of disadvantage, for example, large dimensions or a complex connection diagram. Despite the fact that the device belongs to the budget category, its transportation, installation and connections do not cause any inconvenience , the diagrams are intuitive, and if this is not enough, a connection diagram and instructions are included with the machine.

The second advantage is ease of transportation and installation.

Everything is set up, there is enough material, electricity is supplied. The mechanism is equipped with a control panel, with which you can control the operating mode, set various parameters and stop the product preparation process at any time. Therefore, operating the machine is not difficult at all.

Machine for bending reinforcement SGA-1. Production - Russia. Photo VseInstruments.ru

The third plus is ease of use and ease of use.

It is also worth noting the economic factor. Most modern machines with high power consume enormous amounts of energy, however, their efficiency does not increase from this. The SGA-1 model is made taking into account this factor and does not consume electricity above normal .

The fourth plus is savings.

Another undeniable advantage is the use of a worm gear . This factor extends the life of the device and reduces the chance of failure of the feed mechanism.

This is interesting: G-40 - machine for bending reinforcement

Selection principles

The selection of metal bending machines is based on the following parameters:

• power unit power;
• maximum width of the working surface;
• bending method, angle range;
• structural strength, types of parts used;
• machine weight;
• desktop sizes;
• traverse lift height;
• maximum bending thickness of sheets, rods, fittings.

Advantages and disadvantages

Advantages of sheet metal bending machines:

• wide choice of designs, technical parameters of models;
• simple equipment design, ease of maintenance;
• high bending speed, uniform bending line;
• maintaining the strength of the part after deformation;
• precise adjustment of the angle of inclination;
• permissibility of bending various metals and alloys;
• high reliability of components and mechanisms;
• convenience of manual or electronic control;
• changing working attachments that allow you to form the desired profile when bending sheets.

Among the main disadvantages are:

• high price;
• difficulty in controlling the final dimensions of parts;
• bending may damage the decorative or protective coating of metals.

Portable plate bending machine

Manufacturers and cost

Sheet steel benders are manufactured at the following enterprises:

• Astrakhan Machine Tool Building, Barnaul;
• Kuvandyksky;
• Construction Machines LLC, St. Petersburg;
• Uniteh LLC, Novocheboksarsk.

Prices for metal bending machines:

• manual for deforming steel 0.7 mm thick - from 66 thousand rubles;
• segmental for creating complex profiles - from 146 thousand rubles;
• electromagnetic for industrial use - from 238 thousand rubles;
• hydraulic with rotating beams, capable of bending sheets up to 3.5 mm thick - from 450 thousand rubles.

Functions

The SGA-1 device has two operating mechanisms, namely mechanical and automatic. In the first version of work, the entire process is completely controlled by the operator, and in the second case, the performer only feeds the workpieces and removes the finished products.

For bending what kind of reinforcement

Using SGA-1 you can process such types of reinforcement as :

• working;
• constructive;
• installation;
• anchor

Examples of bending possibilities
Maximum cross-section of a workpiece rod:

• A-I – 40 mm;
• A-II – 36 mm;
• A-III – 32 mm.

Let's summarize. The machine can work with reinforcement with a medium cross-sectional size, which is made of standard carbon and alloy steels. In principle, its power will not be enough to bend very hard metal rods, but most types of reinforcement are made from soft steels.

ATTENTION! Under no circumstances should you try to install two workpieces between the rollers at the same time, even if their total density is less than specified in the specifications for the machine. The fact is that the rollers are calculated taking into account the load on one point, and by installing two workpieces, you disrupt the operating mode, which leads to equipment failure.

Operating instructions and appearance

How does the machine work? It works by bending hooks, which subsequently serve as a support for modifying the shape of the workpiece.

Sequence and guidelines for working on a bending machine:

Reinforcement bending process

• It is necessary to install the workpiece between the central pin, the bending and thrust pin with the adjusting roller.
• As a result of the rotation of the disk, the central and bending fingers clamp the workpiece and bend it to a given angle.
• A subsequent reverse movement releases the bent reinforcement.
• The machine stops by pressing the second cam on the second limit switch.
• Additional spare parts, stops, on the disk are needed to perform different amounts of bending.

For a diameter of 110 millimeters, the workpiece is bent with a roller, and for 40 millimeters - with a central finger. To obtain products with a diameter of up to 28 millimeters, a fork and bracket are installed on the disk.

Operating modes

Operation of SGA-1 in manual mode:

• power is supplied to the machine using a circuit breaker;
• pressing the pedal causes the contacts to close and the disc rotates forward;
• to stop rotation, you must release the pedal;
• reverse occurs the next time you press the pedal;
• releasing the pedal stops reverse rotation.

