{"id":1100,"date":"2018-06-11T05:56:15","date_gmt":"2018-06-11T05:56:15","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=1100"},"modified":"2026-10-27T06:02:32","modified_gmt":"2026-10-27T06:02:32","slug":"automatic-online-hdpe-pipe-coiling-and-hose-winding-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-online-hdpe-pipe-coiling-and-hose-winding-machine\/","title":{"rendered":"automatic online HDPE pipe coiling and hose winding machine"},"content":{"rendered":"
> **Executive summary**\n>\n> Continuous plastic extrusion requires downstream take-up equipment that eliminates buffering stops and prevents line back-pressure. The automatic online HDPE pipe coiling and hose winding machine integrates directly downstream of the haul-off caterpillar. It incorporates dual-station cantilevered indexing reels, closed-loop optical\/rotary meter counting, a pneumatic guillotine cutter, and pneumatic collapsible spider mandrels. This configuration enables seamless transfer between winding stations at full line speed, allowing the operator or automated strapping unit to unload finished coils without interrupting the extrusion line.\n\n---\n\nA precision dual-station turret coiler engineered for continuous plastic pipe and flexible hose extrusion lines. The machine integrates a pneumatic pinch-wheel length-measuring counter, a servo-driven dynamic traverse traversing guide, and dual 180° indexing collapsible winding mandrels. Controlled via an integrated Siemens PLC and high-resolution HMI touchscreen, it guarantees consistent winding tension, uniform layer pitch, and smooth coil discharge for high-density polyethylene (HDPE), low-density polyethylene (LDPE), polypropylene (PP), and corrugated flexible conduit lines.\n\n<h2 id="table-of-contents">Table of Contents<\/h2>\n\n<ul>\n<li><a href="#online">Why coil online<\/a><\/li>\n<li><a href="#sequence">Winding sequence<\/a><\/li>\n<li><a href="#data">Machine data<\/a><\/li>\n<li><a href="#speed">Matching the extruder speed<\/a><\/li>\n<li><a href="#layers">Layer build and coil height<\/a><\/li>\n<li><a href="#selection-checklist">Selection checklist<\/a><\/li>\n<li><a href="#safety">Safety<\/a><\/li>\n<li><a href="#engineering-faq">Engineering FAQ<\/a><\/li>\n<li><a href="#next-step">Next step<\/a><\/li>\n<li><a href="#related-reading">Related reading<\/a><\/li>\n<li><a href="#sources">Sources<\/a><\/li>\n<\/ul>\n\n<h2 id="online">Why coil online<\/h2>\n\nOffline coiling requires batch collection onto bulk storage bobbins followed by secondary unwinding and rewind operations. This dual-handling method increases production footprint, multiplies direct labor requirements, and introduces surface scuffing, ovality deformation, and stress-cracking risks on semi-rigid pipes.\n\nOnline continuous coiling executes length counting, winding, cutoff, and reel changeover directly at extrusion line speed. Key operational advantages include:\n\n- **Zero Extrusion Interruption:** Line speed remains synchronized between the caterpillar haul-off and coiler through analog\/fieldbus speed trim signals.\n- **Surface Integrity:** Pipe travels along polished guide rollers, eliminating drag abrasion and micro-scratches.\n- **Accurate Bundle Lengths:** Real-time pulse encoders eliminate manual metering errors and ensure consistent package dimensions for commercial distribution.\n- **Labor Rationalization:** One line operator manages coil strapping and palletizing, replacing multiple off-line rewinding crews.\n\n<h2 id="sequence">Winding sequence<\/h2>\n\nThe automated changeover cycle executes via PLC sequencing across six distinct stages:\n\n1. **Meter Counting:** Pipe exits the haul-off and enters the spring-loaded pinch tracking assembly, where an optical rotary encoder measures linear footage within ±0.2% accuracy.\n2. **Mandrel Clamping:** The leading pipe tip enters the active winding station and is locked by a pneumatic clamping jaw on the inner spider hub.\n3. **Traverse Layering:** The primary reel rotates via variable-frequency drive (VFD). A servo ball-screw traverse guide traverses bidirectionally, laying uniform, pitch-controlled pipe wraps between the side containment flanges.\n4. **Target Length Cutoff:** Upon reaching the programmed coil length, an electro-pneumatic clamp secures the pipe, and a high-speed chipless guillotine blade executes a clean, perpendicular shear.