Those who invest in occupational safety do not merely cultivate their image towards their own employees. The reputation among customers also increases. Larger companies in particular are including factors such as sustainability and occupational safety in their purchasing decisions. "That is one of the reasons why we are constantly developing our products, also from a safety point of view," confirms Klaus Pfeifer, technical manager at Alfra. For the customer, however, there are also tangible financial benefits. According to a study by the Justus Liebig University in Gießen, every Euro invested in occupational safety brings a "Return of Prevention" (ROP) of 1.60 Euros. This figure, which was determined for Germany with regard to the costs and benefits of corresponding measures, becomes even more vivid when it is seen against the background of the damage caused by an occupational accident. Even in the case of a comparatively less serious event, such as a sprained ligament as a result of a fall, the employer incurs costs of around 4,500 Euros for a sick leave of 2 weeks, which must be compensated by higher turnover. Everyone can work out the economic consequences in the case of possibly permanent health impairments, for example due to cuts.

"This is precisely why our S 125 busbar cutter, for example, now has an effective hand protection. On the right and left side of the device, there is a Plexiglas partition shielding the blade in the cutting area," explains Pfeifer. The user can no longer reach into the area and is protected from injury. The special safety foot switch is serving the same purpose. On the one hand, this enables convenient operation by foot, and on the other hand, the switch mechanism is stopping the machine immediately in an emergency situation. "Experience shows that employees at the machine tend to depress the foot switch down completely in reflex, rather than pulling their foot out of the switch to interrupt the process. That is why this design is particularly reasonable," he emphasizes.

Millimetre work saves time and effort

The Hockenheim tool manufacturer is just as conscientious in keeping an eye on the processes in the everyday work of its target group. In order for busbars to fit perfectly into the control cabinet, the control cabinet builder has to cut them exactly to size and bend them at the right angle. Precise perforations ensure that individual modules can be screwed to the rail and several busbars can be connected to each other.

"Our products are designed to save the users time and effort," says the technical manager. The hydraulically operated S 125 conductor rail cutter e.g, is cutting rails measuring 125 x 12 millimetres to length precisely, centrically and without waste – thanks to the hold-down clamp and practical guide device, there is no play that could affect the cutting result. The heart of the machine is the resharpenable and replaceable upper blade. It convinces with a cutting time between 5 and 15 seconds, depending on the bar width and the hydraulic unit used.

The Alfra busbar bending device makes bending electrical conductors effortless – thanks to the bending die with movable jaws and electric angle reader. "Bending angles of up to 90 degrees are possible," says Klaus Pfeiffer, technical manager at Alfra. "We recommend setting 1 to 3 degrees beyond the desired degree, depending on the material thickness, as copper springs back," he adds. With the available oblong and round punch with die, the user is working with pinpoint accuracy.

Here, too, new features ensure that risks of damage to people or machines are minimized: The hydraulic hose and electrical control cable for the BS 120 busbar bending and punching unit, are now contained in a sturdy protective hose. This fixture not only serves to prevent damage, but also ensures clean cable routing.

Busbar machining on wheels

The 4-station processing trolley from Alfra offers a total of four workstations in busbar processing. This is because, in addition to the bending, punching and cutting functions, it has two additional hydraulic outlets for various applications – for example, to connect an additional cylinder or a tool for hexagonal pressing. Another advantage: because the tools are integrated in the trolley, they are at the same working height, which is comfortable and ergonomic for the user. Contact-protection and hold-down devices make it easier for control cabinet builders to process busbars precisely and safely at the mobile and compact station – as does an emergency stop switch on both sides of the trolley. In addition, the manufacturers have improved the entire structure of the hydraulics.

The 4-station trolley is also equipped with a foot switch with emergency stop function, which stops the pump driving the machine when it is fully pressed down.

Conclusion: Alfra equipment offers busbar processing functions for every requirement – for smooth and safe processes in control cabinet construction.

Special devices for particular challenges

The company with three production sites in Germany, has been manufacturing hydraulic punches since the end of the 1970s. Alfra later expanded the range by adding suitable solution applications. The use of stationary hole punchers makes particular sense when the number of knock-outs or the thickness of the material pose special challenges for control cabinet builders. "If cables have to be routed through the openings, Harting plugs have to be inserted, or an opening for a filter has to be created – the models from the ALFRA PRESS line improve the production processes during punching with a bundle of features," says ALFRA’s technical manager Klaus Pfeifer. Most importantly, they are punching square, rectangular and round openings not only in control cabinet doors and housings, but also in mounting plates, terminal boxes, cable ducts or cable routing plates. The three variants AP 600, AP 400 and AP 250 are suitable for processing switch cabinets or switch cabinet doors with a throat depth up to 600 mm, 400 mm, or 250 mm. Depending on the model, the punches can be used on sheet steel with a thickness between 2.5 mm and 3.0 mm. Stainless steel can be processed up to a thickness of 2.0 mm. In addition, the machines from the AP line are punching plastic up to a thickness of 4.0 mm.

