The only tool that can change shape profile pipe, are rollers. And since they are bent hardware Often used in construction, this tool is simply irreplaceable. Rollers for profile pipes are different types, including you can make them yourself.

Roller types

Structurally, this tool for forming arc-shaped profile pipes can be divided into types, according to the source of the applied force.

Electric rollers are the most productive, they are characterized the largest number produced bent products per unit of time compared to other types. Productivity increases due to the presence of a working electric motor, with the help of which the formation of a new pipe shape occurs quite quickly.

Basic structural elements electric pipe bender:

• base, which is a metal frame;
• from 3 to 5 rollers, which rotate by means of an electric motor;
• power plant in the form of an electric motor;
• deforming clamps.

Manual rollers for bending profile pipes are considered practical portable tool. Due to their relatively small size and the absence of an electric drive, they can be installed in any suitable location, even where working space limited. The design of manual rollers for bending a profile pipe is similar to the design of electric ones, the only difference being that they do not have an electric drive, and the feed rollers are connected to each other by a transmission on a chain, which deforms the pipe using clamps.

Manual pipe benders are characterized by design flaws. Despite the fact that such rollers are very convenient for performing a small amount of work, their operation requires the use of considerable physical force. It is not so easy for one person to bend a metal pipe by transmitting force to clamps and chain transmission. If the worker is not a sufficiently physically developed person or has accumulated fatigue from frequent repetition of operations, such a tool will be unproductive in production. Therefore such hand tool useful only when making small batches of bent products.

Hydraulic rollers are considered the most powerful equipment in comparison with the above-described analogues of bending tools. Hydraulic Press in combination with the clamp, it transmits such a powerful force to the profile pipe that it bends like a reed. Such a unit can rightfully be called a “super heavyweight”. In a particular case, the bending force is increased by a hydraulic complex, which is easy to maintain and control. If, in addition to the existing equipment, we add an electric motor acting on the feed rollers, the efficiency of the unit will significantly increase - the possibilities of productivity and power will be combined.

Note! This device can be improved even further. If the feed drum is replaced with a profiled shaft, then several profiled pipes can be bent at once in one go. Thanks to the properties of a hydraulic press and an electric drive, such a machine can process any number of products.

Unfortunately, hydraulically driven rollers weigh a lot. This disadvantage is manifested in the fact that if it is installed somewhere, then this place will remain working for the unit for a long time - it will be very difficult to move it from its place. In order to understand the structure of the tool and the principle of deformation of a profile pipe, you can look at the drawings of rollers given below with the dimensions marked.

Operating principle of rollers

To bend a profile pipe on rollers, you do not need special knowledge and skills. The employee only needs to perform a few operations:

• The pipe rests on two feed rollers.
• With a certain force, the pipe is pressed against one bending roller of your choice.
• The transmission mechanism is turned on.

As a result of the passage of a profiled pipe through work area it bends at the planned angle. If the degree of deformation is insufficient, the workpiece is passed through the working elements of the tool again, and the clamping force must be controlled.

Making homemade rollers

Today, hand-made rollers for profile pipes are often found in everyday life. A wide channel is used for the bed. The bending mechanism can be made from a U-shaped structure using a hydraulic jack or by welding with a nut top plate.

• If a jack is used, it should be located under the bed, and the force should be directed from above onto the feed rollers.
• In another case, the pipe is bent with a threaded clamp. The stud is screwed into the nut, and a heel of the desired shape is welded to the end.

When feeding the pipe, you can use a regular bicycle chain. Sprockets are welded onto the drive and driven shafts and the chain is tensioned. A handle is attached to the drive shaft.

Note! The hardness of the feed rollers must exceed the profile pipe, so they are hardened.

Video

We invite you to look at homemade pipe bender:

Why are rollers needed and what are they? If the design uses a profile pipe, it may be necessary to make it a semicircular or arbitrary curved shape. This is what rolling is used for. This is common practice in specialized factories.

Details about rolling

You can make the pipe take a different shape using a simple torch. This approach is often practiced, but the employee faces a number of difficulties:

• there is a need for a large lever to change the shape;
• you need emphasis and, as a result, a lot of physical strength;
• It is almost impossible to make the product even; this is due to inaccurate movements and improper distribution of effort.

