New: The STAUFF Form EVO Tube Forming System
Increased Level of Efficiency and Versatility as the Result of Continuous Optimisation
The STAUFF Form tube forming system was first presented in 2015. Since the beginning it has undoubtedly been one of the most efficient solutions available on the market for connecting metric tubes. In addition to its simplicity, it convinces with a high degree of safety, reliability and reproducibility.
With STAUFF Form EVO, STAUFF now presents the latest generation of the tube forming system, which is characterised by an increased level of efficiency and versatility as a result of continuous optimisation.
STAUFF Form EVO has been designed as standard for seamless cold-drawn precision steel tubes as well as stainless steel tubes with dimensions between 6 x 1.5 mm and 42 x 4 mm in the Light Series and between 6 x 1.5 mm and 38 x 6 mm in the Heavy Series.
If required, parameters for alternative materials are available upon request and can be added by the manufacturer or via the optional cloud connection module integrated in the machines.
Video of the STAUFF Form EVO Tube Forming System
Main Features of the STAUFF Form EVO Tube Forming System
System Design and Components
The system is based on standard parts and consists of only four key components:
The STAUFF Form EVO Sealing Ring is slid onto the tube end, which has previously been mechanically contoured. This creates a positive-locking connection that provides a reliable, permanent and maintenance-free seal when used with a conventional fitting body with 24° conical bore and a union nut, both according to ISO 8434-1.
Versatility and Flexibility
Users benefit from the great versatility and flexibility of the system, as well as the many combination and adaptation options offered by using standard components from the STAUFF Connect product range.
There is therefore no need to duplicate the stock-keeping of similar components with a correspondingly high likelihood of confusion, as is often the case with comparable systems. Material and logistics costs can thus be correspondingly reduced.
Materials and Surface Finishing
All components in the STAUFF Connect product range are designed as standard with a high-quality zinc/nickel surface coating.
With over 1,200 hours of resistance to red rust / base metal corrosion in the salt-spray chamber in accordance with DIN EN ISO 9227, the coating offers most reliable corrosion protection far beyond previously accepted market standards.
Even after shipping, handling and assembly of the components, the coating significantly exceeds the requirements for the highest corrosion protection class K5 defined in VDMA Standard Sheet 24576 for tube connectors.
The sealing of the only possible leakage path is provided primarily by the large-volume elastomeric sealing of the STAUFF Form EVO Sealing Ring
which is specifically positioned between the surface of the tube and the 24° conical bore of the fitting body during assembly.
FKM (Viton®) is used as the standard sealing material and enables problem-free use of the STAUFF Form EVO tube forming system for challenging applications involving high temperatures or aggressive media.
Thanks to the combined metal-elastomer sealing, the usage of the systeme in low-temperature ranges down to -35° C is possible without restriction – as is also the case with NBR (Buna-N®).
The unique sealing profile has a particularly large cross-section in order to sealsecurely and permanently, even in the event of unfavourable tolerances of the tube or the tube fitting. Possible errors during assembly on the formed tube end are consistently avoided by the laterally equal profile of the sealing ring. The sealing effect is supported by the system pressure of the hydraulic system, so that the STAUFF Form EVO tube forming system is perfectly suited for high-pressure applications.
Final Assembly in the Fitting Body
Final assembly is performed by tightening the union nut until the point with clearly noticeable increase in force (fixed point). The assembly is completed with another turn by approximately 15° to 20° beyond this point.
This incredibly simple assembly method has several benefits for the user:
- Considerably lower torques and short assembly paths (once the fixed point has been reached)
- Significant increase in torque to clearly indicate the end of the assembly
- Maximum safety to combat over-assembly
- No need for time-consuming and expensive training
Connections made with the STAUFF Form EVO can be untightened as often as required and reassembled without wear, as any damaging expansion of
the 24° conical bore of the fitting body is technically avoided.
When the STAUFF Form EVO tube forming system is used in conjunction with genuine products from the STAUFF Connect product range, it provides
pressure resistance of up to 800 bar in the Heavy Series and 500 bar in the Light Series (generally with a four-fold safety factor and depending on the series, design and size of the fitting body and taking into consideration various pressure reducing factors).
This is the result of exceptional care taken in the development of the system and the selection, handling and processing of the raw materials.
Maximum tear-out strength can be guaranteed for the system due to the contour shaped at the tube end.
Key Benefits of the STAUFF Form EVO Tube Forming System
Based on standard components including the standard union nut of the STAUFF Connect product range according to ISO 8434-1 – No duplicate storage
of similar stocking of similar components with a correspondingly high risk of confusion
Positive-locking connection with an elastomer sealing with a particularly large cross-section to provide secure and permanent sealing even in the event of unfavourable tolerances
Sealing of the only possible leakage path primarily via the STAUFF Form EVO sealing ring as well as the secondary, face sealing
Preservation of the flow behaviour through the optimised shape of the formed tube end
Assembly Tools and Devices
Robust table-top device for continuous operation in the workshop
High efficiency of the system with low cycle times
Optimum tool concept with exchangeable internal tube supports, so that only a small number of tools is required to cover all tube diameters
Intuitive operation via touchscreen
Optional cloud connection as well as machine briefings and trainings
All tools needed for the forming process clearly labelled with the tube dimensions so that assembly errors caused by incorrect assignment can be largely ruled out
Short times required for tool changes as clamping jaws, tube shaper and internal tube supports can be simply replaced without the need for any tools
Attractive maintenance packages to ensure best possible service
Low insertion depths compared to alternative systems for even more complex tube geometries and smaller bending radii
Durability and Application
Suitable for both steel and stainless steel tubing as standard – also applicable for alternative tube materials on request
Covers all common metric tube dimensions from 6 x 1.5 mm to 42 x 4 mm in the Light Series and 38 x 6 mm in the Heavy Series respectively
Suitable for nominal pressures up to 800 bar in the Heavy Series – designed with four-fold safety and maximum tear-out strength
The use of FKM (Viton®) as the standard seal material makes the system perfect for the most challenging applications. Thanks to the combined metal-elastomer seal, low-temperature ranges down to -35° C are possible without restriction
High-quality zinc/nickel surface coating provides maximum protection and corrosion resistance – standard for all parts in the STAUFF Connect range
Incredibly simple final assembly in the fitting body with low assembly torques as well as short assembly paths (once the fixed point has been reached) with a minimised risk of over-assembly
Assembly errors are consistently avoided due to the laterally identical profile of the sealing ring
Connections can be untightened as often as required and reassembled without wear, as any damaging expansion of the 24° conical bore of the fitting body is technically avoided
No need for time-consuming and expensive training