This is a retrofit from a little while ago. It is a massive Italian pipe bender from the '80s.
In principle, it is a simple machine in terms of kinematics, but the size is intimidating. It had dozens of powerful hydraulic actuators and sensors, most of which would destroy themselves if actuated in the wrong sequence.
Two axes were driven by servo motors. We had to keep the old analog servo drivers, which was a requirement. They have resolvers and translators to encoder-like signals in each driver.
The 'bender' axis is hydraulic and uses a proportional valve for control. It is massive, and it’s hard to describe the sheer force this machine has—quite scary.
The kinematics were implemented in G-code, and the final result consists of several O-codes and routines working with custom HAL components to make everything function. In the end, it was about a second slower than the original one.
I had the opportunity to work with a great company that handled everything else. I just had to do the CNC work. It was a three-week job, working an average of 10-12 hours a day. It was worth it. The machine is working flawlessly.
This piece below is one of the most complicated ones in terms of logic. To avoid collisions, the machine has to release the pipe, bend it, hold it once again, and then push it to the last bend. The operator only has to input the dimensions, and the code is able to figure out on its own if there will be a collision and choose a way to avoid it.
This is the typical speed the machine runs