To obtain best result, it is worth using rollers. With their help, a profile pipe can be easily transformed with your own hands. The photos and videos show the features of working with the tool. To familiarize yourself with the result of the tool's work, drawings are presented.

1 Type of machine is designed for radius bending of profile pipes.

Characteristics of a standard machine:

The maximum pipe cross-section is 40 x 40 x 2, 50 x 25 x 2 mm.

Minimum circle diameters:

• 30x30x2 - 650 mm,
• 40x20x2 - 650 mm,
• 40x40x2 - 1800 mm,
• 50x25x2 - 800 mm.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 25,000 rubles.

2 Type of machine is designed for radius bending of profile pipes, round pipes and strips.

Characteristics universal machine :

The maximum pipe cross-section is 40x40x2, 50x25x2 mm.

The maximum cross-section of a round pipe is 32x2.8 mm.

Strip 40x4 mm.

Minimum diameters of a circle of profile pipes:

• 20x20x2, 25x25x2, 15x15x1.5 –560 mm
• 30x30x2 - 650 mm,
• 40x20x2 - 650 mm,
• 40x40x2 - 1800 mm,
• 50x25x2 - 800 mm.

The maximum arc diameter is unlimited.

Drive type: manual.

Hardened rollers – all 3 pcs.

Price: 30,000 rubles.

At the Customer's request, for an additional fee, the machine is equipped with a dial indicator for the production of more accurate all subsequent workpieces.

For an additional fee, the machine can be equipped with a 220-380V electric drive

2 year warranty

Contacts:

Tel: 8-919-831-25-14

Saratov region Engels

Delivery within the Russian Federation.

Industrial and home rollers

Not all modifications of this amazing tool can be used at home. How do you think a profile pipe is made? Of course, with the help of rollers. This is done as follows. The sheet of metal is rolled into a cylinder and the seam is welded. Next, the pipe is passed through rollers. Under the influence of high pressure it turns out desired profile.

To do the work, enormous effort is required, so the profile pipe is produced using special equipment. Rollers installed in factories weigh more than ten tons. How can you do this kind of work yourself?

We do it ourselves

At home you will need other rollers, not so heavy. Drawings and photos of some modifications are presented on the website. To do the job yourself, you will need a small, mobile instrument. Home rollers are available mechanical and electric. Here you have to choose between saving energy and the amount of effort expended.

Electrical appliances “eat” electricity, but making a profile pipe with your own hands is much faster, it turns out like it came from a factory. Mechanical analogues are not inferior in results, but the worker has to apply force to change the shape of the workpiece. In case of electrical appliance There is one more pitfall. Its power can be so high that the aluminum wiring simply cannot withstand it and burns out. This is worth remembering. Electric rollers are available in different versions, but the most popular are those with motors ranging from 500 to 1500 W.

Manual devices are no less in demand. You can make them yourself. To do this you will need three rollers made of durable steel. Two of them are located on the same plane. A handle for rotation is attached to one of the rollers. The third is lowered from above using a simple worm gear. The profile pipe changes shape as a result of pressing its surface during rotation. Drawings of the instrument circuit are presented here.

If you don’t plan to make products for sale, homemade rollers are what you need. It is very cheap, the device is compact, and if necessary, you can also screw in the drive - the device will be electric. In this case, it is important to calculate the power that will be required during rolling.
http://www.youtube.com/watch?v=b4NSJo-FZNY
If the pipe is not profiled, then it can also be bent. To do this, a groove is cut the right size. If you plan to use an electrical appliance, then during its manufacture you should also calculate the gearbox. Thanks to optimal values gear ratio, the forces on the motor shaft are minimized.

We are all a little Kulibina

It is human nature to create. The desire to do something on their own never leaves even the laziest people. When designing rollers, it is worth keeping safety in mind.

Profile pipe is an element of many building structures and frames. Used in the construction of industrial and residential buildings. The main characteristic that distinguishes it from other types of pipes is the non-round shape of the cut. A profile pipe is produced from a sheet, welded and bent lengthwise in in the required form. If necessary, you can make rollers for a profile pipe with your own hands - you will find drawings and explanations in this article.