Saving work steps

The clock is ticking for all activities related to control cabinet construction. In addition to speed, precision is required. With all three models, concentrated punching power is at play. This means, that the sheet metal punches used with the AP 250 and AP 400, are hitting the material with 46 kN punching force, the AP 600 is even coming up with 60 kN. ALFRA electro-hydraulic pumps act as drive units for the variants with 250 mm and 400 mm throat depth. An inexpensive "entry-level solution" would be to operate the machine by means of a manual foot pump. A built-in hydraulic unit provides power for the AP 600. The result: The fast punching process alone contributes a great deal to the accelerated sequences, because they take only seconds – just like the swift tool change. Alternatively, panel builders use jigsaws to create the necessary openings. However, this does not only cost valuable minutes, it also produces chips and sharp edges. Further work steps, such as deburring and chip removal, are necessary because the paint on the enclosure is damaged and cables can chafe. There is also the risk of a short circuit due to metal chips in the assembled control cabinet. In contrast to punching processes with manual punching devices, there is no need for pre-drilling with the models of the AP line. The user is achieving a burr-free punching in just a few steps.

Accurate to the millimetre, even at the edges

A company with the goal of producing products close to the needs of control cabinet builders, must immerse deeply into their working world. The machines from the ALFRA PRESS series therefore have various details drafted for the requirements of the industry. One example: thanks to different die supports, users can also punch in areas, which are situated very close to edges. A laser pointer is indicating the centre of the tool. Punching or scribing, to position the tool exactly, is no longer necessary. Instead, a simple marking with a pen is sufficient.

"The swiveling and height-adjustable support arms, which are standard equipment for all our AP punchers, are also practical," says Pfeifer. When using e.g the AP 250 and AP 400, this design makes it possible to put on control cabinet doors, side parts or flange plates in order to process them. Thanks to the attachable folding stops, control cabinet builders can fix the attached parts and punch them in line.

Constant advancement

Each unit in the AP series has functions, that are individually tailored to to the everyday work of control cabinet builders. The AP 600 is punching doors, panels or side panels of all common enclosure types, provided they do not exceed the 600 mm throat depth of the unit. An alternating quick clamping system is creating the conditions for the bending to face either upwards or downwards, and the die bed holder is ensuring that a tool change can be carried out even when the enclosure door is clamped. "In addition, the AP 600 is the perfect punch for large openings, such as those required for the use of fans and filters," explains the technical manager. The AP 250 and AP 400, on the other hand, can be used to process small and medium-sized enclosures as a whole. "So that we can keep up with the demands of our customers, we are constantly developing the devices further," he says. One example is the power bank for operating the laser pointer. This makes the AP 250 and AP 400 more compact and mobile because the cable for the power supply no longer takes up space. All three punches are now available in the "clean look" in elegant white. "This means that the look of the devices emphasises their high quality even more clearly," says Pfeifer.

At three German locations, Alfra is producing equipment that is also showing its full potential in maritime working environments, e.g. application solutions in the field of magnetic technology. Independent of power supply, these products do not only lift reliably, but also accelerate welding processes. Alfra Rotabest metal core drilling machines with magnetic bases ensure safe drilling in any position.

Load lifting and levelling with just one magnet

When it comes to building, maintaining or repairing ships, welders and metalworkers often have to meet high standards under difficult conditions. The average time spent in a shipyard is two weeks. Time is money. For this reason, every day of it is a challenge for the craftsmen in the dock. One of the tasks: Lightning-fast welding seams, which require as little reworking as possible and withstand stringent quality tests such as ultrasound or X-ray tests.