\n5. **Turret Station Indexing:** The central 180° rotary star-arm indexes, shifting the completed coil to the outboard standby position while bringing the secondary empty mandrel into the winding centerline. The new pipe end is clamped and begins winding immediately without upstream speed throttling.\n6. **Coil Collapse and Ejection:** On the outboard station, radial mandrel arms retract pneumatically to loosen internal coil tension. The coil is strapped (manually or via integrated strapping unit) and cleared by a pneumatic ejector plate or manual handling.\n\n<h2 id="data">Machine data<\/h2>\n\nThe standard series accommodates small-to-medium flexible conduit, drip-irrigation lines, and high-pressure PE piping.\n\n| Specification Parameter | Value \/ Technical Envelope |\n| :--- | :--- |\n| Pipe Outer Diameter (OD) Range | Series A: 2–16 mm<br>Series B: 8–20 mm<br>Series C: 15–30 mm |\n| Coil Outer Diameter (OD) | 400–600 mm (Up to 800 mm on heavy frames) |\n| Coil Inner Diameter (ID) | 200–400 mm (Continuously adjustable via linkage) |\n| Coil Package Width (Height) | 40–120 mm \/ 40–200 mm \/ 100–300 mm (By model) |\n| Linear Length Preset Range | 20–100 m per coil (Extended lengths configurable) |\n| Line Speed Capability | 10–80 m\/min (Matched to extruder output) |\n| Operating Pneumatic Supply | 0.6–0.8 MPa (Clean, dry compressed air) |\n| Core Automated Functions | Pulse meter counting, servo traverse, pneumatic cutting, 180° indexing, radial arm collapse |\n\n*Note: For heavy-gauge pipes (OD 32–63 mm) or larger coil configurations up to 1,600 mm OD, consult the specialized FCL-800\/1200 heavy coiler documentation.*\n\n<h2 id="speed">Matching the extruder speed<\/h2>\n\nThe winding package cycle time is determined by total coil package length and line extrusion velocity:\n\n`t_coil = L_coil ÷ V_line`\n\n`Output (coils\/h) = 3600 ÷ t_coil`\n\n*Where:*\n- `t_coil` = Active coiling time per station (seconds)\n- `L_coil` = Programmed pipe length per coil (meters)\n- `V_line` = Continuous extrusion linear speed (meters per second)\n\n**Engineering Calculation Example:**\n- Pipe Length (`L_coil`) = 100 m\n- Haul-off Line Speed (`V_line`) = 60 m\/min (1.0 m\/s)\n- Total cycle time per coil: `t_coil = 100 ÷ 1.0 = 100 s`\n- Nominal production output: `3600 ÷ 100 = 36 coils\/h`\n\n**Line Synchronization Condition:**\nThe entire turret station changeover—including blade cutoff, 180° arm indexing, and new lead-end clamping—must complete within 3–8 seconds. A vertical counterbalanced dancer arm or pneumatic buffer loop absorbs continuous line feed during the momentary indexing transition, preventing pipe kinking or haul-off speed surge.\n\n<h2 id="layers">Layer build and coil height<\/h2>\n\nTo prevent loose coils, cross-turn entanglement, or axial flange binding, the traverse guide pitch must match pipe OD and expansion properties:\n\n`Turns per Layer ≈ W_coil ÷ (OD_pipe × k_pitch)`\n\n`Total Layers ≈ (OD_coil - ID_mandrel) ÷ (2 × OD_pipe)`\n\n*Where:*\n- `W_coil` = Internal coil width \/ height between containment arms (mm)\n- `OD_pipe` = Nominal pipe outer diameter (mm)\n- `k_pitch` = Pitch correction coefficient (typically 1.03–1.08 to prevent wedging)\n\n**Engineering Dimensioning Example:**\n- Coil width (`W_coil`) = 96 mm\n- Pipe nominal outer diameter (`OD_pipe`) = 16 mm\n- Effective pitch factor (`k_pitch`) = 1.0\n- Layer capacity: `96 ÷ 16 = 6 turns per layer`\n\nThe servo-driven traversing carriage traverses precisely by one calculated pitch value per mandrel revolution. Digital position limit switches and PLC-driven edge ramps reverse the traverse at each flange boundary, maintaining square coil profiles and consistent packing density for outbound strapping.\n\n<h2 id="selection-checklist">Selection checklist<\/h2>\n\nPrior to machine specification and layout approval, verify the following mechanical and interface parameters:\n\n1. **Pipe Material & Wall Characteristics:** Resin grade (HDPE PE100\/PE80, LDPE, PVC, PA, corrugated PP), wall thickness (SDR rating), and minimum bend radius.\n2. **Extrusion Line Parameters:** Minimum, nominal, and maximum extrusion haul-off line speeds (m\/min).\n3. **Finished Coil Dimensions:** Target core ID (mandrel hub), maximum coil OD, and target coil pack width (traverse stroke).