Manufacturing of profile pipes using the rolling method

Assortment of profile pipes

In the factory, two methods are used for the production of profile pipes from metal sheet:

• hot method, in which straight-seam round pipe heats up;
• cold method, in which rollers for a profile pipe are rolled over unheated metal.

The basis for production is carbon, low-alloy, less often stainless steel. Modern factory equipment will allow you to obtain a profile with high accuracy seams and bends, since the process is controlled by transmitting data from a computer and receiving it from sensors that take readings with an accuracy of thousandths of a millimeter. Homemade rollers for profile pipes cannot provide such detail, but they cope with the task of producing elements for home construction and household work. This technique is used to produce consumables for fences and canopies, greenhouses and technical buildings, gutters and cable ducts. It is not recommended to make a profile pipe for large-scale buildings at home. Factory equipment makes it possible to subject each manufactured element to test tests and check both the quality of the seam and the accuracy of profile calibration. The absence of such equipment does not give the master the opportunity to guarantee the quality of a homemade product.

Assembly of a machine for profile production

Application of curved profile pipes

Rolling machine for a profile pipe with your own hands, it looks similar to a design for bending pipes. It consists of the following elements:

• supporting frame;
• roller system;
• pressing mold:
• stop and levers for activating the rolling mechanism.

Actually it's two different mechanisms and only the frame can be similar. All structural elements are assembled from durable elements and welded: any defects or negligence can result in a work-related injury. The machine itself is firmly fixed to the surface.

Almost impossible to provide required pressure manually: it is advisable to equip the press for creating a profile pipe with an electric drive.

In the machine for giving a profile about round shape the main thing is a press that twists a sheet of metal. Such pressure only gives robust design: The pipe must be held motionless throughout the welding period. To simplify the work, the metal is heated and then rolled. After welding, the round pipe is checked for the quality of the connection: an insufficiently smooth and clean seam will separate when rolling of the profile pipe from a round shape to a rectangular or square one begins.

Workpiece processing process

The finished straight-seam pipe is rolled hot or cold. At home, it is difficult to organize hot rolling, so the process is often carried out on already cooled metal.

The pipe is placed under a press of rollers, forming the required shape.

Rolling is carried out gradually with a decrease in the distance between the upper and lower rollers. Sudden pressure will cause internal folds in the metal, which will affect the strength of the knees. The last rolling reaches the planned diameter and cut contour.

The pipe is checked for cracks and metal deformation in the bend area after each rolling. Zone special attention– the seam area, it is the most vulnerable.

After processing with rollers, the pipe is calcined: this measure eliminates the stress of the metal layers and increases the strength of the structure as a whole.

Bending of profile pipes

Craftsmen rarely decide to independently manufacture a profile pipe, preferring to purchase ready material factory production. The profile pipe is an inexpensive consumable element, so bending is necessary with my own hands No. A machine for bending profile pipes with your own hands is a more popular equipment, since the element is sold in direct form, and ordering bending according to your own drawings is an expensive service. A curved or rounded profile is used for construction and construction decorative elements as more aesthetic. Frames and cornices, greenhouse arches and gate arches can be made with your own hands. The simplest rollers for bending a profile pipe are assembled in a few hours. They will not provide industrial volumes and accuracy, but they will reduce the costs of producing individual elements.

Bending quality requirements

The simplest way bending of profile pipes - glow and pressure. In this way, you can even create an acute angle, but you should not count on the accuracy and strength of the knot. Folds on inner surface knees and cracks on the outside are guaranteed. Bending without defects is achieved only by gradually rolling the pipe on rollers and calculating the minimum diameter. The maximum bend angle is not standardized, the minimum is limited by safety requirements. A standard factory machine for bending a profile pipe sets the minimum diameters of a round bend, and you can use these same indicators when creating homemade machine:

• pipes 20x20x2, 25x25x2, 15x15x1.5 - 56 cm;
• pipes 30x30x2 – 65 cm
• pipes 40x20x2 - 65 cm;
• pipes 40x40x2 – 180 cm;
• pipes 50x25x2 - 80 cm.

