Chain Bending Machines
for Cold Bending Round Steel Chains

SeriesKER x.2

Series
KER x.2

T Feed and straightening unit
with feed control

Our Accomplishments for your Benefit
The new generation of chain manufacturing machines
benefits from decades of experience in mechanical machines in order to meet the requirements of high-strength
chain materials.
J The WAFIOS control system supports the operator by
an easy correction of chain dimensions, its programs
facilitate the repeat set-up of a chain and increases themachine's productivity.
J The newly developed chain bending machine KER 4.2
combines conventional chain production with modern
servo technology which makes it an important milestone
in chain production.
J The software-supported machine monitoring system
supports the operator in case of errors, synchronizes thebending and welding machine and reduces rejects.
J Due to the use of servo technology and the roll bending
technology of the KER x.2, expensive chain-dependent
tools, such as cam segments, as well as their changeover,are no longer required. This reduces set-up times and allows chains to be produced cost-efficiently without oilingand in a surface-friendly manner.
JT Die forming device andnotching device

T The chain link blank transport passes
the chain link to the bending station

Design Features
Modern servodrive and control technology
15 Servomotors for different machine functions
J Designed for higher tensile strengths of modern chain materials
J Wire feed, die forming, notching and bending are no longer
set up mechanically but electronically
J Bending technique with continuous-path control, the contouring path can be varied
J New control technology allows an electronic programming of
the bending process
J Most set-up parameters are electronically saved
J Cam segments and cam must not be held available andchangedJJ

S KER 4.2
W Embossing module (option):
The embossing module is used to make a raised or recessed mark on the wire.
This happens before the die forming process of the chain link's back curvatureand before the notching process.
2 WAFIOS Precision Machinery for Wire and Tube

Quality, Reliability, and Efficiency WAFIOS KER x.2 Chain Bending Machines

Mode of Operation
The chain wire drawn off the pay-off unit is straightened on
two levels by the straightening unit. It is then passed to the die
forming device and to the notching device that can both bedisplaced in wire direction. The die forming device produces
a wave-shaped dent in the wire which later becomes the bent
chain link's back curvature. The notching device cuts X-shaped
notches at a distance of one chain link blank length between
each notch into both sides of the wire. These notches will laterbe the chain link ends.
Next, the chain wire is transported to the cutting device where
it is held by the transport gripper while it is being cut off inaccordance with the chain link blank length. Then the transport gripper passes the cut-off chain link blank to the bending
station. There, the chain link blank is inserted into a previously
produced, vertically standing chain link that is held by the tilting
tongs. In the bending station, the chain link is finish-bent arounda bending mandrel by two swivel-mounted bending levers
with rollers. With this bending method, wire surface damage isavoided.

b)

c)

d)

e)

f)

g) h)

g)

a)
i)
j)

S Tool design for the KER x.2 roller bending method
New: Cam segment and chain link blank stop are not required anymore.

a) Chain materiale) Counter cutting toolh) Tilting tongsb) Diesf) Transport gripperi) Bending mandrelc) Notching toolg) Bending levers withbending rollersj) Cam segmentd) Cutting bushing

Application
Chain bending machines of the KER x.2 series are used to cold
bend round steel chains. The material is fed in from a wire coil.
The bent chain can then immediately be electrically welded on aseparate machine.
T Control panel with WPS 3.2 EasyWay

Quality
For more than 125 years, the name of WAFIOS has been synonymous with highest quality, safety standards, and technicalinnovations in the German machine manufacturing industry.
Reliability
Strict quality controls, state-of-the-art production systems, andmany years of experience guarantee that your investment is safein our hands. Our global service network ensures high availabilityof WAFIOS machinery.
Cost efficiency
High production output and a long service life will save money
and shorten the amortization time of your investment.
WAFIOS Series KER x.2 Chain Bending Machines 3

Technical Data

KER 4.2KER 5.2

KER 7.2

Nominal wire Ø:
Adm. tolerances in accordancewith DIN EN 818-2
up to 800 N/mm²
up to 900 N/mm²
up to 1,000 N/mm²

5.0 – 10.0 mm
5.0 – 9.0 mm

8.0 – 13.0 mm
8.0 – 12.0 mm

10.0 – 18.0 mm
10.0 – 17.0 mm
10.0 – 16.0 mm

14.5 – 53.0 mm
min. 2.9 x d
17.0–38.0 mm

23.0 – 75.0 mm
min. 2.9 x d
22.0–52.0 mm

29.0 – 95.0 mm
min. 2.9 x d
33.0–75.0 mm

Chain link blank length:max. 155 mm

max. 210 mm

max. 250 mm

Output:abt. 75 – 50 links/min

abt. 60 –  38 links/min

abt. 50 –  25 links/min

Compressed air consumption:(Sl/min at 6 bar)

100 Sl/min

not yet specified

not yet specified

ca. 3,945 ×
2,677 × 2,400 mm

not yet specified

not yet specified

not yet specified

not yet specified

Bent chain link:
Pitch / inside length of chain link
Outer chain link widthSpace required:(l × w × h)

Net weight:
Feed unit body without embossing module
Bending unit body
Switch cabinet

abt. 1,400 kg
abt. 3,500 kg
abt. 650 kg

Our product range includes a wide variety of high-quality
chain machines.
J Chain bending machines, KEB x.1 and KEB x.2 series
J Chain bending machines, KER x.2 and KER 8 series
J KBA 601 chain bending machine with conduction (WED 601)
heating or with induction (IEW 601) heating of chain link blanks
J Chain bending machine KBF 60
with induction heating (IEW 60) of chain link blanks
J Chain (resistance butt) welding machines,
KEH x.2 and KEH 8 series
J Chain (flash butt) welding machines,
KSH and KSF 60 series
J Chain calibrating machines, KPH series

WAFIOS AG
Silberburgstraße 572764 Reutlingen, Germany
Phone +49 7121 146-0
Fax+49 7121 146-250
sales@wafios.de
www.wafios.com
Precision Machinery for Wire and Tube
Pictures may differ from agreed scope of delivery – Subject to technical changes - © WAFIOS AG 2022
4532 en. - C06/22