Unison Ltd, the UK’s foremost manufacturer of tube bending technology, marks three decades since it revolutionized tube manipulation by launching the world’s first all-electric tube bending machine in 1994. This groundbreaking innovation has significantly influenced precision industries worldwide.
In the late 1980s, Terry Pickering, founder of Unison, and his son Alan, now the company’s joint managing director, embarked on a mission to improve the precision of tube bending. Dissatisfied with the inconsistencies of hydraulically operated machines, they aimed to develop a more accurate method.
“The accuracy of hydraulic tube bending machines was often compromised by fluctuating oil temperatures,” explained Terry Pickering. “The viscosity of cold oil differed from that of hot oil, necessitating manual adjustments throughout the day to maintain consistency.”
Unison sought to eliminate the need for these manual adjustments by capturing the correct machine axis settings through CNC technology, ensuring repeatable and precise results. They recognized the importance of controlling not just the position but also the force of each axis to achieve this goal.
In 1991, a Brite Euram feasibility study into automatic setup tube bending paved the way for Unison to secure a SMART award in 1992. This enabled them to develop three all-electric tube bending machines. “We were already on the path to creating the world’s first all-electric tube bender,” Pickering added.
The main challenge lay in developing mechanisms for axes other than the bend arm. Through rigorous R&D, Unison leveraged servo actuators and low-friction-slide adjusting mechanisms powered by electric motors with torque control to achieve precise pressure control. This innovation led to the creation of the first all-electric tube bending machine, which offered unparalleled accuracy and repeatability without the issues associated with hydraulic systems.
Named the Unison Breeze for its efficiency and ease of use, the world’s first all-electric three-axis tube bending machine debuted in 1994. UK and German patents were secured, establishing a new standard in tube bending technology.
Over the years, Unison expanded its product line, introducing the world’s first all-electric five-stack tube bending machine, as well as multi-stack machines and specialized benders for various industrial applications. Today, Unison operates facilities in the UK and the USA, offering a comprehensive range of ultra-precise, all-electric tube and pipe bending machines for diameters from 4 mm to 275 mm.
Unison has also introduced high-accuracy hybrid machines for straightforward, repetitive applications. Reflecting on the journey, Terry Pickering acknowledged initial resistance to the new technology. “It took visionary customers to adopt our technology before others followed suit,” he said. A significant breakthrough came when Airbus purchased their first all-electric tube bender, which paid for itself in reduced scrap within 16 weeks.
As all-electric tube bending became mainstream, Unison faced competition but remained focused on innovation and quality. “Today, our machines are the preferred choice across diverse industries, including aerospace, automotive, marine, oil & gas, energy, and general manufacturing,” Pickering stated.
Unison’s commitment to build quality, exceptional customer support, user-friendly control systems, and advanced simulation software ensures they maintain their competitive edge. “Thirty years after the first Unison Breeze machine, we continue to lead the industry,” Pickering concluded. “We are the original and the best.”