Machine drawings for home use

The simplest deformable structure can be assembled directly in the yard or technical room, securing all the elements to a dense shield or directly to the fence. Elementary models will help out if you need to bend several pipes into a single shape, for example, to install the upper arches of a greenhouse. Regardless of the selected bend diameter and the size of the pipe itself, you will need:

1. A frame that follows the contour of the required arch. It is cut from a single piece of wood or assembled from a series of planks. The pipe will bend according to this stencil.
2. Support on one side of the frame. The gap between the stop and the stencil is made corresponding to the diameter of the pipe being processed. A smaller one will make it difficult to install the element into the device, a larger one will not secure the knee firmly.
3. A block with which the pipe is manually pressed against the template.

Working with such a pipe bender is difficult: all efforts will have to be done manually. But the design will ensure accuracy when bending: you can make several elements with an identical angle of deformation on it.

The pipe bender for permanent use is assembled on a durable U-shaped frame. The following elements are required in his system:

• two rotating shafts mounted on a rail, along which the profile will pass during rolling;
• an extrusion shaft located above them, which presses the profile during rolling;
• a clamp or jack that provides pressure;
• a chain with which the set of rollers will move.

To assemble rollers for a profile pipe with your own hands, you will need a welding machine and engineering skills. Inaccuracies in calculating the diameter of the functional shafts will make the device inoperable.

Video: working with a manual profile bender

Assembling a bending device with your own hands is a complex, time-consuming and expensive process. Against the background of moderate prices for equipment, it is worth thinking about the rationality of the purchase. Perhaps, to bend several elements, it is more profitable to contact a workshop, but for permanent job purchase a factory model with a quality guarantee.

Bend metal pipes under the right angle or along a given contour, preferably without loss of strength qualities and internal working sections, this happens quite often. IN pipeline systems- an excellent opportunity to do without unnecessary connecting parts; in structural structures made from profile pipes - a certain freedom of design and design thought.

We specifically introduced this section in order to slightly cool down the natural fervor of our fellow citizens to do everything with their own hands: artisanal mechanical or hydraulic pipe bender, rollers for it from random metal tubes, and damaged rolled metal - entertainment, of course, worthy for a real man, but it’s easier to look for ready-made profile products that just need to be brought to condition.

For people who are far from such purely mundane topics, let us explain:

Pipe bender – mechanical device, which is capable of bending pipes of any size and configuration. There are only three industrial versions of the drive type:

• manual: the simplest in principle of operation and the most complex in operation; the final deflection pattern of the pipe can be changed, but the physical effort to perform shaping work remains equally large;
• hydraulic: a version of a semi-professional pipe bender with rollers made of alloy steel, allowing you to roll pipe profiles up to 80 mm without losing the strength properties of the pipe, crushing and stretching the working section;
• electromechanical: industrial machine tool production, which produces most ready-made structures from rolled pipes.

The rollers of a pipe bender are simply two round shafts made of high-strength material, between which the material being processed (in our case, an ordinary steel pipe) is “rolled” and takes a given shape.

Make a pipe bender yourself or buy a ready-made one

The question is funny because it touches on two absolutely different areas: financial and psychological. For many of our compatriots, it is easier to buy a ready-made pipe bender, not to worry about calculating rollers and loads, but simply take the instructions and quickly bend all the pipes that are available on a suburban site.

Most important question The thing that always comes up when purchasing expensive equipment is the price. For reference, let us inform you: a high-quality hydraulic pipe bender costs in the range of 22-35 thousand rubles. Perhaps your entire structure, built from bent profile pipes (shed, garage, summer cuisine) are priced cheaper. A manual pipe bending device with six bending profiles and a jack rod will cost 9,500-12,000 rubles.

Agree, if you do not plan to build up all your land with openwork greenhouses and gazebos of complex architectural forms, then such equipment costs are clearly unnecessary. Our natural intelligence begins to work and, as a result, the traditional Russian answer: we’ll do it ourselves.

How to make a pipe bender for a profile pipe with your own hands

We considered the entire range of profile steel pipes, their structural advantages and scope of application separately. Now we will try to bend them with our own hands along a given radius of the final product.