"From this point of view, the versatility of our lifting magnets is particularly advantageous in shipbuilding," says Alfra product manager Christian Schulz. "When we think of a lifting magnet in shipyard operations, we first think of lifting flat steel, pipes or T-beams. But our permanent magnets are also excellent for use as levelling aids when welding plates and sheets," he emphasizes. These models include, for example, TML 100, TML 200, TML 250 and TML 1000. The numbers stand for the maximum load capacity in kilograms with an additional safety factor of 3:1. Thanks to the rotating load swivel, workers at the shipyard can move ship parts effortlessly and with pinpoint accuracy, for example with an overhead crane or forklift. The special plus point: if two sheets or plates of ferromagnetic metal have to be brought to the same height level and fixed before welding, the compact lightweights also do a great job. "The magnets are placed over the edges. With a single-handed operation, the craftsman activates the magnetic forces and fixes the plates at the same height in a few seconds. Conventional methods, such as a welded-on eyelet through which a wedge is driven, on the other hand, take up to 20 minutes," he notes.

Magnetic holding force from only two millimeters

Different material thicknesses are another issue in the daily operations in the dock. While four millimeter thick sheets are processed on the main deck, material thicknesses of up to 50 millimeters are not uncommon for particularly stressed structures, such as the machine foundation. This is where the patented technology of the Alfra magnets from the TML (Thin Material Lifting) series comes into play. "The magnetic field is concentrated directly on the metal, which is why there is significantly less stray loss," explains Schulz. In detailed terms this means, that depending on the model, the magnets from this line already develop considerable magnetic holding forces from a material thickness of only two millimeters.

New in the product range of the tool manufacturer headquartered in Hockenheim, is the smallest magnet in the line, measuring 5x5x 2.5cm. Like all models from the product group, the TMC 70 enables welding processes very close to the magnet – because the arc that is created is only deflected when a distance of up to 15 millimeters to the tool is not reached. In addition, it is suitable for fixing guiding aids for straight welding seams on ferromagnetic materials, for example an aid for welding at an angle, or for fixing filigree metal parts that would alternatively have to be fixed with clamps.

Centered and safe at any angle

The patented technology is also a significant aspect for Alfra Rotabest magnetic core drilling machines. The permanent magnet in the base is not only ensuring smooth drilling processes due to its stable hold, but is also scoring points when it comes to "occupational safety". In shipbuilding, craftsmen often have to show their skills in working areas that are difficult to access, such as on steep metal walls or in narrow angles. With the Alfra drilling devices from the SP line, the machine adheres to the material independently of power supply. This advantage is virtually eliminating "crashes" – even when drilling "overhead". "These machines are used in demanding projects all over the world. At the moment, for example, in metal works on the Sidney Harbour Bridge," says the product manager.

A flexible partner for battery- or cable-operated drilling machines on a shipyard is the SP-V magnetic drill stand, which weighs only 6.8 kg. Its variable brackets and the Euro collar are offering a wide range of combination possibilities with different drilling machine neck diameters – for centered horizontal or vertical drilling.

Conclusion: Accelerated processes in the construction and refit of ships are gaining in importance. Well thought-out application solutions make a decisive contribution to making work in shipyards faster and safer.

Expert Verdict

Since the end of the 70s, Alfra has been manufacturing and developing high quality tools in Hockenheim. The Standard: „Made in Germany“. „The assembly here at the site is an important reason why our customers are trusting in us“, says Product Manager Ingo Kroiss. In any case, tools for cabinet engineering have a long tradition in the company. Last year their percentage of the total turnover was more than 40 %. That’s why the specialists have every reason to be proud of their products – although a positive valuation by an expert, like the test report in the magazine “Motor&Maschine”, is highly appreciated.

On the trial: the cable duct cutting device-VKS 125, being referred as „top class”. Included in the evaluation have been the categories “function“, „operation“ and „equipment“, whereby the user-friendliness of the cutting device had been most prominent. Ever since cable ducts have replaced fabric tape, it belongs to the daily routine of cabinet manufacturers, to cut fitting sections of the usual 2-meter-part. The option to a cutting device is a circular saw. But this would require to deburr the cut edges after sawing, because the cables in the cabinet might chafe otherwise. Burr-free cuts, without plastic splinters and annoying noise are few of the many advantages of the VKS 125. „Fundamental for the conception of our Alfra products is a close connection to our user’s workflow“, emphasizes Kroiss. „ It’s one of our most important concerns, to make our customers work routine easier“, he amends.

Proaktive thinking makes a difference

The result of this consideration is a sum of extras, improving the workflow of cutting and saving the time of cabinet manufacturers. For example the point of positioning: stabile fixing tabs, attached to the device and at the length stop, make sure that the user is able to install the VKS 125 easily on the work bench. „The full-surface supporting table prevents the deflecting of the cable duct, which ensures a precise crosscut“, Kroiss confirms. Furthermore the laser-engraved length stop with metric and inch-division is helping the craftsman to work accurately.

