{"id":1374,"date":"2018-07-31T04:14:52","date_gmt":"2018-07-31T04:14:52","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=1374"},"modified":"2026-10-27T11:53:14","modified_gmt":"2026-10-27T11:53:14","slug":"automatic-hose-coiler-with-strapping-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-hose-coiler-with-strapping-machine\/","title":{"rendered":"Automatic Corrugated Hose Coiler with Integrated Strapping System: Operation, Sizing, and Line Integration"},"content":{"rendered":"<blockquote>\n<p><strong>Executive Summary<\/strong>\nContinuous extrusion of flexible and semi-rigid corrugated hose requires synchronized coiling and reliable radial strapping directly at the discharge end of the cooling trough. Uncontrolled tension, irregular turn laying, or inconsistent strapping lead to deformed pipe corrugation, unwound coils during transit, and warehouse palletizing failures. This technical guide outlines the operational kinematics of our horizontal automatic hose coiler, provides exact consumable calculations for polyester (PET) and polypropylene (PP) strapping per coil geometry, and defines essential safety configurations compliant with EN 415-10 and ISO 12100 standards for continuous extrusion lines.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/T6PQNPeGcB0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2>Table of Contents<\/h2>\n<ul>\n<li><a href=\"#system-architecture-and-kinematic-overview\">System Architecture and Kinematic Overview<\/a><\/li>\n<li><a href=\"#how-the-corrugated-hose-coiler-works\">How the Corrugated Hose Coiler Works<\/a><\/li>\n<li><a href=\"#consumable-sizing-strapping-length-calculation\">Consumable Sizing: Strapping Length Calculation<\/a><\/li>\n<li><a href=\"#coil-handling-retention-and-storage-optimization\">Coil Handling, Retention, and Storage Optimization<\/a><\/li>\n<li><a href=\"#safety-engineering-guarding-and-compliance-standards\">Safety Engineering, Guarding, and Compliance Standards<\/a><\/li>\n<li><a href=\"#engineering-checklist-for-machine-selection\">Engineering Checklist for Machine Selection<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step--technical-inquiry\">Next Step &amp; Technical Inquiry<\/a><\/li>\n<li><a href=\"#related-packaging-solutions\">Related Packaging Solutions<\/a><\/li>\n<li><a href=\"#reference-standards-and-sources\">Reference Standards and Sources<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2>System Architecture and Kinematic Overview<\/h2>\n<p>Automated coiling of flexible corrugated tubing\u2014ranging from PVC electrical conduits to heavy-duty HDPE drainage pipes\u2014requires strict synchronization between the extrusion haul-off caterpillar and the coiler&#8217;s rotary turntable.<\/p>\n<pre><code>[ Extruder &amp; Haul-off ]\n           \u2502 (Continuous feed: V_line)\n           \u25bc\n[ Dancer \/ Tension Buffer ] \u2500\u2500\u25b6 Speed Synchronization (0&ndash;10 V \/ Modbus TCP)\n           \u2502\n           \u25bc\n[ Servo Traversing Guide Arm ] \u2500\u2500\u25b6 Pitch control (Pitch = Pipe OD &times; 1.05)\n           \u2502\n           \u25bc\n[ Horizontal Turntable Disc ] \u2500\u2500\u25b6 Core Mandrel Clamping &amp; Winding\n           \u2502\n           \u25bc\n[ Radial Strapping Unit ] \u2500\u2500\u25b6 2&ndash;4 Polypropylene \/ Cord Ties through Core Eye\n           \u2502\n           \u25bc\n[ Ejection &amp; Stacking Buffer ]<\/code><\/pre>\n<p>The machine consists of a heavy-duty structural steel chassis housing the lower variable-frequency drive (VFD) transmission, an adjustable inner core mandrel, and an overhead dual-axis traversing guide arm. Rather than relying on operator manual guidance, the traversing arm maintains a dynamic pitch relative to the instantaneous turntable rotational speed (RPM) to lay adjacent corrugations smoothly without cross-turn overlapping or structural crush.