It is very important to avoid the following technical defects:

• cracking; such a metal profile will have to be thrown away;
• compression or tension of surfaces at points of potential load on a structural element;
• deformation of the original profile, leading to a violation of the resistance of the metal (corrosion and mechanical) in the bending and fracture units of the supporting structure.

If you are ready to make a unit and rollers for such work with your own hands, honor and praise to you. The simplest handicraft pipe bender with electrically driven rolling rollers (any electric motor with a gearbox is suitable) and clamping device from ordinary steel pipe. It is mounted on a regular car jack and, judging by the reviews, produces high-quality arched products.

We appreciate the technical discoveries of our “Kulibins”, but we recommend buying ready-made rolled metal of any configuration or making it to order according to your drawings and ideas, without particularly straining your hands and head.

The emergence of cellular polycarbonate for the manufacture of greenhouses determined new type structures of protected ground structures – arched structures. To create a metal frame for such buildings, you need to have a machine capable of bending structural profiles along a certain curve. Homemade rollers for profile pipes are designed to help in the manufacture of arches along a given radius.

Technological process profiling of long workpieces is based on pulling the part through rollers located at a certain distance from each other. To give a bend in one direction or another, the length of the length is not passed in a straight direction, one or two rollers are offset.

Pipe rolling machine

When rolling long pipes on a machine, the center of movement is shifted. Due to this displacement, a curve is formed between the rollers. One roller presses from the inside of the radial contour, and the other two form the external contour of the future product.

Drawing of a pipe bender for pulling profile pipes. All dimensions of parts required for manufacturing are indicated:

Structurally, such a device is made on a strong support made of channel. The lower rollers are located in bearings. Usually the distance between them does not change (there are versions of the machine where, by changing the location of the lower rollers, a different rolling radius is created).

The top roller is located on top. It can be moved in height. By moving the supporting part downward along the thread, significant forces can be developed. They will act on the pipe during the rolling process.

To perform rolling, it is necessary to apply additional pulling forces in longitudinal direction. A handle is installed for this purpose. By rotating it, you can make the pipe move in one direction or another.

For self-made you can go another way. The walls of the device are cut out of a sheet 2...4 mm thick, where the rollers are installed.

Simplified pipe bender design:

The most difficult thing is to make the sidewalls, inside of which are located:

1. Support shafts – 2 pcs.
2. A pressure roller located on a suitable device.
3. A handle that allows you to roll a profile pipe.

Industrial machines are made with manual or electric drive. When manufacturing an electrified machine, the possibility of reverse must be provided. Then you can roll, forcing the length to move in both directions.

Making a pipe bender with your own hands

The simplest pipe bender It is relatively easy to make. Need to purchase:

• bearings No. 206;
• bearing housings;
• shafts Ø 35 mm made of hardened steel HRC 40…45 (suitable for inner size bearings);
• bicycle sprockets of the same diameter;
• bicycle pedal;
• lead screw with nut;
• channel No. 8;
• channel No. 6;
• M8 bolts with nuts;
• strip 40 mm, thickness 4 mm.

To make it you need to use:

1. Electric drill.
2. File.
3. Angle grinder with cutting and cleaning discs.
4. Welding machine.
5. Set of wrenches.

Step-by-step manufacturing of the machine

Having prepared a set of components, we begin manufacturing.

General form machine It is installed on timber 100·50 mm.

All details are displayed in a visible place. The performance of the bearings and lead screw is preliminarily checked.

Blanks are cut from channels. A vertical stand is welded from them, installed perpendicular to the supporting channel.

A hole is drilled for the lead screw. A nut is welded to it. Then screw in the screw. A cross member is welded on top; it will be needed to move the screw along the thread.

Bearings move along the support channel. They are pre-installed in the housings. Shafts are inserted inside. Chain sprockets are welded to one of the ends.

A bicycle pedal is welded to one support shaft. By rotating it in one direction or another, you can force the pipe to move in the desired direction.

Having manufactured the clamping mechanism, the location of all elements is checked. They try to install them according to the drawing presented earlier.

Having installed the parts in place, they are welded. Now it’s time to check the functionality of the device.

Place the pipe and roll it in both directions. There is no pressure from above yet; we are checking how easily the pipe moves.

By turning the screw, press the pressure roller down and push the pipe. By moving the pressure roller, roll the pipe. After each pass, move the roller down. Periodically remove the part and compare it with the template.

