{"id":7944,"date":"2024-11-27T07:19:31","date_gmt":"2024-11-27T07:19:31","guid":{"rendered":"https:\/\/www.fhopepack.com\/videos\/?p=7944"},"modified":"2026-10-29T04:40:14","modified_gmt":"2026-10-29T04:40:14","slug":"pu-air-pipe-coiling-machine-with-bobbin","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/pu-air-pipe-coiling-machine-with-bobbin\/","title":{"rendered":"PU Air Pipe Coiling Machine with Bobbin: Capacity, Tension and Twin-Station Winding"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong><\/p>\n<p>A PU air pipe coiling machine with bobbin winds pneumatic tube directly from an extrusion line onto a flanged spool instead of into a loose, unsupported coil. The winder maintains uniform web tension, traverses the tube side by side across the bobbin width to eliminate cross-winding, and automatically shifts winding to a secondary station so the upstream extrusion process runs uninterrupted during changeover. This guide details machine layout, bobbin volumetric holding capacity formulas, tension control dynamics, and operational selection criteria comparing spools against strapped coils.<\/p>\n<\/blockquote>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/iinyDq9dZX4\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<p>Each winding station is built on a heavy-duty structural steel frame with an independent drive motor, cantilevered bobbin shaft, precision low-friction guide wheels, and a mechanical tension regulator. A dedicated control cabinet equipped with industrial push buttons, indicator lamps, and an HMI interface manages station sequencing. As pneumatic PU tubing feeds through the guide wheel assembly, it winds evenly across the driven bobbin shaft while the adjacent station stands in standby ready for cutover.<\/p>\n<hr \/>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#why-bobbin\">Why wind PU tube on a bobbin<\/a><\/li>\n<li><a href=\"#how-it-works\">How the winder works<\/a><\/li>\n<li><a href=\"#capacity\">Bobbin capacity: how many metres<\/a><\/li>\n<li><a href=\"#tension\">Tension and lay quality<\/a><\/li>\n<li><a href=\"#bobbin-vs-coil\">Bobbin or strapped coil<\/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<h2 id=\"why-bobbin\">Why wind PU tube on a bobbin<\/h2>\n<p>Polyurethane (PU) and polyamide (nylon) pneumatic tubing exhibit high flexibility, structural resilience, and natural elastic memory. When wound into loose, coreless coils, continuous package stacking often results in kinked bends, ovalization under compressive weight, and tangled inner coils during field unwinding.<\/p>\n<p>Winding onto a rigid, flanged bobbin mechanically captures every turn, prevents cross-layer crushing during transit, and allows end users to smoothly unspool required lengths on standard pay-off dispensers without uncoiling the entire package. Continuous lengths\u2014such as 100 m or greater of small-bore pneumatic tube\u2014provide the highest return on investment when packaged on spools. Conversely, short consumer-length tubing bundles remain more economical as strapped loose coils.<\/p>\n<h2 id=\"how-it-works\">How the winder works<\/h2>\n<ol>\n<li><strong>Feed:<\/strong> The tube enters the winder from the extrusion line downstream of the water cooling bath and haul-off unit, or from a primary master reel in secondary rewinding operations.<\/li>\n<li><strong>Tension:<\/strong> Adjustable guide wheels and a dedicated tensioner maintain calibrated pulling force, preventing slack slippage without plastically elongating the tube wall.<\/li>\n<li><strong>Traverse:<\/strong> An automated mechanical or servo traverse lays the tube evenly across the bobbin traverse width, layering turn-by-turn with precision pitch matching.<\/li>\n<li><strong>Speed synchronization:<\/strong> A variable frequency inverter adjusts rotational shaft speed continuously as the package build-up increases winding diameter, matching haul-off line speed. Exact synchronization via dancer arm position or active closed-loop tension feedback is confirmed during technical quotation.