<\/p>\n<hr \/>\n<h2>How the Corrugated Hose Coiler Works<\/h2>\n<p>The coiling cycle functions as an inline automated sequence designed to match upstream line speeds up to 35 m\/min:<\/p>\n<table>\n<thead>\n<tr>\n<th>Sequence Phase<\/th>\n<th>Mechanical Operation<\/th>\n<th>Technical Control Parameters<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Feed &amp; Buffer<\/strong><\/td>\n<td>Extruded corrugated hose enters through the guide arm rollers.<\/td>\n<td>Driven by line speed tracking; dancer sensor maintains 5\u201315 N back-tension.<\/td>\n<\/tr>\n<tr>\n<td><strong>Leading-End Fixation<\/strong><\/td>\n<td>Hose leading end is secured against the adjustable center mandrel clamps.<\/td>\n<td>Pneumatic mechanical jaw clamps pipe without wall collapse.<\/td>\n<\/tr>\n<tr>\n<td><strong>Synchronized Coiling<\/strong><\/td>\n<td>Horizontal turntable rotates while the servo guide arm reciprocates across coil height.<\/td>\n<td>Winding speed adjusts automatically as coil diameter grows from ID to OD.<\/td>\n<\/tr>\n<tr>\n<td><strong>Radial Strapping<\/strong><\/td>\n<td>Turntable stops; strapping head feeds PP\/PET strap or cord through the core eye.<\/td>\n<td>Band tension adjusted to 150\u2013450 N depending on pipe wall rigidity.<\/td>\n<\/tr>\n<tr>\n<td><strong>Pneumatic Discharge<\/strong><\/td>\n<td>Core mandrel pins collapse pneumatically; coil pushes onto buffer conveyor\/rack.<\/td>\n<td>Cycle reset takes &lt; 15 seconds before the next coil sequence begins.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>To achieve moisture, dust, and UV protection for storage and export transport, coiled bundles can be transferred directly to an <a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-pipe-coiling-and-wrapping-machine-for-hose-and-plastic-tubes\/\">automatic pipe coiling and wrapping machine<\/a> for orbital stretch film wrapping.<\/p>\n<hr \/>\n<h2>Consumable Sizing: Strapping Length Calculation<\/h2>\n<p>Radial strapping holds the coiled turns tightly in compact bundles. Strapping passes axially through the center eye of the coil and wraps around the radial cross-section (coil wall and height).<\/p>\n<pre><code>          \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500 OD = 1,200 mm \u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2510\n          \u2502                                               \u2502\n     \u250c\u2500\u2500\u2500\u2500\u2534\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2510                           \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2534\u2500\u2500\u2500\u2500\u2510\n     \u2502  Coil Wall   \u2502                           \u2502  Coil Wall   \u2502\n     \u2502  W = 300 mm  \u2502                           \u2502  W = 300 mm  \u2502\n     \u2502   \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2510   \u2502                           \u2502   \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2510   \u2502\n     \u2514\u2500\u2500\u2500\u2524 Hose \u251c\u2500\u2500\u2500\u2518                           \u2514\u2500\u2500\u2500\u2524 Hose \u251c\u2500\u2500\u2500\u2518\n         \u2502 Coil \u2502 Height = 300 mm                   \u2502 Coil \u2502 Height = 300 mm\n         \u2502      \u2502                                   \u2502      \u2502\n         \u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2518   \u250c\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2510   \u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2518\n                    \u2502    Coil Eye (ID) = 600 mm \u2502\n                    \u2514\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2500\u2518<\/code><\/pre>\n<h3>Engineering Sizing Example<\/h3>\n<ul>\n<li><strong>Coil Outer Diameter (OD)<\/strong>: 1,200 mm<\/li>\n<li><strong>Coil Inner Core Diameter (ID)<\/strong>: 600 mm<\/li>\n<li><strong>Coil Axial Height (H_coil)<\/strong>: 300 mm<\/li>\n<li><strong>Coil Radial Wall Thickness (W_coil)<\/strong>:\n<code>W_coil = (OD - ID) \/ 2 = (1,200 mm - 600 mm) \/ 2 = 300 mm<\/code><\/li>\n<li><strong>Theoretical Single Band Perimeter<\/strong>:\n<code>L_theoretical = 2 &times; (W_coil + H_coil) = 2 &times; (300 mm + 300 mm) = 1,200 mm<\/code><\/li>\n<li><strong>Heat-Seal Joint Overlap &amp; Corner Allowance (L_seal)<\/strong>: 80 mm<\/li>\n<li><strong>Effective Cut Length per Band (L_band)<\/strong>:\n<code>L_band = L_theoretical + L_seal = 1,200 mm + 80 mm = 1,280 mm (1.28 m)<\/code><\/li>\n<\/ul>\n<table>\n<thead>\n<tr>\n<th>Metric Parameter<\/th>\n<th>Engineering Design Value<\/th>\n<th>Production Practical Note<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Coil OD \/ ID \/ Height<\/strong><\/td>\n<td>1,200 mm \/ 600 mm \/ 300 mm<\/td>\n<td>Custom set via telescoping mandrel pins<\/td>\n<\/tr>\n<tr>\n<td><strong>Calculated Wall Cross-Section<\/strong><\/td>\n<td>300 mm<\/td>\n<td><code>(OD - ID) \/ 2<\/code><\/td>\n<\/tr>\n<tr>\n<td><strong>Strap Path Perimeter<\/strong><\/td>\n<td>1,200 mm<\/td>\n<td>Rectangular profile before tensioning<\/td>\n<\/tr>\n<tr>\n<td><strong>Joint Overlap &amp; Feed Clearance<\/strong><\/td>\n<td>80 mm<\/td>\n<td>Required for heat-seal or ultrasonic blade<\/td>\n<\/tr>\n<tr>\n<td><strong>Total Cut Length per Strap<\/strong><\/td>\n<td>1,280 mm (1.28 m)<\/td>\n<td>Net consumable strap consumed per cycle<\/td>\n<\/tr>\n<tr>\n<td><strong>Radial Bands per Coil<\/strong><\/td>\n<td>4 bands (at 90\u00b0 intervals)<\/td>\n<td>Standard bundle stability requirement<\/td>\n<\/tr>\n<tr>\n<td><strong>Total Strapping Consumed per Coil<\/strong><\/td>\n<td><strong>5.12 m<\/strong> (<code>4 &times; 1.28 m<\/code>)<\/td>\n<td>Base figure for consumable cost planning<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: For light-duty corrugated tubes or thin PE conduit, twisted polypropylene cord can replace rigid strap to prevent localized creasing of outer corrugation ribs.<\/em><\/p>\n<hr \/>\n<h2>Coil Handling, Retention, and Storage Optimization<\/h2>\n<p>Optimizing coil dimensions directly dictates warehouse space utilization, shipping container floor fill rate, and product stability on industrial racks:<\/p>\n<table>\n<thead>\n<tr>\n<th>System Parameter<\/th>\n<th>Engineering Consideration<\/th>\n<th>Operational Impact on Packing Line<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td><strong>Radial Straps (2, 3, or 4)<\/strong><\/td>\n<td>Mechanical bundle rigidity<\/td>\n<td>2 straps suffice for retail bundles (&lt; 8 kg); 4 straps required for heavy-duty coils to prevent &quot;telescoping&quot; during tilt handling.<\/td>\n<\/tr>\n<tr>\n<td><strong>Strap Tensile Rating<\/strong><\/td>\n<td>PP (Polypropylene) vs. Elastic Cord<\/td>\n<td>PP strap (12 mm \u00d7 0.6 mm) provides structural rigidity; elastic cord prevents denting on ultra-thin electrical conduit.<\/td>\n<\/tr>\n<tr>\n<td><strong>Coil Axial Height<\/strong><\/td>\n<td>Extruder batch length vs. rack spacing<\/td>\n<td>Setting coil height to standard pallet modules (e.g., 300 mm or 400 mm) allows stable cross-stacking up to 2.4 m.<\/td>\n<\/tr>\n<tr>\n<td><strong>Mandrel ID Sizing<\/strong><\/td>\n<td>Minimum Bending Radius (R_min)<\/td>\n<td>Mandrel diameter must exceed <code>10 &times; Pipe OD<\/code> to avoid permanent wall kinking and inner wall stress whitening.