The heart of the unit is a sprung cutter made of hardened tool steel, cutting cable ducts and lids up to a width of 125 mm easily. With the fixed blade 90° angle-precise cutting is no problem. It’s significant that the grinding of the knife is concentrated on all available cable ducts. „This also applies for non-halogen cable ducts, which are used in places with special safety requirements, like public buildings and computer centers,” says Kroiss. The used plastics do not generate dangerous gases in the case of a fire. On the other hand, these materials are a real challenge for cutting devices because of their exceptional hardness. When the cutter is not being used, a sprung cutter protector is covering the blade to protect the user’s fingers. The enlarged opening height in the construction provides some additional scope for further applications. „That’s why the VKS 125 is suitable for ducting with special webs“, he amends.

Conclusion: Cabinet manufacturers, who have to cut cable ducts regularly, need to rely on their device. The VKS 125 is practically maintenance-free – a dependable assistant in the daily work-routine, who’s going to be indispensable in no time.

Drei für alle Fälle

Mit Schneidgeräten für den Schaltschrank- und Steuerungsbau fertigt die Alfra- GmbH am Standort Hockenheim Produkte, die von Profis für Profis entwickelt wurden. Der Grund für den Erfolg der Geräte: sie sind „Made in Germany“ und exakt auf die Bedürfnisse von Schaltschrankbauern ausgerichtet. „Unser Programm bietet für jedes Budget und jede Anforderung das richtige Profilschienenschneidgerät“, sagt Produktmanager Ingo Kroiss. „Wer hauptsächlich die gängigsten Tragschienentypen mit den Maßen 35mm/7,5 und 35mm/15 bearbeitet, ist mit dem PSG DUO® gut bedient“, erläutert er. Weitere Möglichkeiten stehen Anwendern zur Verfügung, die ein PSG 4® oder ein PSG 5+®nutzen. Neben den beiden gängigen Hutschienenvarianten bearbeitet das PSG 4® auch Tragschienen mit den Maßen 15 mm/5,5 und Kupfer-Erdungsschienen mit 10 X 3 Millimetern. Über das größte Leistungsspektrum verfügt das PSG 5+®. Dieses Hochleistungsgerät schneidet nicht nur zusätzlich C- Profile, G-Profile und Erdungsschienen aus Kupfer – es stanzt auch Löcher in die Tragschienen.

Jeder Arbeitsschritt bedacht

Ihre große Stärke sehen die Experten mit jahrzehntelanger Erfahrung in ihrer Nähe zu den Anwendern. „Wir kennen die Herausforderungen jedes Arbeitsschritts im Schaltschrankbau“, sagt der Produktmanager. Die Führungsschienen für die einzelnen Profile sind ein Beispiel für diese Überlegungen. Der Steuerungsbauer führt die Schiene bis zum Anschlag ein, weshalb diese durch die doppelte Führung nicht mehr verrutschen kann. Das Ergebnis: gratfreie, exakte 90 Grad-Schnitte wegen des extrem geringen Schnittspiels. Ausschlaggebend ist hierbei unter anderem die Scherplatte im Schneidgerät. Von oben

wirken die Scherkräfte gegen die durch die Frontplatte fixierte Schiene und trennen auf diese Weise sauber das gewünschte Teilstück ab. Eine Klinge wäre wegen der Festigkeit und Dicke der Schienen nicht für diese Aufgabe geeignet. Neben der einwandfreien Funktion der Geräte steht bei Alfra auch immer der Komfort des Anwenders im Blickpunkt. Ein verstärkter Exzenter direkt über der Scherplatte führt zu einer spürbar besseren Kraftübertragung. „Das ist in dieser Produktgruppe einzigartig“, bestätigt Kroiss. Zusammen mit dem softtouch-verstärkten Handgriff sorgt der Exzenter dafür, dass Schaltschrankbauer nahezu alle Halteschienen mühelos schneiden. Die lasergravierte Skalierung in Metrischen- und Zollangaben ermöglicht zudem die winkelgenaue Bearbeitung der Schienen. Möglichst lange Standzeiten gehören zum Anspruch der Werkzeug-Spezialisten aus Hockenheim. Deshalb kann der Kunde, sofern dies wirtschaftlich Sinn ergibt, die Scherplatten an den Geräten der PSG-Familie nachschleifen zu lassen. Ein Wechsel des Lochstempels ist ebenfalls möglich. Den Slogan „Passion for Tools“ nimmt das Unternehmen sehr ernst. Das heißt, wenn ein Schaltschrankbauer ein Anforderungsprofil benötigt, das die Geräte aus dem laufenden Programm nicht erfüllen, kümmert sich das Alfra-Team, wann immer dies möglich ist, auch um Sonderanfertigungen – zum Beispiel im Falle eines Spezialprofils.

