Innovation Redefining Electro-Upsetting

Building on decades of experience in the development of advanced manufacturing technologies, CEMSA International Srl presents its new single-station electro-upsetting machine, specifically engineered for the high-precision production of special tubular bars for automotive suspension systems.

Leveraging CEMSA’s extensive expertise in resistance welding and electrothermal forming processes, the new machine combines high productivity, energy efficiency and outstanding process reliability, addressing the growing demands of the automotive industry for quality, sustainability and manufacturing efficiency.

Advanced Technology for Enhanced Performance

The machine features an innovative power system combining a three-phase inverter with a high-power single-phase transformer, designed for continuous operation at a 100% duty cycle.

This configuration delivers significant benefits:

• up to 40% lower energy consumption compared with conventional SCR-controlled AC systems;
• highly accurate and repeatable control of the heating process;
• consistent and reliable component quality;
• improved machine availability and reduced operating costs.

Optimized Production Process

In the single-station configuration, the tubular bar is heated inside a closed forming die, positioned between the conducting electrodes and the anvil.

The machine has been engineered to provide simple operation, high process repeatability and maximum operator safety. A single operator can load and unload the tubular bars safely, with access to the working area protected by safety light curtains.

The two ends of the tubular bar are processed sequentially, accurately forming the required internal and external upset sections.

Following the electro-upsetting operation, a final mechanical forming step completes the component geometry, eliminating the need for additional machining operations and streamlining the overall manufacturing process.

The machine is also designed to accommodate future integration with robotic automation systems, providing customers with a flexible production platform ready to evolve towards smart manufacturing and Industry 4.0 applications.

Technical Specifications

• Rated power: 160 kVA (100% duty cycle)
• Power supply: 400 V (other voltages available upon request)
• Frequency: 50/60 Hz
• Maximum upsetting force: 10,000 daN
• Maximum clamping force: 20,000 daN
• Clamping jaw stroke: 500 mm
• Anvil stroke: 250 mm
• Maximum bar length: 2,000 mm
• Cooling water flow rate: 180 l/min

Technology Engineered for the Future

Development is already underway on a two-station electro-upsetting machine, designed to process both ends of the tubular bar simultaneously.

This next-generation configuration will deliver a substantial increase in throughput, shorter cycle times and further improvements in overall process efficiency.

It represents the next step in CEMSA’s ongoing commitment to continuous innovation, advanced manufacturing technology and engineering excellence.