Having manufactured the machine, you can begin to manufacture greenhouses and greenhouses, which are based on profile pipes. Below are examples and information on how to make such structures.

Video: homemade pipe bender for a profile pipe.

Arches for greenhouses and greenhouses

Different types greenhouses are used in the practice of gardeners

Greenhouse metal frame 3·4 m:

Most often, three-meter arcs are chosen. An entrance is created at the ends. Additionally, a window is installed that can be opened while leaving the door closed. Profile pipes of 20·20 and 25·25 mm are used.

Reinforced arc arched greenhouse:

IN winter period the load can reach over 200 kg/m². Therefore, a curved arc inside is welded to the outer contour. Additionally, radial connections are welded. Now a more rigid circuit is working that will withstand high loads.

Stationary greenhouse “Butterfly”:

Small designs greenhouses can be made stationary and portable. They are convenient because you don’t need to go inside to work with the plants being grown. It is enough to open the doors slightly to gain access. The greenhouses are called “Butterfly” because they open in both directions. From the end, the raised doors look like butterfly wings.

Greenhouse "Breadbox":

In the beds for spring and autumn periods portable greenhouses “Khlebnitsa” are installed. In this design, the door opens in a similar way to how this issue is resolved in bread bins. It rises up and moves along back wall. Such devices are in enviable demand among vegetable growers.

Greenhouse "Droplet":

The desire to reduce snow load and create a durable metal frame encourages designers to create drop-shaped greenhouses. The generatrices of the walls are built along complex curves. The top is pointed, the snow rolls down without stopping on the surface.

Joining semi-arches in the “Droplet” greenhouse:

Inside, the semi-arches are connected in the center of the frame. This solution facilitates the production and delivery of products to the gardener’s plot. All that remains is to make the halves and assemble them on site.

When constructing greenhouses, designers count on the length of rolled products, as well as polycarbonate rolls. Standard length profile pipes is 6 m. You can bend them different ways. But the condition remains that there should be a distance of 3 m between the ends of the pipes.

Drawing of a radial arch for a greenhouse made of 20·20 mm profile pipe. Doorway:

The most common design is made along a radius of 1500 mm ( outer profile). In it, a height of 2115 mm is reached in the center of the structure. Vertical sections are created on the sides of the generative arc; their length is 615 mm. Users will enter through a 780mm wide doorway. The opening height of 1830 mm is sufficient for the passage of people of average height.

Practice shows that such a greenhouse is in demand in most areas. There is enough space inside to accommodate beds and walkways.

Arch for a heifer 2800 mm wide:

Some people like to use a greenhouse that has a slightly smaller width (2800 mm). In it, the height in the central part is slightly higher, amounting to 2195 mm. Here the vertical sections along the edges have a height of 795 mm. The radius of the generating curve is 1400 mm ( outer size).

The large height (2085 mm) and width (800 mm) of the doorway attracts attention. Even tall users will be able to walk inside freely without bending over when entering.

For a greenhouse 6 m long you need:

• 7 arcs, they are placed at a distance of 1 m from each other;
• for the manufacture of end elements, 33.3 m is required;
• the longitudinal elements between the arcs will total 42 m;
• To manufacture a metal frame, 20 profile pipes (6 m) will be required. The calculation was performed for a 20·20 mm profile pipe with a wall thickness of 1.5 mm. total weight is 99 kg.

Arch for a greenhouse type “Pavilion”:

When manufacturing a “Pavilion” type structure, a reinforced arc is created. Distance between vertical supports will be 5400 mm. Profile pipes 40·60 mm (wall 2 mm) are used. Pipes of 40·40 mm are used as supports (you can also bigger size in the manufacture of carports).

Reinforcement is necessary so that such an arch can withstand a snow load in winter equal to 200...220 kg/m². They are placed at a distance of 1 m and covered cellular polycarbonate thickness 6...8 mm. For winter greenhouses use polycarbonate with a thickness of 10 mm.

Drawing of a small-sized greenhouse bread box:

Using a machine for rolling profile pipes, you can make for yourself and to order a wide variety of arcs for greenhouses and greenhouses.