Semi-Automatic Pipe Roll Bender Design

I need a complete mechanical and control design package for a semi-automatic roll-type bender that can curve copper, carbon-steel and stainless-steel alloy tubing up to 40–50 mm OD.

The machine will sit on a workshop floor, fed by straight stock and guided by an operator, while the drive, pinch/load settings and repeat passes are handled through a modest control panel or small PLC/HMI. I will build the prototype here, so every part must be ready for fabrication or off-the-shelf purchase.

Please supply:
• 3D CAD model (SolidWorks or Inventor) with fully defined assemblies, weldments and sheet-metal parts
• 2D manufacturing drawings and GD&T for the frames, rolls, shafts, bearing blocks and any guards
• Motor/gearbox and power-transmission calculations showing how we reach the required bending force for the 50 mm stainless tube worst case
• Control architecture: wiring diagram, PLC I/O list, panel layout and concise ladder/structured-text sample for speed, direction and pass counting
• Bill of materials with supplier part numbers and cut-lengths for plate and profiles
• FEA or hand-calcs that validate frame deflection under maximum load; an ANSYS or equivalent file is fine

If there’s a smarter way to meet the spec—alternate roll shapes, different drive arrangement, or hybrid manual features—let me know; I’m open to solutions as long as the semi-automatic core stays intact.