Tube Expanders and all tooling for Heat Exchangers, Boilers, Condensers and oil Coolers.

Electric Tube Rolling / Expansion Systems.

Advantages of a Wattage Based Torque Controller.


TCW-09-PC Torque Controller
TCW-09 Torque Controller
Drill down on either Torque Controller above for full Specifications:
Either 120v or 240v / 60Hz or 50 Hz
Electronic Drives for use with Torque Controllers
 Drivers for rolling tubes come in 4 sizes and depending on the tube size  and material determines which driver is required. Each driver will be recognized by the torque controller and automatically adjusts the maximum torque output. See below for driver size required.
Electric Drives for use with Torque Controllers
Supply Voltage
Single Phase
50/60 Hz		 Drive Model Speed
I / II		 No
Load
R.P.M.		 Expansion Range Drive Weight Kgs.
Steel Tube O.D. Copper Tube O.D.
inch mm inch mm
230 V MPB - 0N I 2200 1/4” - 3/8” 6 - 10 1/4” - 1/2” 6 - 12 2
MPB - 1N I 1000 3/8” - 5/8” 10 - 16 3/8” - 3/4” 13 - 20 2.5
II 1900 5/16” - 3/8” 8 - 13 5/16” - 1/2” 8 - 13
MPG - 2N I 480 5/8”-1.3/4” 16 - 45 5/8” - 2” 16 - 50 7.5
II 1080 5/8”-1.1/4” 16 - 32 5/8”-1.1/2” 16 - 38
MPG - 3N I 130 1” - 3” 25 - 76 1” - 4” 25 - 102 8.5
II 430 1” - 2” 25 - 50 1” - 3” 25 - 76
110 V MPB - 0L I 2200 1/4” - 3/8” 6 - 10 1/4” - 1/2” 6 - 12 2
MPB - 1L I 1000 3/8” - 5/8” 10 - 16 3/8” - 3/4” 13 - 20 2.5
II 1900 5/16” - 3/8” 8 - 13 5/16” - 1/2” 8 - 13
MPG - 2L I 480 5/8”-1.3/4” 16 - 45 5/8” - 2” 16 - 50 7.5
II 1080 5/8”-1.1/4” 16 - 32 5/8”-1.1/2” 16 - 38
MPG - 3L I 130 1” - 3” 25 - 76 1” - 4” 25 - 102 8.5
II 430 1” - 2” 25 - 50 1” - 3” 25 - 76
Comparison between a Wattage based system and a voltage based system.
  1. Tube expansion can best be done by expanding tubes at a set torque value. Torque is nothing but a rotary force acting on the tubes. For a given drive, the 'RPM' being constant, torque becomes proportional to the drive power.

    Hence, if the drive power is controlled for tube expansion, the results will be excellent. All tubes will be expanded equally. Supply voltage fluctuations which are very common, do not affect the performance of a wattage based controller as the controller will trip at a set wattage irrespective of the supply voltage.

  2. In case of a voltage based tube expansion torque controller, the drive current can become proportional to the torque if & only if the supply voltage is absolutely constant. This is never the case. Practically, the supply voltages vary as much as 10% to 55%. This directly affects the expansion results as the drive trips at a set current. That means for a 10% higher supply voltage, the tubes will be effectively expanded by 10% more torque than the required one. Hence tubes will be over-expanded. For supply voltages less than normal, tubes will be under expanded proportionately.

    Since, the supply voltages fluctuate quite often, the expansion results of current based controllers will be unpredictable. They will have no consistency.

    It is our experience that a seasoned operator will more consistently expand tubes with just a drive than if he is to use a current based Torque Controller. Of course if he were to use a Wattage based torque controller, he would achieve near perfect tube expansions all the time.

  3. With a TCW Torque Controller coupled to an MPG-2L Driver, we carried out extensive tests on 3/4" OD Copper/Nickel 70/30 tubes and found we could consistently roll tubes to have an internal tolerance of
    (+0.0001+/-0.00001"). This was in a 1.25" tube sheet with tube sheet holes reamed to 0.758" to TEMA Spec.
Rolling Tubes with the MPG Series Driver and TCW Torque Controller.

 

 

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