Fest steht: Für Profis im Schaltschrank und Steuerungsbau, die täglich Halteschienen zuschneiden, sind die Geräte aus der PSG Serie eine wertvolle Unterstützung.

Fachmännisches Urteil

In der Rennstadt Hockenheim produziert und entwickelt Alfra seit Ende der 70er Jahre Qualitätswerkzeuge „Made in Germany“. „Die Montage hier bei uns am Standort ist ein wichtiger Grund für das Vertrauen der Anwender“, so Produktmanager Ingo Kroiss. Dabei nehmen Produkte für die Bearbeitung von Schaltschränken traditionell eine wichtige Position ein. Der Anteil am Alfra-Gesamtumsatz lag im vergangenen Jahr bei rund 40 Prozent. Obwohl die Spezialisten allen Grund haben, von der Qualität ihrer Entwicklungen überzeugt zu sein, ist eine positive Bewertung durch einen Fachmann höchstwillkommen – so geschehen im Testbericht in der Zeitschrift „Motor & Maschine“ im Frühjahr 2019. Auf dem Prüfstand fand sich das Verdrahtungskanalschneidgerät VKS 125, das mit einer Bewertung von 1,3 als „Spitzenklasse“ bezeichnet wird. In diese Benotung flossen die Kategorien „Funktion“, „Bedienung“ und „Ausstattung“ ein, wobei vor allem die Präzision und Bedienerfreundlichkeit des Schneidgeräts überzeugten. Seitdem Verdrahtungskanäle das früher übliche Gewebeband zum Bündeln zusammengehöriger Kabelstränge abgelöst haben, gehört es zum Arbeitsalltag von Schaltschrankbauern, passgenaue Teile vom handelsüblichen 2-Meter-Stück abzutrennen. Wer hierzu eine Kreissäge benutzt, muss die Schnittkanten anschließend entgraten, weil die Kabel im Schrank sonst aufscheuern könnten. Gratfreie Schnitte ohne die mit dem Sägen verbundenen Kunststoffspäne und Geräuschemissionen gehören zu den zahlreichen Vorteilen des VKS 125. „Die Basis für die Konzeption unserer Alfra-Produkte ist grundsätzlich eine enge Verbindung zur Arbeitswelt der Anwender“, betont Kroiss. Deshalb gehört es zu unseren wichtigsten Anliegen, den Kunden das Leben bei jedem Arbeitsschritt leichter zu machen“, ergänzt er.

Mitdenken ist Programm

Das Ergebnis dieser Überlegungen ist eine Summe von Extras, die den Prozess des Zuschnitts reibungslos verlaufen lassen und dem Schaltschrankbauer Zeit sparen. Dies kommt bereits bei der Positionierung zum Tragen: Stabile Befestigungswinkel am Gerät und am Längenanschlag schaffen die Voraussetzungen dafür, dass der Anwender das VKS 125 sicher und unkompliziert auf der Werkbank montieren kann. „Der vollflächige Auflagetisch verhindert, dass sich der Verdrahtungskanal durchbiegt. Somit ist ein präzises Ablängen möglich“, bestätigt Kroiss. Darüber hinaus hilft das lasergravierte Lineal mit metrischer- und Inch-Teilung dem Handwerker dabei, millimetergenau zu arbeiten.

Das Herzstück des Geräts ist ein Messer aus gehärtetem Werkzeugstahl, das Verdrahtungskanäle und Deckel mit einer Breite bis zu 125 Millimeter mühelos schneidet. Weil die Klinge fest steht, sind Schnitte genau im 90 Grad Winkel kein Problem. Entscheidend ist, dass der Schliff des Messers speziell auf alle am Markt gängigen Verdrahtungskanäle ausgerichtet ist. „Das gilt auch für halogenfreie Kanäle, die an Orten mit besonderen Sicherheitsanforderungen wie in Rechenzentren oder in öffentlichen Gebäuden eingesetzt werden“ so Kroiss. Die hierfür verwendeten Kunststoffe entwickeln bei Bränden keine gefährlichen Gase, sind jedoch wegen der besonderen Festigkeit des Materials eine Herausforderung für Schneidgeräte. Ist das Werkzeug nicht in Gebrauch, verdeckt ein federnder Messerschutz die Klingen und sorgt dafür, dass die Finger der Anwender unversehrt bleiben. Zusätzlichen Spielraum schafft die vergrößerte Öffnungshöhe der Konstruktion. „Damit ist das VKS 125 beispielsweise auch für Kanäle mit Sondersteg geeignet“, fügt er hinzu.

