Rolling Controls

Tools that set the standard

Outstanding performance, incredible durability, and ease of maintenance have made Airetool tube rolling controls the standard against which all other manufacturers are measured.

Torque Controlled Rolling Motors from Airetool

Torque Controlled Rolling Motors

Airetool rolling motors control expansion by the accurate measurement of torque. They automatically stop expanding according to a predetermined setting. Torque control prevents over- and underexpansion of tubes, assures uniformly tightened tube joints, and provides maximum holding strength for individual tubes. All Airetrols include torque sensing cams designed and manufactured specifically for tube expanding applications.

DAS II Dominator Tube Rolling Systems from Airetool

DAS II Dominator Tube Rolling Systems

The Airetool DAS II Dominator Tube Rolling System was designed to take pneumatic tube rolling technology to the next level using time proven Airetrol rolling motors outfitted with on-board pneumatic control logic.

Electronic Controllers and Electric Rolling Motors from Airetool

Electronic Controllers and Electric Rolling Motors

The ATC-900 Electronic Controller is a compact, lightweight and durable microprocessor based electronic motor controller. It is designed to provide accurate torque control for Airetool electric rolling motors by monitoring the amperage that the tool is using and comparing it to a preset current limit value. When the preset current limit value is reached, the controller opens the circuit which stops the motor. The current limit value is adjusted using the up/down push-buttons on the front of the controller to increment or decrement the current limit set point.

The TEC 7000 series electronic controller is for use with hand-held rolling motors and trolley type units (with telescopic shaft).

The TEC 8000VS series electronic controller is for use with trolley type units (with telescopic shaft).

Multi-Spindle Rolling Controls from Airetool

Multi-Spindle Rolling Controls

Airetool multi-spindle rolling controls utilize a microprocessor controlled expanding cycle with programmable expansion parameters including torque, speed, and time. This ensures a very accurate, uniform, and repeatable process. Expansion modules are available for single or multiple spindles (up to 16) with fixed or adjustable pitch designs.

Rolling Controls Accessories from Airetool

Rolling Controls Accessories

Use the P-15 analyzer to set a specific torque value on Airetrol rolling controls. The torque analyzers’ readings may be used as a standard for the Airetrols performance providing greater quality control over rolled tube joints.

Airetool rolling control accessories also include adapters for the P-15 analyzer and optional chucks.


Why use torque control when expanding tubes?

Torque controlled tube rolling increases productivity by achieving the desired tube wall reduction each and every time a tube is expanded. Torque-controlled tube rolling compensates for variations in the tube wall thickness and the tube sheet hole dimensions.

What is tube wall reduction?

Tube wall reduction is the percent the tube wall is reduced after the tube OD has contacted the tube sheet ID. The amount of tube wall reduction varies with the tube material, the tube sheet material and the design requirements of the unit. Several factors including pullout strength, tube and tube wall thickness, tube sheet material and thickness, and operating pressure are considered in determining the optimum wall reduction.

Tube Rolling Set-Up Guide

Tube Rolling Set-Up Guide

Pick five tubes in the vessel to be rolled and complete the work sheet below. It is important that the measurements used in the set-up are actual. Never use averaged dimensions.

Always Use Engineering Design Specifications for Tube Wall Reduction Percentage
Satisfactory joints are produced using the above listed percentage of tube wall reduction.

  • Step A – Measure tube sheet hole
  • Step B – Measure tube OD
  • Step C – Calculate clearance (A-B)
  • Step D – Measure tube ID
  • Step E – Calculate 2x wall thickness (B-D)
  • Step F – Calculate 5% wall reduction* (.05 x E)
  • Step G – Calculate finished rolled ID (C+D+F)

After the work sheet is finished, start setting up the torque control motor by test rolling the first of the five tubes. The first test roll must be done with the Airetrol or Electric tube rolling motor set for low torque to avoid over rolling.

Measure the tube ID after rolling the first tube. If more expansion is needed, increase the torque setting on the control and roll the second tube. Check the finished ID. This step may require repeating on tube three, but by the fifth tube you should have achieved your desired finished rolled ID of step G below. The tubes rolled to calibrate the tube wall reduction can now be re-rolled at the correct setting.

Drag your finger across the table to scroll

Joint Number
STEP EXAMPLE 1 2 3 4 5
A Tube Sheet Hole  .760"    
B - Tube OD  .750"    
C = Clearance  .010"    
D Tube ID  .620"    
E 2 x Wall Thickness  .130"    
F +5% Wall Reduction*  .006"    
G = Finish Rolled ID  .636"    

* Example only