Pipe Clincher Evolution: From Gen 2 to Gen 3
At Cylform Automation Design, we’re constantly refining our systems to improve reliability, safety, and throughput for our clients. One of the best examples of this continuous improvement is the evolution of our Pipe Clincher system. Over multiple generations, we’ve redesigned core assemblies, simplified mechanisms, and boosted performance while reducing maintenance demands.
Improved Changeover and Accessibility
In Gen 2, the mandrel and punch assembly operated within a confined space, making changeover and tooling access more demanding. With Gen 3, we moved key tooling operations into a more open area. This reduces setup time, improves technician access, and creates a more predictable workflow for both adjustments and routine service.
Enhanced Safety
Earlier generations required heavy mandrels to be lifted and manipulated in tight quarters, often needing specialized handling. Gen 3 addresses this by fully supporting the mandrel assembly in an open, accessible orientation. This redesign minimizes risk during changeover and inspection and aligns with our focus on operator-safe automation.
Higher Throughput with Lower Stress on Components
The Gen 2 system delivered a 9-second cycle time, but only when operating at 100% axis speeds. With Gen 3, we achieved an 8-second cycle while running at just 90% axis speeds. This not only increases throughput but also extends axis life, reduces vibration, and ensures more consistent performance over long production runs.
A major contributor to this efficiency improvement is the redesigned hydraulic system. Gen 2 required a pump with an accumulator to meet the high-flow demand of a longer press stroke. In Gen 3, a streamlined design and a 300% shorter press stroke allow us to operate with a pump-only approach—reducing complexity, parts count, and long-term maintenance.
Better PM Access and Visual Inspection
Preventive maintenance was more challenging in Gen 2 due to the limited access around the mandrel and punch assembly. Gen 3 solves this with a punch tooling eject position that fully exposes forming buttons and punch surfaces. Operators can now visually inspect and maintain critical tooling without disassembly, significantly reducing downtime.
System Simplification and Smarter Layout
Gen 2 relied on additional devices in the crimp area to prebend the pipe’s inside edge. Gen 3 removes this complexity by integrating a robust gathering roll directly onto the punch carriage, improving repeatability and reducing tuning requirements.
We also optimized the machine footprint and overall layout. Gen 3 reduces total width by 25 inches, making it easier to fit into tighter production lines. Additionally, the hydraulic pump has been moved away from the press, improving access for maintenance and keeping the working area more open and ergonomic.