Innovative Flight Forming Machines


What is the principle difference between previous technologies and Helix Flights new technology?

Our software and machines are a significant step change in the global sectional helix forming industry and produce a number of savings due to speed and quality, and reduce management issues due to improved safety, online diagnostics, and ease and speed of training.  Just to give an example if you currently operating an inefficient machine that takes around 6-10 minutes in forming an average size helix and it requires rework every time to make it fit to the shaft, on an average 8 hours shift you will be producing around 48 helices a day. In real situation you are only using 1/3 of your production capability. Instead you can produce 160 helices a day with our revolutionary technology.  Multiply that number by 360, we are talking about significant savings!

What is Blank Cut Design Manager software?

Blank Cut Design Manger (BCDM) is specifically designed software that allows users to design flight blanks of true shape. The software is very intuitive and takes very little time to learn how to use. The software is capable of designing round or square centre helicies, variable dia and thickness

What is a true form helix and why is it so important?

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
4.    Therefore - A true pitch helix shall have;
a)    Flange perpendicular to shaft and
b)    Uniform pitch angle


What is a sectional flight forming?

Sectional flights are individual 360 degree sections of helices or flights formed from flat plate. These individual sections are then welded together to form continuous flights for conveyors or augers or any machine with a screw flight requirement. The individual flights being of a true-form in order to give a constant pitch angle, accurate fit to the shaft, and flush joins.

What are the key drivers of performance for flight manufacturers?

Users of flight forming machines must control the following concerns while forming flights:


•    Dependency on a highly skill operator (artisan) and the consequent key person pay and issues with training delays.
•    Perfect prediction of blank cut to ensure first time perfect fit of resultant helix
•    True form of helix with perfect constant pitch, flush joins, and flange perpendicular to shaft to ensure inside edge parallel to shaft.
•    Elimination of rework for perfect fit up on to the shaft
•    Single weld specification for linear weld for each side of helix
•    High speed of production
•    Ease of handling in and out of machine
•    Speed of adjustment to take account of small or large variation in material strength characteristics to enable uniformity in out put
•    Robustness of machine and reliability
•    Ready support
•    Minimise running costs

Is this a world leading technology?

Yes, our innovative flight forming technology is a result of years and years of research and development. With the help of NZ government agency, Callaghen Innovation, and the hard work of our mathematicians, material and design experts we came up to a solution that allows companies to move away from the “Craftsman’s Black Art” of making helix flights.

Is Roll Form Technology or Sectional Flight Forming Technology Better?

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 customize 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.

Does the machine have a CE mark on it?

Yes, our machines are built up to the highest safety standards and embraced with CE mark.

Can this machine form helices straight from wear plate?

This depends on the specific machine and capacity. Helix Flight’s HF1 Medium Diameter Advanced Ultra Adjustable Sectional helix forming machine has limited wear plate capability. Helix Flight’s HF1 Medium Diameter Advanced Heavy Duty Ultra Adjustable Sectional helix forming machine has an extensive wear plate capability. There are many types of wear plate and we have yet to test all materials but as an example Hardox 450 is formable in these machine.  Further details on capacities will depend on ratios of thickness, pitch, actual grade, and bore to pitch ratio, and ID to OD ratio.

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