Auto mode

Bending of rods on the machine can take place automatically. For this purpose, manufacturers offer to additionally equip the machine with an electronic unit, which helps control the process of working with rods.

Working in automatic mode provides for the presence of two submodes:

• single bend mode;
• n-bend mode using eight installed programs.

The display is made of shockproof material and is located on the side panel of the machine. It displays the current value for the bend angle, which can be changed using the +/- keys. Pressing the key once changes the angle by one degree, and pressing the button for a long time changes the angle by ten degrees.

Specifications

Features of the bending machine for reinforcing steel SGA-1

• On the plate of the SGA-1 machine there is a funnel for removing scale with a flange for joining to the aspiration system;
• The bending disk is driven through a V-belt transmission from the engine;
• It is possible to perform simultaneous bending of several reinforcement bars;
• All spare parts for the machine are easily interchangeable.

Machine characteristics

• Power - 3 kW
• Maximum permissible diameter of fittings, mm. — from 10 to 32 mm (Rebar class GOST 5781-82 and 10884-94, A-240, A-400, A-500S, At-500)
• Internal bending radius, mm. — 20-55
• Dimensions LxHxW, cm - 79x69x68
• Weight, kg. - 380.

The machine can perform up to 8 bends per minute.

Operating procedure on the machine SGA-1 (UGA-40)

• When operating the machine, you should pay attention to the technical condition of the machine.
• At the end of work, clean the machine from scale and dirt.

Wiring diagrams

The machine consists of a support frame on which a plate and a gearbox with a special device are placed, which is responsible for bending parts from rods. The electronics are controlled using a pedal ; pressing it begins the process of closing the contacts. There are also clamps between which the part and the bending roller itself are installed.

Most often, in the SGA-1 machine, the bar for the thrust pins fails , since the walls between the compartments are quite thin. As a result of improper operating conditions, or processing of workpieces made of too hard metal, the walls may be damaged. The bending disk for reinforcement also suffers (for the same reason), although it can fail due to unbalance of the rotation axis.

In addition, for correct operation you need oil , which is poured into the gearbox, and the machine parts are lubricated with it. Without it, the worm shaft heats up and the efficiency of the entire working process drops.

Electrical control circuit

Kinematic diagram

Composition, structure and operation of the SGA-1 (UGA-40) machine

1. frame
2. gearbox
3. plate
4. fixtures for bending reinforcement
5. pedal control
6. electrical equipment

The machine frame consists of a frame and a carriage.
The frame is welded, made of angle steel and serves to fasten all components of the machine.

The carriage is used to mount the electric motor and tension the V-belts. On the upper belt of the frame there is a plate assembled with a gearbox and a device for bending reinforcement.

Magnetic starters and a circuit breaker are installed in the front part of the frame.

A pedal-controlled plate is welded to the lower belt of the frame.

Gearbox 2 consists of a closed worm pair and two pairs of open spur gears.

Changing the rotation speed of the bending disk is done by rearranging gears 6 and 7.

Technical problems

FAQ.

Reverse does not change

For example, the reverse of a machine does not change . In order to solve this problem, you need to inspect the three-phase motor, and specifically test it in idle mode. If the same changes are observed at idle, then most likely the engine needs to be replaced or repaired.

Vibration

Machine SGA-1, used for bending reinforcement.
Photo by PromStroyMash Another common problem is machine vibration , even due to the absence of a workpiece. This may indicate that the motor is not running properly, or the main center axis is unbalanced, or the unit is not securely secured to the floor, or the pad between the unit and the floor is uneven or at an angle.

Other questions

It is also possible for the bent rollers to go beyond the working plane . In other words, the mechanism tends to bend the part outside the workbench. This problem is typical for machines that have a broken converter bus, that is, the breakdown occurred at the software level. The control panel does not convert commands properly, transmitting incorrect instructions and incorrect rotation and pressure coordinates to the mechanism.

Another type of such a breakdown is normal readings on the control panel and incorrect operation of the mechanism in reality. That is, on the control panel the operator will observe that the process is proceeding according to the standard algorithm, and the workpiece will not bend or will bend incorrectly. In this case, you need to inspect the operating system of the machine. You may need to change the software or install it again.

Machine SGA-1 for bending reinforcement. Photo Machine World

Another common problem that can be either hardware or mechanical related is workpiece flyout. In other words, when installing the workpiece, it does not bend properly, but flies off the rollers. The reasons may be the following: the first and most common is a violation of the integrity of the fastener walls; the second is the failure of the clamping rollers, the third reason is violations in the software shell, which provoke too fast or incorrect operation of the mechanism. Before starting work, it is recommended to remove the clamping bending rollers and the central shaft and reinsert them in order to inspect the grooves and the integrity of the entire system, and diagnose the device for damage.

