The FCL series automatic pipe coiling and strapping line provides in-line coiling, length metering, cutting, and radial strapping for small-bore flexible thermoplastic pipes including PE, PEX, PE-RT, PA, and PU tubing (OD 4 mm to 63 mm). Engineered to interface directly with continuous extrusion haul-offs, the system stabilizes line tension, eliminates manual reel changes, and delivers compacted, tied coils ready for storage or direct carton packaging.
Principio de funcionamiento
The FCL packaging line integrates four synchronized electromechanical modules on a heavy-duty welded steel chassis: a pneumatic dancer tension control unit, a servo-driven precision length metering counter, a vertical cantilevered expanding reel coiler, and an automatic through-core strapping mechanism.
Extruder / Haul-off ──> Dancer Accumulator ──> Metering Rollers ──> Traverse Guide ──> Expanding Reel Coiler ──> Radial Strapping Unit ──> Tilting Discharge Cradle- Tension Regulated Intake: Flexible tubing exits the extrusion cooling bath and haul-off unit, entering the vertical dancer accumulator. The pneumatic float arm modulates back-tension (typically between 15 N and 85 N depending on tube wall thickness) to prevent tube ovalization or stretching.
- Servo Traversing and Coiling: An optical encoder on dual ground-urethane metering wheels tracks linear footage with an accuracy of ±0.2%. The tubing enters the traverse distributor, which matches its lateral pitch (
Pitch = Tube OD + Clearance) to the expanding reel’s rotational speed governed by the line PLC. - In-Line Cut and Clamp: Once the preset batch length is registered, the line clamping jaw grips the tube, an orbital pneumatic shear performs a clean, square cut without swarf, and the tail is retained against the outer coil wrap.
- Through-Core Strapping: The radial strapping head feeds polypropylene (PP) or polyester (PET) strap through dedicated gaps between the expanded core segments, applying 2, 3, or 4 radial ties with heat-welded or friction joints.
- Core Collapse and Coil Ejection: The reel segments collapse radially via a central pneumatic linkage. The front retaining arm swings open, allowing a hydraulic or pneumatic tilting cradle to lower the finished coil onto an exit gravity roller table.
All core operating parameters—pipe diameter, target length, strap count, core ID expansion, and line speed matching—are governed via an industrial HMI touchscreen recipe system (Siemens S7-1200/1500 controller via Profinet).
Características principales
- Vertical Space-Saving Architecture: Edge-oriented vertical coiling minimizes footprint while utilizing gravity to stabilize coil alignment during the strapping cycle.
- Precision Dual-Wheel Metering: Non-slip urethane counter wheels with high-resolution incremental encoders guarantee consistent batch lengths, preventing product giveaways or short-length claims.
- Pneumatically Expanding Coiling Core: Radial multi-segment mandrel expands and collapses pneumatically, maintaining cylindrical geometry during winding and rapid collapse for clean coil stripping.
- Integrated High-Speed Strapping Mechanism: Applies tension-controlled radial straps through the coil eye; eliminates operator intervention in high-pinch hazard areas.
- Extrusion Line Interlock Synchronization: Closed-loop 0–10 V or fieldbus communication dynamically tracks extruder haul-off acceleration and deceleration, preventing loop sagging or pipe necking.
- Gentle Surface Handling: Guide rollers, traverse eyelets, and contact surfaces are lined with engineering plastics (UHMW-PE or POM) to prevent scratching on glossy, coated, or barrier-layer pipes.
Especificaciones
| Modelo | Rango de diámetro exterior del tubo | Rango de identificación de bobina | Diámetro exterior máximo de la bobina | Ancho máximo de la bobina | Velocidad máxima de línea |
|---|---|---|---|---|---|
| FCL100 | 4 – 12 mm | 150 – 250 mm | 350 mm | 150 mm | Hasta 120 m/min |
| FCL200 | 8 – 28 mm | 200 – 400 mm | 650 mm | 200 mm | Hasta 80 m/min |
| FCL600 | 8 – 28 mm | 380 – 600 mm | 1,050 mm | 300 mm | Hasta 50 m/min |
| FCL800 | 12 – 32 mm | 490 – 860 mm | 1,200 mm | 350 mm | Hasta 40 m/min |
| FCL1000 | 20 – 63 mm | 600 – 1,300 mm | 1,600 mm | 400 mm | Hasta 25 m/min |
Note: Dimensions and maximum line speeds represent baseline configurations. Custom mandrel expansion strokes and heavy-wall traverse mechanisms can be engineered for rigid or larger-bore materials.
Cálculo de ingeniería
1. Coil Geometry and Layer Turn Modeling
Accurate coil diameter estimation requires calculating the center-line neutral axis diameter of each concentric layer to avoid cumulative length errors.
Dado:
- Diámetro exterior de la tubería:
d(mm) - Mandrel expanded core inner diameter:
ID(mm) - Traverse usable spool width:
W_coil(mm) - Required target length:
L_total(metro)
Turns per single layer (n):
n = floor(W_coil / d)
Center-line winding diameter of layer k (D_center,k):
D_center,k = ID + (2k - 1) × d
Linear length wound on layer k (L_k):
L_k = n × π × (D_center,k / 1,000) [meters]
Cumulative length after k capas (S_k):
S_k = Σ (from i = 1 to k) L_i
Calculate sequentially until S_k ≥ L_total. The final coil outer diameter (Coil OD) is governed by the total completed layer count k_max:
Coil OD = ID + 2 × k_max × d
2. Ejemplo de cálculo práctico
Escenario: Coiling a 200 m pack of 20 mm OD PEX barrier pipe on an FCL600 estación.