Wer im Schaltschrankbau täglich Verdrahtungskanäle zuschneidet, muss sich auf sein Gerät verlassen können. Das VKS ist praktisch wartungsfrei – ein zuverlässiger Helfer im Arbeitsalltag, der bald unverzichtbar wird.

The Alfra lifting magnet TML 1000 is strong and flexible at the same time

What do a compact car, a giraffe and 20 meters of railway track have in common? They are all heavy weights, because each of them is weighing about a ton. Metalworkers on construction sites, in shipyards or in industrial companies have to face the challenge to lift similar heavy metal sheets and panels every day. But there’s good news: If these loads are magnetic, the task is manageable. The Alfra lifting magnet TML 1000 is transporting flat materials up to 1000 kg securely from A to B. And due to the fact that the high performance magnet is a member of the TML-family, there are further skills…

Compact and one-handed operable

The measurements of the TML 1000 are self-evident: With a length of 470 millimeters (with locked lever), a width of 154 millimeters and a height of 338 millimeters (with open lever), the magnet is applicable for a wide range of scenarios – due to the low tare weight of only 18 kilogram along with a load bearing capacity up to 1000 kilogram. That makes a difference of nearly 70 percent, compared to conventional magnets with an assimilable performance.

Thereby Alfra is guaranteeing a 3:1 safety margin – which means, the actual tearing force is about 3,8 tons. „Our customers workflow is a very important aspect, when we’re developing new products”, so product manager Christian Schulz. That’s why the magnet is one-handed operable. „By this means, you can transport an H-beam without turning it over before”, he’s explaining. The reason: the lever is fixed in a way to the magnet, which allows the user to activate the tool right between the flanges of the H-beam – an advantage when it comes to protect the coating against scratches, too. Because of the ergonomic design of the lever it can be flipped effortlessly to unfold the full power of the TML 1000.

„Thin Material Lifting“ makes a difference

The load-bearing-capacity up to 1000 kilogram is qualifying the magnet as a suitable tool for a large variety of applications, for example to lift loads in a 90 degree angle. Actually the TML 1000 is showing its true strength, when things are getting more filigree. The magnet is moving thin-walled materials starting from a thickness of only 2 millimeters. „This unique selling feature matters for the metal working sector, such as control cabinet engineering“, says Schulz.

Customers, who are investing in a high-end-product like the TML 1000, make a point of a long service life of their tool. Guaranteed is this, amongst other topics, because of the resistant magnet surface made of hardened steel. The main principle: Titanium- and Nitrogene-atoms are combining to a PVD coating, making the surface extremely sturdy.

The material properties and the biochemical functions are not changed by the process. For the customer this means concretely: the surface is less phrone for scratches. The user is saving effort and time, because the magnet surface doesn’t have to be reground, to secure the performance of the magnet in the long term.

Flexible power pack

As a solution for heavy loads, the TML 1000 is not only a powerful tool – furthermore it is very flexible. Due to the pivotable and 360° rotable load swifel, even bulky components can be transported and dropped exactly. For example, if the magnet is applied along with a crane: This means, because of the rotably mounted load swifel, the user can fix the load with the rope and place it strictly framed.

Another typical application is the levelling of steel sheets. For this purpose the metal worker is usually using a U-bar, which has to be welded on the sheet. By means of a hammer, the user is driving a wedge through the U-bar, until the sheets are leveled at exactly the same height. After this process, the U-bar has to be removed again. A magnet is getting the job done quicker and easier, because there’s only one step necessary to attain the requested result. The user benefits from the highly time-effective alternative.

A special application-profile is requiring a special measure. That’s why customers are sometimes individualizing the TML 1000 for a certain task. „Very often this is about leveling metal parts“, remarks Christian Schulz. These modifications are possible, because there’s an option to screw the magnet with other constructions.