<\/li>\n<li><strong>Continuous changeover:<\/strong> The integrated PLC tracks continuous linear metreage. Upon reaching the preset target length, the tube is clamped and cut, and the line diverts immediately to the alternate winding station without stopping upstream extrusion.<\/li>\n<li><strong>Unload:<\/strong> The completed bobbin is secured at the outer tail end, mechanically unlatched from the cantilevered shaft, and transferred for packaging.<\/li>\n<\/ol>\n<p>The system operates under centralized PLC and HMI control with selectable automatic and manual modes [manufacturer rating]. Integrated sensors continuously detect tube position and feeding status, while automatic diagnostic routines trip visible and audible alarms if tension loss or process faults occur [manufacturer rating].<\/p>\n<h2 id=\"capacity\">Bobbin capacity: how many metres<\/h2>\n<p>Theoretical holding capacity on a flanged cylindrical spool is determined by spool geometry and tube outer diameter (OD):<\/p>\n<ul>\n<li><strong>Turns per layer = traverse width \u00f7 tube OD<\/strong><\/li>\n<li><strong>Layers = (flange diameter \u2212 core diameter) \u00f7 2 \u00f7 tube OD<\/strong><\/li>\n<li><strong>Total length \u2248 3.14 \u00d7 mean diameter \u00d7 turns per layer \u00d7 layers<\/strong><\/li>\n<\/ul>\n<p><em>Where: Mean diameter = (flange diameter + core diameter) \u00f7 2.<\/em><\/p>\n<p>The following calculation illustrates capacity for an 8 mm OD tube wound onto a spool with a 200 mm core, 400 mm flange diameter, and 300 mm traverse width (illustrative example only):<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Check<\/th>\n<th style=\"text-align: left\">Calculation<\/th>\n<th style=\"text-align: left\">Result<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Turns per layer<\/td>\n<td style=\"text-align: left\">300 \u00f7 8<\/td>\n<td style=\"text-align: left\">37 turns<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Layers<\/td>\n<td style=\"text-align: left\">(400 \u2212 200) \u00f7 2 \u00f7 8<\/td>\n<td style=\"text-align: left\">12 layers<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Total turns<\/td>\n<td style=\"text-align: left\">37 \u00d7 12<\/td>\n<td style=\"text-align: left\">444 turns<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Mean diameter<\/td>\n<td style=\"text-align: left\">(400 + 200) \u00f7 2<\/td>\n<td style=\"text-align: left\">300 mm (0.3 m)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Total length<\/td>\n<td style=\"text-align: left\">3.14 \u00d7 0.3 m \u00d7 444<\/td>\n<td style=\"text-align: left\">about 418 m<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Fill time at 30 m\/min<\/td>\n<td style=\"text-align: left\">418 \u00f7 30<\/td>\n<td style=\"text-align: left\">about 14 min<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Fill cycle time dictates station transfer frequency and defines the time window available for an operator to unclamp, offload the finished spool, and load an empty bobbin core. In practical operation, net usable capacity is marginally lower than theoretical maximums because the outermost layer requires clearance below the flange rim to prevent edge spillage. Final bobbin core, flange, and traverse dimensions are verified at order quotation.<\/p>\n<h2 id=\"tension\">Tension and lay quality<\/h2>\n<p>Maintaining calibrated line tension and traverse kinematics directly impacts structural package integrity and tubing dimensional tolerances:<\/p>\n<ul>\n<li><strong>Insufficient tension:<\/strong> Winding turns lose inter-layer grip, leading to loose packs that telescope, sag, or collapse during high-speed dereeling.<\/li>\n<li><strong>Excessive tension:<\/strong> Soft elastomeric PU tube elongates axially under excessive tensile pull, shrinking outer diameter and thinning wall thickness. This dimensional variance can cause tubing to leak or blow out of precision pneumatic push-in fittings.