Hose machines to pay back in two years

Two custom hose machines for a vehicle hose supplier could payback within two years, through improved productivity and reduced waste, writes Dean Palmer Two companies have collaborated on the successful design of two custom hose manufacturing machines for a US-based automotive hose supplier, which will help it improve productivity, reduce waste and improve product quality. The two machines, one a bias cutting machine and the other a roll/wrap unit, were designed and built by West Sussex-based systems integrator MMES Automation, with Bosch Rexroth providing specialist technical support and supplying pneumatic components and systems plus electric drives and controls. The first machine takes calendared silicone sheet with a woven or knitted reinforcement and creates a bias-cut, four-metre wide continuous roll, with reinforcing polythene film on each face. The second machine removes the polythene and feeds the silicone fabric into a roller system for creating elongated hose. The number of plys, the length and diameter of hose and joint overlap are all set through the HMI control screen. Both machines employ innovative technology such as ultrasonic cutting and a digital SERCOS interface with fibre optic connections. More than 100 metres of aluminium profile were used for structural frames and safety guards and MMES used Bosch Rexroth's Autocad-based design software for design, load calculation and project visualisation. Each machine uses an intelligent servo drive, EcoDrive, an HMI unit, a PPC motion controller, SERCOS-interfaced drive amplifiers and standard synchronous servo motors, all supplied by Bosch Rexroth. The PPC controls and synchronises all six axes, including pneumatic and linear, without the need for an additional PLC. It combines motion and logic control in one compact device and eliminates the cost and complexity of additional interfaces. And, using fibre optic cabling and SERCOS technology provides very fast drive communication, with the position of each axis updated every 2m/s. Rexroth carried out the initial programming using its dedicated Windows-based VisualMotion control software. IT specialists from MMES later received on-the-job training to familiarise themselves with the system and enable them to input parameter and recipe changes, aided by the icon-based programming environment. An HMI panel, with high contrast LCD display, is integrated into each machine, for operating the menu-based drive system and for changing variables such as batch quantity and tube length. Rexroth's linear motion actuators, each with heavy duty compact aluminium frame and steel-reinforced drive belt, are used for various mechanical drive functions, including carrying the ultrasonic cutting head and automatic polythene taping device. Modules of 5m and 2m stroke were supplied, each driven by the AC servo motors, their linear technology ensuring high accuracy and repeatable positioning. Linear rails and runner blocks were also specified for functions such as lifting the pinch rollers on the roll/wrap unit. Each machine also uses precision guide actuators, which are controlled via solenoid-operated valves, by the PPC controller. Consisting of a central piston and two rigid guide rods supported by bearings, this actuator configuration is widely used for automation applications that require high precision and increased side load capacity. In this particular example, they were used for the positioning of cutting heads and for raising and lowering the rollers. The two machines have now been installed and commissioned in the US by MMES, where the customer already estimates payback within two to three years and a further order has now been received. Pointers * The hose manufacturer expects payback on the two machines to be within two to three years * The machines will help cut waste, improve product quality and increase productivity * A range of pneumatic, electric and linear systems and components were supplied by Bosch Rexroth. Design and build was by systems integrator MMES Automation