Conclusion: The TML 1000 is a reliable and versatile helper for users who have to move heavy metal sheets and – parts in their business every day. It’s transporting and adjusting loads up to 1000 kilograms – showing an excellent performance from a material thickness of 2 millimeters.

Kompakt und einhändig bedienbar

Schon die Maße des Hochleistungsmagneten sprechen für sich: Mit einer Länge von 470 Millimeter bei geschlossenem Hebel, einer Breite von 154 Millimetern und einer Höhe von 338 Millimetern bei offenem Hebel, ist der TML 1000 in den verschiedensten Situationen unkompliziert anwendbar. Dafür sorgt auch sein relativ geringes Eigengewicht von nur 18 Kilogramm bei einer Tragekraft von bis zu 1000 Kilogramm. Das sind bis zu 70 Prozent weniger als bei konventionellen Magneten mit vergleichbarer Leistung. Dabei garantiert Alfra einen Sicherheitsfaktor von 3:1 – das heißt, die eigentliche Abrisskraft des Magneten liegt bei 3,8 Tonnen. „Bei der Entwicklung unserer Produkte behalten wir immer die Arbeitsabläufe unserer Kunden im Blick“, so Produktmanager Christian Schulz. Deshalb ist der Magnet auch einhändig bedienbar. „Auf diese Weise lassen sich beispielsweise T-Träger ohne vorheriges Umdrehen transportieren. Denn der Hebel am TML 1000 ist so am Magneten angebracht, dass es auch möglich ist, das Gerät innerhalb des T-Trägers zu aktivieren“, erklärt er weiter. Ein weiterer Vorteil: Bei dieser Art des Transports vermeidet der Anwender, dass die Beschichtung am Stahlträger beschädigt wird. Dabei aktiviert der Metallarbeiter den Magnet ausgesprochen komfortabel, denn dank des ergonomisch geformten Hebels ist nur ein minimaler Kraftaufwand nötig, damit der TML seine volle Haftkraft entfaltet.

„Thin Material Lifting“ für dünnwandige Materialien

Die Tragkraft von bis zu 1000 Kilogramm qualifiziert den TML 1000 als Hilfsmittel mit Potenzial für die verschiedensten Anwendungssituationen. Zum Beispiel beim Heben von Lasten im 90 Grad Winkel. Seine wahre Stärke zeigt der TML 1000 jedoch, wenn es filigran wird. Tatsächlich bewegt der Magnet dünnwandige Materialien schon ab einer Stärke von nur 2 Millimetern. „Dieses Alleinstellungsmerkmal ist für metallverarbeitende Branchen, wie beispielsweise im Schaltschrankbau, von Bedeutung“, sagt Christian Schulz.

Wer in ein High-End-Produkt, wie den TML 1000 investiert, legt Wert auf eine lange Lebensdauer des Werkzeugs. Gewährleistet wird dies unter anderem durch die widerstandsfähige Magnetfläche aus gehärtetem Stahl mit TiN-Beschichtung. Das Prinzip: Titan- und Stickstoffatome verbinden sich zu einer PVD Beschichtung, die die Oberfläche extrem widerstandsfähig macht. Materialeigenschaften und biochemische Funktionalität werden durch den Prozess nicht verändert. Für den Kunden bedeutet das: Die Oberfläche ist weniger anfällig für Zerkratzen. Der Anwender spart Aufwand und Arbeitszeit, weil er die Magnethaftfläche nicht nachschleifen lassen muss, um die Leistung des Magneten auf lange Sicht zu gewährleisten

Bewegliches Kraftpaket

Als Lösung für die schweren Fälle ist der TML 1000 nicht nur leistungsstark, sondern auch ausgesprochen flexibel. Der schwenkbare und um 360° drehbare Lastwirbel sorgt dafür, dass selbst sperrige Teile passgenau transportiert und abgelegt werden können. Beispielsweise wenn der Magnet in Verbindung mit einem Kran eingesetzt wird. Die Last am Seil ist durch die drehende Lagerung des Lastwirbels beweglich und kann an einer genau vorgegebenen Stelle platziert werden.

Ein weiteres typisches Anwendungsbeispiel findet sich beim Nivellieren von Stahlplatten. Zu diesem Zweck verwenden die Metallarbeiter gewöhnlich eine Öse, die auf die Platte aufgeschweißt wird. Mittels eines Keils, den der Anwender mit einem Hammer solange durch die Öse treibt, bis die Platten auf exakt gleicher Höhe justiert sind, komplettiert er die Nivellierung. Anschließend muss er die Öse wieder entfernen. Ein Magnet meistert diese Aufgabe schneller und einfacher – schon, weil nur ein Arbeitsschritt nötig ist, um zum gewünschten Ergebnis zu kommen. Der Anwender profitiert von der zeitökonomisch sinnvolleren Variante.