<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>If total weatherproofing or soil-tight transport is required, view our specialized <a href=\"https:\/\/www.fhopepack.com\/videos\/flexible-corrugated-pipe-rolls-wrapping-machine-and-hose-packing-mahcine\/\">corrugated pipe rolls wrapping machine<\/a> for full surface film encasement.<\/p>\n<hr \/>\n<h2>Safety Engineering, Guarding, and Compliance Standards<\/h2>\n<p>Automated coiling systems generate significant centrifugal force and pinch hazards along the rotating turntable and reciprocating traversing arm. Safe line operation mandates adherence to international industrial machinery norms:<\/p>\n<ul>\n<li><strong>Perimeter Guarding (ISO 14120 \/ OSHA 1910.212)<\/strong>: The turntable zone is enclosed with rigid, powder-coated steel mesh fencing (minimum height 1,800 mm) located beyond the maximum reach hazard envelope.<\/li>\n<li><strong>Access Interlocks (ISO 14119 \/ ISO 13849-1)<\/strong>: Maintenance and inspection access doors incorporate dual-channel Category 3, Performance Level d (PLd) safety limit switches that trigger emergency stop (Safe Torque Off &#8211; STO) circuits instantly if breached.<\/li>\n<li><strong>Machinery Directives Compliance<\/strong>: Fully compliant with <strong>EN 415-10<\/strong> (Safety requirements for packaging and wrapping machines) and <strong>ISO 12100<\/strong> (General design principles for risk assessment and reduction).<\/li>\n<li><strong>Zero-Speed Mandrel Interlock<\/strong>: Tube loading, end-clamping, and manual adjustments are programmatically locked out until the drive feedback signals absolute zero mechanical rotation (0 RPM).<\/li>\n<\/ul>\n<hr \/>\n<h2>Engineering Checklist for Machine Selection<\/h2>\n<p>Evaluate the following parameters prior to coiler specification to ensure seamless integration with the extrusion line:<\/p>\n<ul>\n<li><strong>Hose Geometry<\/strong>: Outside Diameter (OD), Inside Diameter (ID), wall thickness, and rib profile.<\/li>\n<li><strong>Material Formulation<\/strong>: PVC, PA (Nylon), PE, PP, or thermoplastic rubber (TPE\/TPU).<\/li>\n<li><strong>Minimum Allowable Bend Radius<\/strong>: Maximum safe curvature before inner diameter ovalization exceeds 5%.<\/li>\n<li><strong>Extruder Line Speed<\/strong>: Continuous haul-off rate (m\/min) and cut-to-length target.<\/li>\n<li><strong>Target Coil Dimensions<\/strong>: Core mandrel ID, max outer OD, and max axial coil stack height.<\/li>\n<li><strong>Retention Specification<\/strong>: Polypropylene (PP) strapping, polyester (PET) strapping, or cord tie; manual vs. automatic feed.<\/li>\n<li><strong>Upstream Synchronization Interface<\/strong>: Digital I\/O, 4\u201320 mA dancer pot signal, or Profinet\/EtherNet\/IP integration.<\/li>\n<li><strong>Plant Power and Air Supply<\/strong>: Voltage tolerance (3-phase 380V\/480V, 50\/60 Hz) and clean compressed air supply (0.6\u20130.7 MPa).<\/li>\n<\/ul>\n<hr \/>\n<h2>Engineering FAQ<\/h2>\n<p><strong>Q: How does the traversing guide arm prevent irregular turn overlapping?<\/strong>\nA: The traversing guide arm uses a closed-loop stepper or servo drive synchronized to the turntable rotary encoder. Pitch velocity is calculated by:\n<code>V_traverse = (Pipe OD &times; Clearance Factor) &times; (Rotary RPM \/ 60)<\/code>\nThis ensures each consecutive loop drops cleanly adjacent to the previous turn across every layer.<\/p>\n<p><strong>Q: What is the rule of thumb for calculating strapping consumable demand?<\/strong>\nA: For a 4-band radial configuration on a rectangular cross-section, total strap length equals:\n<code>Total Strap = 4 &times; [2 &times; (Coil Wall + Coil Height) + Joint Overlap]<\/code>\nFor a 1,200 mm OD, 600 mm ID, and 300 mm high coil with an 80 mm joint overlap, total consumption is exactly 5.12 meters per bundle.