Deratech Tandem Press Brake Cell One-Pass Integral Forming of Ultra-Long Structural Components

In the manufacturing of large metal structural components such as lamp and tower poles for lighting and power transmission, the bending and forming of ultra-long shafts has long been constrained by equipment processing capacity. Limited by workpiece dimensions, traditional processes require sectional bending followed by splicing to complete the forming, which introduces issues including large forming angle deviations, insufficient straightness, and redundant process steps—adversely affecting both the structural strength of the components and production efficiency.

To address these industry pain points, Deratech has launched the 2-UBB-800/7000D electro-hydraulic hybrid tandem full-process bending forming cell, providing a systematic solution for high-precision processing of ultra-large-dimension, multi-pass bending operations.
The forming cell is built around two Deratech ULTIMA (UBB-D) series 800-ton electro-hydraulic hybrid CNC press brakes as its core units, complemented by high-precision servo front-and-rear positioning mechanisms. The complete machine is equipped with the Swiss CYBELEC CT15 Win CNC System, enabling tandem synchronized scheduling. An optional side-discharge conveying mechanism accommodates automated material output for long shafts. The system integrates multiple core technologies, including patented mechanical crowning compensation, dual servo pump-controlled electro-hydraulic hybrid drive, and linear encoder closed-loop synchronization. Core seals and electrical components are sourced from internationally leading brands such as Germany’s SKF and France’s Schneider Electric, ensuring long-term operational stability under heavy-load conditions, and efficiently enabling flexible bending of various ultra-long structural components including octagonal and polygonal profiles.
Tailored specifically to the forming characteristics of ultra-long shafts, the cell features dedicated optimizations: tandem linkage achieves millisecond-level synchronized control via bus communication, combined with real-time position feedback from linear encoders, delivering slider positioning accuracy of ±0.02 mm and a bending angle tolerance of ≤±45′ across the full 7-meter workpiece length, with straightness of 0.3 mm/1000 mm—enabling one-pass integral forming with zero splicing error. The front-and-rear dual-axis servo pushing mechanism precisely controls multi-pass bending step increments, adapted to continuous multi-cut bending sequences for octagonal shafts, with positioning repeatability of ≤±0.01 mm. The worktable adopts Deratech’s patented three-layer wedge-type crowning compensation mechanism, combined with a heavy-duty rigid frame subjected to high-temperature annealing, ensuring controllable deformation under high-tonnage bending and consistent angle and straightness throughout the entire shaft.

The equipment is powered by Deratech’s patented dual servo pump-controlled electro-hydraulic hybrid system, offering faster response than conventional proportional-valve machines while consuming only 50% of the energy of standard electro-hydraulic bending equipment. The CNC system supports automatic bending sequence calculation and 3D simulation, simplifying programming and commissioning for complex multi-sided shafts. The optional side-discharge conveying mechanism enables automated material output for long workpieces, reducing manual handling intensity and further elevating the overall automation level of the production line.

Upon implementation, this project enables one-pass integral bending forming of large-diameter ultra-long lamp and tower poles, eliminating the need for sectional splicing and secondary straightening processes, dramatically improving both the forming efficiency and structural strength of ultra-long components. The tandem/stand-alone dual-mode production configuration accommodates both ultra-long shafts and conventional sheet metal parts, significantly enhancing equipment flexibility and overall utilization, and consistently delivering high-efficiency, high-precision large-scale sheet metal forming value to customers.
The forming cell is now operating stably in actual production, capable of completing integral bending forming of large-diameter ultra-long lamp and tower poles in a single pass. By eliminating sectional splicing and secondary straightening steps, it significantly enhances the forming efficiency and structural strength of ultra-long components. The tandem/stand-alone dual-mode production system covers both ultra-long shafts and conventional sheet metal parts, markedly improving equipment flexibility and overall utilization, delivering lasting high-efficiency, high-precision large-scale sheet metal forming value to customers.
Ultra-long shafts no longer require section-by-section splicing—this is not only a leap in process technology, but also tangible, real-world gains for our customers. Deratch believes that good equipment lies in genuinely solving production challenges. Deratch will continue to deepen its expertise in sheet metal forming equipment, accompanying manufacturing enterprises every step of the way with more stable performance and finer control.