Besondere Anforderungsprofile erfordern besondere Maßnahmen. Deshalb kommt es immer wieder vor, dass Kunden den TML 1000 für eine bestimmte Aufgabe individualisieren. „Oft geht es dabei darum, Metallteile auszurichten. Möglich wird eine Modifizierung des Magneten beispielsweise durch die Option, andere Konstruktionen mit diesem zu verschrauben“, so Christian Schulz.

Fazit: Der TML 1000 ist ein ebenso zuverlässiger wie vielseitiger Helfer für alle, die im beruflichen Alltag schwere Metalplatten und -Bleche bewegen müssen. Er transportiert und justiert Lasten mit einem Gewicht bis zu 1000 Kilogramm – dabei zeigt er schon bei Materialien ab einer Dicke von 2 Millimetern hervorragende Leistungseigenschaften.

The new TML 250 and TML 500 lifting magnets from Hockenheim-based tool manufacturer Alfra redefine the standards in lifting technology: they are already suitable for use on thin-walled materials from a thickness of 2 millimetres, such as are usual for example in façade and container construction but also generally common in many welding applications. The TML 250 model exerts its full lifting force of 250 kilograms from a material thickness of 9 millimetres and provides a lifting force of around 100 kilograms even from material that is 3 millimetres thick. The TML 500 provides its full power from a thickness of 10 millimetres. Even from materials 5 millimetres thick, it delivers an impressive 250-kilogram lifting force. With respect to safety, both models fulfil the legal requirements: the force required to pull off the magnet is 3 times the lifting force of the respective model.

Alfra took a completely new approach in the development of the permanent magnets: “We have developed a type of magnet that forms its magnetic field optimally. With it, we avoid scatter losses and focus the force field in the desired direction. This pays off positively in nearly all applications. As a result, we achieve considerable magnetic forces even with small mass application,” Alfra director Markus Döring states. In the past, permanent magnets have frequently been large, heavy, or awkward. “Our enthusiastic users rate our new magnets as handy, sporty and even trendy,” Markus Döring reports.

Magnets for the harshest applications

In addition to above-average performance values compared with conventional lifting magnets as well as high operating safety, the TML series also stand out for their compact dimensions and light weight. As such, the casings of the TML 250 and TML 500 are made entirely of aluminium.

With a deadweight of 3.7 kilograms in the case of TML 250 and 6.5 kilograms in the case of the TML 500, both models are more than 50 percent lighter than a conventional magnet with the same performance. Because of its TiN coating, the magnetic holding surface is also permanently durable and able to withstand even the harshest applications. The surfaces are optimally protected, which makes dirt or adherent metal shavings easy to remove.

Huge range of applications

The light, ergonomic handling and the new operating concept further improve the performance of the TML series. The ergonomic activation of the magnets has been redesigned with a handy strap positioned on the side, close to the body of the magnet – unlike conventional systems in which the magnet is activated by a side lever that projects at a 90-degree angle. With the new operating concept, the lifting magnets in the TML series can also be positioned between the flanges of a steel beam with no problem. Even the recoil problem of the activation lever, which occurs in systems that are standard for the market particularly when they are used on thinner material, is almost entirely eliminated with the TML 250 and the TML 500. “Our TML magnets open up new application areas to our customers. The performance density and almost unlimited range of uses are unique in the industry,” Markus Döring explains.

…Holding as if by magic

A further highlight of both magnet systems: Being pre-stressed, they can be fitted easily onto a workpiece or steel plate with one hand, even when working overhead, vertically or at an angle. Pre-stressing ensures that the lifting magnet holds its own weight. Once attached, it can then be positioned exactly and activated with the strap. The anchor point, which can swivel through 360 degrees, automatically follows the optimal line of force and is able to withstand strain under full load in any position, ensures smooth load lifting here.

Transporting steel sheets with no grippers

With the flexible positioning and optimal magnetic material penetration, sheet steel for example can be transported without the use of grippers. “Such an application is almost impossible with conventional magnet systems. Furthermore, undesirable claw prints on the material can be avoided completely with our TML magnets. Anyone who ever holds and uses a TML will never want to part with it,” Markus Döring is confident.