IMPORTANT! Machine tools are classified as potentially hazardous mechanisms. Therefore, it is recommended to contact specialists rather than repair them on your own, even if the contractor has experience. After all, a breakdown of a mechanism can result in more than just a failure in the entire electronic network. loss of time, reduction in production volumes, but also injury to the machine operator.

Exploitation

The reinforcement rod that needs to be bent is placed on the work table (bending disk) between a stop with a roller, a working finger for bending and a finger installed in the center. During the working stroke of the bending disk, the reinforcement bar is jammed with a bending pin, after which the workpiece is bent around the installed roller at a set angle. The required bending angle is set by installing the cam. If the bending radius of the rod is 55 mm, the bending of the reinforcement is done with a roller, and if the radius is 20 mm, then the central pin will serve as a stop for bending. In some cases, to bend the rods at the required angle, it is necessary to additionally install a special bracket and fork.

Manufacturing plants

• Mashstroykonstruktsiya
• PromStroyMash
• RusInStroy
• Gigant (Machine tool company)

This is interesting: Where to buy a manual machine for bending reinforcement

All production facilities of the above companies are located in Russia. This is due to the low price and fast delivery speed. Nevertheless, the SGA series is perhaps the only one that has found application abroad.

These certified manufacturers have at their disposal all the necessary documents and certificates for sale; their machines undergo a quality control procedure and suitability for work.

ATTENTION! If you purchase used equipment and the seller refuses to provide certificates or documents that confirm the fact that the machine was purchased at the factory, most likely you are dealing with a fake.

Purpose and advantages of bending machines

Bending equipment is used in the production of any products from sheet and coil metal:

• Housings for appliances, household appliances, metal cabinets.
• Tanks, reservoirs and containers for various liquids.
• Elements of roofing and structures: ridges, valleys, gutters, chimneys.
• Parts of industrial equipment and vehicles, protective covers, bodies, etc.
• Elements of air conditioning and ventilation systems: air ducts of various shapes and air intake and air outlet devices, etc.
• Hardware and plumbing products.

Sheet bending machines can significantly reduce the time for production of parts, reduce the percentage of defective products, allow the production of products of complex configurations, and reduce production costs.

Spare parts, gears, repair kits, repairs

The same applies to components. Manufacturers do not just focus on purchasing factory spare parts. Check out the contact block on our website, which contains trusted manufacturers and component suppliers to be sure of the correct operation of the purchased machines.

Companies involved in the repair and service of machine tools are presented here.

Let's summarize the review. The SGA-1 machine is a universal mechanism for working with fittings for various purposes and structures . Its price and characteristics will allow you to start production from scratch and receive a net profit in just a few months, taking into account the costs of electricity and maintenance. Operation, installation, and transportation of the machine does not bring additional inconvenience if you order the equipment from certified manufacturers that were listed in the article.

Do not neglect diagnostics and inspection of equipment, since one incorrectly configured machine can damage the entire electronic network if it is included in the production chain or disable nearby equipment through mechanical damage.

Pipe bending machines

Pipe bending machines (Fig. 1) are designed for bending pipes of various diameters and profiles. They are used both in repair work and in the construction of new facilities. They are classified depending on several parameters.

Figure 1. Pipe bending machines.

Figure 1. Pipe bending machines.

1. Based on the type of drive, pipe bending machines are divided into:

• with manual drive - used for working with polymer or metal pipes of small diameters;
• with hydraulic drive - capable of successfully working with pipes made of various materials with a wide range of diameters;
• electromechanical - designed to create precise radii of curvature and rotation angles of pipes;
• hybrid - combine the advantages of hydraulic and electromechanical types;
• heated - supplemented with a torch, industrial hair dryer or other heating device for bending metal or polymer pipes, which allows bending work to be performed with less effort.

The above classification is valid for most bending machines.

2. According to the bending method:

• mandrel - an elastic filler (mandrel) is placed inside the pipe, and the bending process is carried out using the bypass method along the guide roller, which avoids corrugation at the bending point;
• mandrelless - carried out by feeding the pipe onto the rollers without the use of filler;
• crossbow - here a special template is used, designed to bend a pipe of a certain diameter and length, into which the workpiece is placed, and the bending process is carried out by applying pressure;
• spring - used for manual bending of pipes;
• segmented - a special segment element is used, around which the pipe is pulled to give the desired shape.

These machines are most widely used in pipeline laying work.