<\/p>\n<p><strong>Q: When should a manufacturer use polypropylene (PP) strap versus synthetic cord?<\/strong>\nA: Rigid PP strap (tensioned to 200\u2013400 N) is recommended for structural coiling of heavy corrugated tubing to maintain stack integrity on logistics pallets. Synthetic cord or elastic ties are selected for soft, flexible corrugated conduit where rigid edge banding could pinch or crush outer corrugations.<\/p>\n<p><strong>Q: Can this coiler integrate directly with an upstream rotary flying shear?<\/strong>\nA: Yes. The system receives a cut-complete trigger signal from the shear, momentarily speeds up winding to clear the pipe tail onto the turntable, and triggers the radial strapping sequence automatically.<\/p>\n<hr \/>\n<h2>Next Step &amp; Technical Inquiry<\/h2>\n<p>Our application engineers configure coiler drive kinematics, core mandrels, and integrated strapping heads directly to your extrusion line footprint.<\/p>\n<ol>\n<li><strong>Submit Line Parameters<\/strong>: Email your pipe drawings, resin data sheets, extrusion line speed, and coil size ranges to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Review Custom Layout Proposal<\/strong>: Receive a complete mechanical layout, line integration diagram, and cycle-time analysis within <strong>48 hours<\/strong>.<\/li>\n<li><strong>Factory Acceptance &amp; Integration Planning<\/strong>: Coordinate line interface checks, PLC signal addressing, and safety circuit verification prior to machine shipment.<\/li>\n<\/ol>\n<hr \/>\n<h2>Related Packaging Solutions<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Pipe-packing-machine\/\">Industrial Pipe and Tube Packaging Machinery Systems<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/double-wall-corrugated-hose-coiling-and-strapping-machine\/\">Double-Wall Corrugated Hose Coiling and Strapping System<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/automatic-tube-coiler-and-pipe-coiling-strapping-machine-3\/\">Automatic High-Speed Plastic Tube Coiler with Inline Banding Unit<\/a><\/li>\n<\/ul>\n<hr \/>\n<h2>Reference Standards and Sources<\/h2>\n<ul>\n<li><strong>Equipment Design &amp; Kinematics<\/strong>: Engineering Design Standards, FHOPE R&amp;D Department.<\/li>\n<li><strong>Safety Directive Standards<\/strong>:\n<ul>\n<li><a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 &#8211; Safety of Machinery: General Principles for Design<\/a><\/li>\n<li><a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 &#8211; Safety Requirements for Packaging Machines: Modular Packaging Lines<\/a><\/li>\n<li>ISO 13849-1: Safety-related parts of control systems (Cat.3 \/ PLd compliance).<\/li>\n<\/ul><\/li>\n<li><strong>Operational Video Reference<\/strong>: <a href=\"https:\/\/www.fhopepack.com\/videos\/\">FHOPE Technical Equipment Archive &#8211; Corrugated Hose Coiling Demonstration<\/a><\/li>\n<\/ul>\n<p><em>Document Ref: FHOPE-ENG-HC-415 | Revision 2.4<\/em><\/p>","protected":false},"excerpt":{"rendered":"<p>Executive Summary Continuous extrusion of flexible and semi-rigid corrugated hose requires synchronized coiling and reliable radial strapping directly at the discharge end of the cooling trough. Uncontrolled tension, irregular turn laying, or inconsistent strapping lead [&hellip;]<\/p>","protected":false},"author":1,"featured_media":2492,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Automatic Hose Coiler for Corrugated Hose: Coils and Straps","_seopress_titles_desc":"How our automatic hose coiler winds corrugated hose on a turning disc and the coils are strapped for storage, with a worked example for strap per 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