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Engineering & Fabrication of a Tube Bending Fixture Machine for the Automotive Industry

Bracket Wrap Assembly Machine Photo 1
Bracket Wrap Assembly Machine Photo 2
Bracket Wrap Tooling
Hose Tube Bracket Assembly Tooling
Engineering & Development of a Bracket Wrap/Tube Hose Assembly Machine


Excel Machine & Tool, Inc. was recently contracted for the engineering and development of a custom bracket wrap/tube hose assembly machine. The system that this automotive customer required would have to combine two separate tube assemblies by wrapping brackets around the individual tube assemblies. This project is also another example of how we support our tube bending equipment customers with products that perform related operations.

The machine they required had to not only provide quick effective operation, but also deliver repeatability and tolerances of ±1.5mm. With these requirements we developed and engineered a system that met all of the customers’ requirements. Fabrication required extensive machining, including milling, drilling, turning, and grinding. Machine components consisted of a machine base that was made from 2" X 2" square tubing and 5/8" thick hot rolled steel plate. The guarding consisted of 16 gage sheet and expanded metal, framed in C-channel, and painted yellow and black. The tooling was composed of a combination of heat treated hot rolled steel, as well as A2 and S7 tool steel. All machining process are subject to stringent quality measure including dimensional and gage Inspections. Overall operation is verified through extensive functional testing.

Equipment such as this bracket wrap/tube hose assembly machine has applications beyond the automotive industries. Our capabilities can be applied to equipment for use in applications for the agricultural, appliance, aerospace, and medical Industries.

To learn more about this project, see the table below or contact us directly.

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Highlights of this Engineering & Development Project

Product NameBracket Wrap/Tube Hose Assembly Machine
Product DescriptionThe machine is used to combine 2 separate tube assemblies into 1 assembly by wrapping brackets around the separate tube assemblies ( see photo of finish assembly)
Engineering & Development Capabilities Applied/Processes
Primary:
Engineering/Design
Product Development
Fabrication
  • CNC Milling
  • Welding
  • Grinding
Secondary:
Priming
Painting
Assembly
Hardening
Equipment Used to Manufacture Machine
CNC Mill
Manual Mills
Manual Drills
Manual Grinders
Automatic Grinders
Manual Lathe
Hand Tools
Inspection Tools
  • Gage Pins
  • Gage Blocks
  • Height Gages
  • Micrometers
  • Dial Caliper
Overall Part Dimensions
 Overall Machine Size:
38 x 44
Tightest TolerancesBracket Location: ±1.5mm
Material Used
Machine Base 
  • Square Tubing 
    • Width: 2"
    • Height: 2"
    • Thickness: 3/16"
  • Square Tubing 
    • Width: 1-1/2"
    • Height: 1-1/2"
    • Thickness: 1/8"
  • Hot Rolled Steel Base Plate 
    • Thickness: 5/8"
 Guarding 
  • Sheet Metal: 16 GA
  • Panels
    • Thickness: 16 GA Expanded Metal framed with C-Channel
Tooling: made from a combination of material 
  • Hot rolled steel
  • 1018 steel
  • A2 Tool steel
  • S7 Tool Steel
  • All tooling subject to wear is heat treated for longevity
Material FinishMachine Base: Primed and Painted
Guarding: Painted Yellow & Black
In process testing/inspection performedDimensional Inspection, Gage Inspection, Functionality Testing
Industry for Use
Automotive Industry
Appliance Industry
Agricultural Industry
Aerospace Industry
Medical Industry
Volume1
Delivery/T`urnaround Time7 weeks
Delivery LocationVersailles, Kentucky
Standards MetCustomer Specifications, CAD Drawing

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