\n4. **Preset Cut Lengths:** Standard commercial cut lengths (e.g., 25 m, 50 m, 100 m) and length tolerances.\n5. **Unloading Configuration:** Manual extraction with hoist assist versus fully automatic coil push-off and motorized transfer conveyor.\n6. **Secondary Packaging Integration:** Downstream manual strapping, automated circumferential PP\/PET strapping, or orbital stretch-film wrapping.\n7. **Auxiliary Systems:** In-line optical diameter inspection, inkjet code printing distance, and weight verification stations.\n\n<h2 id="safety">Safety<\/h2>\n\nThe machine is engineered to conform with international industrial machinery safety directives:\n\n- **Risk Assessment & Design Standards:** EN ISO 12100:2010 compliance across all operating modes.\n- **Packaging & Winding Machine Safety:** EN 415-10 technical requirements governing coiling, feed-in, and strapping interfaces.\n- **Electrical & Control Systems:** EN 60204-1 safety compliance for industrial electrical equipment, featuring Category 4 \/ PLe dual-channel emergency stop circuits.\n- **Mechanical Containment & Interlocking:** Fully enclosed poly-carbonate\/sheet-steel safety perimeter fencing around the 180° indexing envelope. The high-speed pneumatic cutoff knife and rotating reels are safety-interlocked via codable magnetic switches, preventing cycle initiation whenever safety doors are breached.\n\n<h2 id="engineering-faq">Engineering FAQ<\/h2>\n\n**Q: Does the extruder need to throttle down during the coil changeover cycle?**\nA: No. The coiler utilizes an upstream dynamic accumulator\/dancer loop combined with high-speed pneumatic cutoff and 180° indexing mechanisms (changeover time < 5 s). The extrusion line and caterpillar haul-off run at constant output speed.\n\n**Q: What maintains consistent length accuracy across different line speeds?**\nA: Precision hardened-steel dual pinch rollers track the pipe under controlled pneumatic contact pressure. A high-resolution incremental rotary encoder reads line motion directly from the pipe surface, bypassing slippage and delivering ±0.2% measurement accuracy.\n\n**Q: Can this machine coil corrugated flexible conduit without crushing the corrugations?**\nA: Yes. The system employs customized polyurethane-coated V-guide rollers, pressure-regulated pneumatic clamping shoes, and low-tension torque control algorithms to prevent profile flattening or deformation.\n\n**Q: Is automated coil strapping available on the same chassis?**\nA: Yes. The standby station can be equipped with an automated radial\/through-eye strapping mechanism (using PP strap) that secures the coil bundle before the radial mandrel arms collapse for discharge.\n\n<h2 id="next-step">Next step<\/h2>\n\n1. **Submit Production Data:** Send your target pipe OD range, resin material, maximum line speed (m\/min), and required coil dimensions (ID, OD, width, length) to **info@fhopepack.com**.\n2. **Engineering Review:** Our mechanical engineering team verifies mandrel expansion strokes, cutting shear forces, and traverse cycle profiles.\n3. **Technical Proposal:** Receive a complete dimensional layout drawing, mechanical specification sheet, and formal quotation within 24 hours.\n\n<h2 id="related-reading">Related reading<\/h2>\n\n- [Automatic hose coiling machine FCL-600 (product)](https:\/\/www.fhopepack.com\/Vertical-Coiling-Machine\/Automatic-hose-coiling--machine-FCL-600.html)\n- [Automatic pipe winding machine FCL-800 (product)](https:\/\/www.fhopepack.com\/Vertical-Coiling-Machine\/Automatic-pipe-winding-machine-FCL-800.html)\n- [Automatic coiler for corrugated hose and plastic pipe](https:\/\/www.fhopepack.com\/videos\/automatic-coiler-for-corrugated-hose-plastic-pipe\/)\n- [Automatic hose packing machine](https:\/\/www.fhopepack.com\/videos\/automatic-hose-packing-machine\/)\n\n<h2 id="sources">Sources<\/h2>\n\n- FHOPE Technical Documentation: FCL-600 & FCL-800 Series Automatic Dual Coiling Units\n- ISO Standards: EN ISO 12100:2010 (Safety of machinery — General principles for design)\n- European Standards: EN 415-10 (Safety of packaging machines — Part 10: General requirements); EN 60204-1 (Safety of machinery — Electrical equipment of machines)\n\n<p><strong>Last reviewed:<\/strong> 2026-10-20<\/p><\/code><\/pre>\n