<\/li>\n<li><strong>Traverse pitch mismatch:<\/strong> Incorrect traverse speed relative to shaft RPM causes inter-turn overlapping, gaps, and localized barrel-shaped bulging across the spool traverse.<\/li>\n<\/ul>\n<p>Winding tension must be configured to match tube polymer grade, durometer, and wall thickness. Outer diameter dimensional stability must be verified on both the initial inner-core turns and outer-layer turns when setting up new production profiles.<\/p>\n<h2 id=\"bobbin-vs-coil\">Bobbin or strapped coil<\/h2>\n<p>Selecting between spooling winders and loose-coil coiling machines depends on target package presentation and downstream secondary packaging requirements:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Parameter<\/th>\n<th style=\"text-align: left\">Twin-Station Bobbin Winder<\/th>\n<th style=\"text-align: left\">Loose-Coil Coiler &amp; Strapping System (FCL Series)<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\">Package format<\/td>\n<td style=\"text-align: left\">Flanged rigid spool \/ bobbin<\/td>\n<td style=\"text-align: left\">Strapped coreless coil<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Package dimensions<\/td>\n<td style=\"text-align: left\">Configured per bobbin drawing, confirmed at quote<\/td>\n<td style=\"text-align: left\">ID 100\u2013300 mm, OD 300\u2013400 mm, width 100 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Coiling envelope (FCL family)<\/td>\n<td style=\"text-align: left\">Custom spool geometry<\/td>\n<td style=\"text-align: left\">Coil OD 200\u2013600 mm, ID 180\u2013250 mm, height 40\u2013140 mm [manufacturer rating]<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Finished pack weight<\/td>\n<td style=\"text-align: left\">Dependent on spool dimensions<\/td>\n<td style=\"text-align: left\">8\u201350 kg<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Station transfer<\/td>\n<td style=\"text-align: left\">Continuous twin-station mechanical cutover<\/td>\n<td style=\"text-align: left\">Dual-wheel continuous winding with pneumatic discharge [manufacturer rating]<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Packaging material handling<\/td>\n<td style=\"text-align: left\">Direct spooling<\/td>\n<td style=\"text-align: left\">Stretch film (PVC\/PE\/PP, thickness 25 \u00b5m, width 50\u201370 mm) via pneumatic film feeding [manufacturer rating]<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\">Downstream operations<\/td>\n<td style=\"text-align: left\">Flange labeling, master carton packing<\/td>\n<td style=\"text-align: left\">OD strapping, perimeter stretch wrapping, robotic palletizing<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: Cycle speeds of 18\u201335 s per coil, rotational speeds up to 100 r\/min, and 380 V 60 Hz 3P power specifications apply strictly to the standalone FCL loose-coil coiler [manufacturer rating]. The twin-station bobbin winder operates continuously matched to upstream extrusion line velocity.<\/em><\/p>\n<h2 id=\"selection-checklist\">Selection checklist<\/h2>\n<ol>\n<li><strong>Tubing specifications:<\/strong> Polymer substrate (PU, nylon, PE, fluoropolymer) and exact OD\/ID tolerances.<\/li>\n<li><strong>Spool geometry:<\/strong> Target length per bobbin, flange outer diameter, core barrel diameter, and overall traverse width based on your customer&#8217;s dereeling equipment.<\/li>\n<li><strong>Line haul-off speed:<\/strong> Minimum and maximum operational extrusion line speeds (m\/min).<\/li>\n<li><strong>Automation requirements:<\/strong> Automatic dual-station length counting, automatic pneumatic cutting, and tail-tucking mechanisms.<\/li>\n<li><strong>Station configuration:<\/strong> Single-station design (requiring line accumulator) vs. twin-station continuous cutover to avoid extruder line stops.<\/li>\n<li><strong>Secondary packaging interface:<\/strong> Downstream requirements for protective flange end-caps, corrugated master cartons, or palletizing cells.