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Helix Flight Manufacturing Machines Ltd.
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Innovative Flight Forming Technology
Innovative Flight Forming Technology

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We are pleased to announce another successful placement of our HF1 Intermediate Diameter machine with one of the leading agriculture equipment manufacturers in USA. Bringing true form helices manufacture in house up to 2.4m diameter in 25mm plate enable significant savings on fit up and better control of stock and delivery times. However, this machine also enable R&D trialling option and ultra adjustability to make refinements with an objective less weld time and less weld materials but also ultimately product performance in the field.
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Trial on 50mm thick mild steel plate

We are pleased to announce that we have successfully completed a trial of 1778mm OD helix, 203mm ID, 900mm Pitch on 50mm thick plate. The helix quality is truly remarkable and true pitch form throughout the helix.
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Trial on 50mm thick mild steel plate

We are pleased to announce that we have successfully completed a trial of 1778mm OD helix, 203mm ID, 900mm Pitch on 50mm thick plate. The helix quality is truly remarkable and true pitch form throughout the helix.
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Blank Cut Design Manager; a result of years of dedication and research. Now calculate the blank cut for square center helices in seconds, one of the most common requirements of screw pile industry in the USA.
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In the heart of New Zealand, we build world's most advanced flight forming technology that allow companies to move away from the “Craftsman’s Black Art” of making Helix Flights to the very quick and flexible design and manufacture of highly accurate flights for many industrial uses.
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Which one is better Sectional flight forming or Roll forming?

Both technologies have their own benefits.
a) Roll Form Technology
For roll forming the material being formed needs to be very ductile and hence you are limited to what material can be used. Also you must limit the number of combinations between internal diameter (bore) and outer diameter, and thickness, and pitch. Otherwise you would encounter a problem of excessive stock of forming materials. This is because you need to buy in large volumes to gain economic supply which means limiting the number of combinations (Internal diameter, Outer Diameter, thickness, and pitch) is very important. As a result you can only provide clients with a very standardized and limited range of solutions which will only suit a small range of applications. But these items will be very efficient and costs will be low. It is also difficult to form products needing having requirements for legs notches or teeth using roll form technology.
b) Sectional Helix Forming Technology
The benefits of sectional helix forming technology are almost the opposite, there are issues in having great accuracy in forming to ensure perfect true helix from and perfect fit up onto shaft and flush joints. However all this is possible. The benefits are the range of options you can make for clients, which are almost unlimited, having total flexibility to change diameter, bore, thickness, pitch, or material grade to suit the client. This allows the client to customise the design of their product without limitation and be assured that you are able to form their requirements. Added to this is the flexibility to form complex helices with have changing (tapered) internal diameter to match a cone shaped shaft or with notches or legs or saw teeth for specific operations, or tapering outside diameter. Thus sectional helix forming technology can support a much wider range of clients and specific applications than roll forming technology.
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TRUE FORM HELICES
1. Accurate Fit to shaft for efficient handling - The helix flight should click into position on the specified shaft in an efficient tight manner and without any secondary process such as grinding or cutting
2. Uniformity for weld procedure - Critical to "robotic welding processes" and very important to manual operations is the consistency of;
(a)Pitch angle - If pitch angle is not a uniform linear spiral, welding will require a variety of tracking adjustments to follow the non linear spiral
(b) Helix flange perpendicular to shaft - a typical incorrect helix usually causes a variety of weld angles around the helix. This will affect both the positional requirements of the weld, and consistency of both throat and root of welding between helix and shaft
3. Helix internal edge parallel to shaft - the potential variability in the gap between the shaft and the edge of the inner helix edge. If not parallel, can result in a significant variation in the weld root and hence consistency and quality of weld
Therefore - A true pitch helix shall have;
Flange perpendicular to shaft and
Uniform pitch angle
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2015-09-14
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3rd Success in winning R&D grant
Success leads to success. The success of previous projects and revolutionary developments for the sectional helix forming industry, involving funding from the New Zealand Government Agency Callaghan Innovation has resulted in a 3rd win. Helix Flight have gained matched funding for a high capacity semi automation development for NZD $100,000 including software and machine prototype work.
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Helix Flight now on googleplus:###
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