- Tubo OD
d= 20 mm - Set core
ID= 600 mm - Usable coil width
W_coil= 300 mm
Step 1: Turns per layer
n = floor(300 / 20) = 15 turns/layer
Step 2: Layer-by-layer progressive accumulation
- Capa 1 (
k = 1):D_center,1 = 600 + (2 × 1 - 1) × 20 = 620 mmL_1 = 15 × π × 0.620 m = 29.22 mCumulative = 29.22 m - Capa 2 (
k = 2):D_center,2 = 600 + (2 × 2 - 1) × 20 = 660 mmL_2 = 15 × π × 0.660 m = 31.10 mCumulative = 60.32 m - Capa 3 (
k = 3):D_center,3 = 700 mm→L_3 = 32.99 m→Cumulative = 93.31 m - Capa 4 (
k = 4):D_center,4 = 740 mm→L_4 = 34.87 m→Cumulative = 128.18 m - Capa 5 (
k = 5):D_center,5 = 780 mm→L_5 = 36.76 m→Cumulative = 164.94 m - Capa 6 (
k = 6):D_center,6 = 820 mm→L_6 = 38.64 m→Cumulative = 203.58 m
Target length 200 m is achieved midway through Layer 6 (k_max = 6).
Final Coil OD:
Coil OD = 600 + (2 × 6 × 20) = 840 mm
The resulting 840 mm OD is well within the 1,050 mm maximum envelope of the FCL600 frame.
3. Throughput and Cycle Time Balance
The winding phase duration (t_wind) is determined by extruder output velocity (v_line):
t_wind = L_total / v_line
Ejemplo: En v_line = 25 m/min for a 200 m coil, t_wind = 200 / 25 = 8.0 minutes (480 segundos).
The automatic cycle (shear cut, 3 radial strap feeds/welds, core retraction, and cradle down-tilting) consumes 35 to 50 seconds.
- In continuous single-coiler lines, a vertical multi-pass dancer accumulator with a storage capacity
L_acc ≥ v_line × t_cycleabsorbs extruder throughput during tying. - In dual-spindle configurations, the tube automatically transfers to an alternate pre-expanded reel within 4 seconds, completely eliminating line throttling.
Lista de verificación de selección
Prior to equipment specification, confirm the following production baseline data:
- Pipe Substrate: Resin grade (HDPE, PEX-a/b/c, PE-RT, PA11/12, Polyurethane) and flexural modulus.
- Cross-Sectional Range: Minimum and maximum tube outside diameter (OD) and nominal wall thickness.
- Coil Packaging Profile: Target core inner diameter (ID), maximum external package diameter (OD), and face width.
- Extruder Line Speed: Nominal and peak haul-off velocity (m/min).
- Especificaciones de flejado: Band material (PP or PET), strap width (9 mm, 12 mm, or 16 mm), and number of radial ties (2, 3, 4, or 6).
- Automatización descendente: Integration requirements for secondary stretch-film wrapping, automated bag insertion, or robotic palletizing.
- Power & Pneumatics: Line voltage (e.g., 380V/480V 3-Phase 50/60 Hz) and clean, dry plant air supply (≥ 0.6 MPa).
Seguridad
The FCL series conforms to harmonized European machinery safety legislation and global operational guidelines:
- EN 415-10: Packaging machines safety; mandates performance-level interlocks on moving traverse arms, rotary strapping guides, and coil ejection zones.
- ISO 12100:2010: Safety of machinery — General principles for design, risk assessment, and hazard mitigation.
- EN ISO 13849-1 (Cat 3 / PL d): Dual-channel safety circuits governing emergency stop interlocks and electro-sensitive protective equipment (light curtains).
Standard plant safety features include full-perimeter welded wire mesh guarding, coded magnetic interlock access gates, pneumatic dump valves for zero residual pressure during intervention, and accessible emergency-stop pushbuttons along the operational envelope.
Preguntas Frecuentes
How does the FCL handle flexible tubing versus stiff, thick-walled pipe? The coiler incorporates variable-torque electronic regulation. For high-flexibility PU/PE tubing, minimal back-tension is maintained to prevent necking. For stiff PEX or PE conduit, hydraulic or heavy-duty pneumatic assist rollers press the outer wrap against the mandrel to secure tight, uniform layer seating.
Can the system coil and tie corrugated conduit? Yes. Corrugated profiles are processed using custom contoured guide wheels and soft-compound polyurethane traverse rollers to prevent crushing or deforming the pipe crown profile.
Is manual intervention required during continuous extrusion? In fully automated cells equipped with a dancer accumulator and automated tilting cradle, the machine executes cutting, strapping, and coil ejection autonomously. The operator is only required to clear finished coils from the exit accumulation buffer.
Can the machine strap using different band materials? The standard thermal sealing strapping head handles commercial embossed PP strapping. For heavy coils requiring high residual retention, a friction-weld head configured for PET strapping can be specified.
Próximos Pasos
To verify machine sizing, cycle balancing, and floor layout for your extrusion line, provide your technical parameters (tube OD range, line speed, coil dimensions, and package weights) to our engineering department.
- Request an engineered integration drawing: Contact our application engineering team.
- Explore complementary packaging units: Review integrated horizontal orbital wrappers and in-line shrink-bundling modules.