<\/li>\n<\/ol>\n<h2 id=\"safety\">Safety<\/h2>\n<p>The machinery is engineered in full compliance with European harmonized safety standards:<\/p>\n<ul>\n<li><strong>EN ISO 12100:2010:<\/strong> Risk assessment and risk reduction principles for industrial machinery design.<\/li>\n<li><strong>EN 415-10:<\/strong> General safety requirements for packaging machines and associated secondary handling units.<\/li>\n<li><strong>EN 60204-1:<\/strong> Electrical safety, insulation, and grounding requirements for industrial machines.<\/li>\n<\/ul>\n<p>Primary operational hazards include high-speed rotational energy at the driven bobbin shaft and mechanical nip-points between incoming tube guide rollers and traversing car assemblies. Every station is equipped with interlocked perimeter physical guarding, low-friction nip barriers, and dual-channel Category 4 Emergency Stop push buttons located at both operator stations.<\/p>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: Which tubing materials can be wound on the twin-station bobbin system?<\/strong>\nA: The system handles thermoplastic polyurethane (PU), polyamide\/nylon (PA6, PA11, PA12), polyethylene (PE), and flexible PVC pneumatic air tubes.<\/p>\n<p><strong>Q: Does the extrusion line need to stop or decelerate during bobbin changeover?<\/strong>\nA: No. The winder switches the tube feed automatically to the secondary empty bobbin shaft upon reaching the programmed batch length, allowing the extrusion line to run at constant line speed.<\/p>\n<p><strong>Q: How is actual packaging capacity calculated for custom spool dimensions?<\/strong>\nA: Apply the volumetric formula: <code>Length &asymp; 3.14 &times; [(Flange Diameter + Core Diameter) &divide; 2] &times; [Traverse Width &divide; Tube OD] &times; [(Flange Diameter &minus; Core Diameter) &divide; (2 &times; Tube OD)]<\/code>. A 5\u201310% safety margin is typically deducted to accommodate flange rim clearance.<\/p>\n<p><strong>Q: Can this machine be adapted to produce coreless, strapped coils?<\/strong>\nA: Coreless, strapped coils require the FCL series horizontal coiling and strapping machine, which features collapsing mandrels and integrated pneumatic strapping units rather than flanged spool shafts.<\/p>\n<h2 id=\"next-step\">Next step<\/h2>\n<ol>\n<li><strong>Submit your technical parameters:<\/strong> Provide tube OD\/ID dimensions, extrusion haul-off line speeds, and target bobbin engineering drawings to info@fhopepack.com.<\/li>\n<li><strong>Engineering proposal:<\/strong> Our engineering team calculates torque constraints, traverse gearing ratios, and station changeover kinematics.<\/li>\n<li><strong>Formal quotation:<\/strong> Receive a detailed equipment layout drawing, functional specification sheet, and formal quotation within 24 hours.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Vertical-Coiling-Machine\/automatic-hose-coiler.html\">Automatic Hose Coiler<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Pipe-packing-machine\/Hose-Coil-wrapper-FPH-200.html\">Hose Coil Wrapper FPH-200<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/hose-coil-packing-machine\/\">Hose Coil Packing Machine Video Overview<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Sources<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Horizontal-Coiling-Machine\/Automatic-pipe-coiler-FCL100.html\">FHOPE Automatic Pipe Coiler FCL100 \/ FCL-H300 Specification<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Horizontal-Coiling-Machine\/Automatic-pipe-winding-machine-FCL200.html\">FHOPE Automatic Pipe Coiling and Strapping Machine FCL-200 \/ FCL-H600 Specification<\/a><\/li>\n<li>EN ISO 12100:2010; EN 415-10; EN 60204-1 Safety of Machinery Standards<\/li>\n<li>Industrial PU Tubing Twin-Station Bobbin Winding Station Kinematic Specifications<\/li>\n<\/ul>\n<p><strong>Last updated:<\/strong> 2026-10-29<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary A PU air pipe coiling machine with bobbin winds pneumatic tube directly from an extrusion line onto a flanged spool instead of into a loose, unsupported coil. 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