Kolli

All you need for tube bending in a single application

Kolli is an automated feasibility analysis for tube bending and profile bending on CNC bending machines. It is the result of 30 years of continuous improvement and refinement. With Kolli 3R offers not only a computerized feasibility analysis with generation of CNC data, but also a design and import platform for tube geometries.

Kolli simulates the tube bending process of the given geometry on one or multiple bending machines. In case of interference or collision during the bending sequence the software independently searches for solutions. In addition the user can intervene manually at any time and adjust the bending process. The search for a suitable bending sequence is dependent on the machine type. The more complex the bending machine is (e.g. right / left bending machines with multiple heads and levels), the more options are taken into account for testing.

Kolli supports both simple mandrel bending machines as well as modern right- and left-bending machines with multiple bending heads and levels. In addition to standard mandrel bending with bending die Kolli also simulates roller and induction bending.

Key Numbers

Features

Tube Bending Simulation and Feasibilty Analysis
Independent from Machine Manufacturers
Quick Customization of new Machine Types
Collision Detection and Collision Avoidance Strategies
Support for multiple Bending Heads and Levels
Support for Mandrel and Roller Bending Machines
Generation of customizable Bending Reports
Generation of CNC Data and Transfer to the Machines
Manual Creation of Tube Geometries in Isometric View
Import of Tube Geometries from CAD Files (STEP, IGES and more)
Automatic Correction with Data from Measuring Systems
Support for Bending with End Preparations or Flanges
Support for Printing and Marking

Features

Tube Bending Simulation and Feasibilty Analysis
Independent from Machine Manufacturers
Quick Customization of new Machine Types
Collision Detection and Collision Avoidance Strategies
Support for multiple Bending Heads and Levels
Support for Mandrel and Roller Bending Machines
Generation of customizable Bending Reports
Generation of CNC Data and Transfer to the Machines
Manual Creation of Tube Geometries in Isometric View
Import of Tube Geometries from CAD Files (STEP, IGES and more)
Automatic Correction with Data from Measuring Systems
Support for Bending with End Preparations or Flanges
Support for Printing and Marking

Bending Simulation

If the bending simulation of a tube geometry results in a collision with the machine, the ground or obstacles in the environment, Kolli checks one or more of these strategies to avoid collisions:

Change of rotation direction
Addition of correction feed
Change of bending direction
Change of bending head
Change of bending level
Change of bending sequence at tool change or retraction of bending arm (depending on machine type)
Leg elongations

Import & Export Interfaces

A continuously growing number of interfaces enables the import and export of data. These interfaces allow the control of CNC bending machines as well as the import of tube geometries from third-party systems, like measuring systems or CAD platforms.

Important and common import formats are:

The import supports reading the full 3D CAD models through STEP and IGES files containing end preps, supports, etc. The user can select the entities of interest and Kolli automatically scans these for tubes to import.

Additional import and export formats can be added on request.

Generating CNC Data & Reporting

Kolli considers all relevant machine, tool, and material-specific parameters when generating CNC data. The CNC data is generated in the format suiting exactly to your individual bending machine. If possible the data can also be transferred to the machine.
Apart from machine data Kolli generates according bending reports containing the material and bending parameters. The appearance of the reports is highly customizable.

Machine and Tool Management

Your bending setup is highly customizable. With Machine Editor you can adjust the geometry and appearance of your machine as also model additional objects like walls, roofs, pillars or other obstacles. With Tool Editor you specify the tooling parameters to be used with the model of the bending machine in the simulation.

Material Management

The Material Manager administers the material-specific properties of the tubes, bars and profiles. Especially in unit production of tubes it is essential to achieve a precise bending result on first try. Using the Material Manager empirically derived material properties can be collected and recorded easily. The information serves the fitting accuracy of the pipelines to be bent and the generation of CNC data. It is used to calculate precise cutting lengths, considering the material’s springback, the reduction in traction lengths caused by overbending and the bend’s radius increase, as well as the material stretching inside the bend.

BATCH Testing of Multiple Products on multiple Machines

Kolli can automatically test a large number of tubes to bend on different machines and tool combinations. For every product Kolli automatically finds the right machine and tool based on feasibility and bending time or costs. The entire simulation of bending products can be evaluated statistically.

Bending with End Preparations or Flanges

Some bending machines are capable of bending pipes with flanges. Depending on the clamping device Kolli calculates the relative rotation of the flanges against each other (flange welding machine) as well as the rotation before the first bend in order to ensure the correct position of the first flange after bending has been completed.

Cycle Times

For each tube geometry Kolli determines a machine-dependent theoretical cycle time. This way the speed and efficiency of axis movement sequences or several machines and can be compared directly for optimizations in mass production.