METZNER PA TUBE PROCESSING Effective solutions for machining PA tubes

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Commercial vehicles perform many different transport tasks. This

results in many and various body types, wheelbases, numbers of

axles and many other differences, giving a very large number of

variants, also for braking systems and other pneumatic components.

The prefabrication of all the necessary hoses results in inter-

mediate storage, which takes up space and increases costs

without added value for the vehicle manufacturer.

As a leading manufacturer of cutting machines for the auto-

motive industry, Metzner has tackled this task and provides

the market with a range of automatic machining systems for

Just-in-Time manufacture. In doing so, the large variety of

hose diameters and the different lettering and marking proc-

esses have also been catered for. Automatic material feeding

and removal has also been perfected in practice in collabora-

tion with leading automotive manufacturers.

Our systems are usually integrated in the IT network of the

customer and receive their machining jobs online from the

production planning. This automatic work processing results in

a further reduction in personnel costs.

„Just in Time“

Metzner Professional Version…………………………… 3

Metzner Profi Plus Version……………………………… 4

Metzner Economy Version…………………….………… 5

Metzner Basic Version……….………….……………… 6

Peripherals: Dereeling and feeding……………………… 7

Peripherals: Storing and coiling…………….…………… 8

Peripherals: Labelling and marking……………………… 9

Software solutions….………………………………… 10

Your benefits….……………………………………… 11

Configuration….………………………………...…… 11

Strong collaboration – world wide…………………...… 12

Metzner Maschinenbau GmbH Messerschmittstraße 30 89231 Neu-Ulm | Germany

Phone: +49 731 40199-0 Fax: +49 731 40199-33

Email: sales@metzner.com Internet: www.metzner.com

Photos: Metzner Maschinenbau GmbH, iStockphoto

© Metzner Maschinenbau GmbH, December 2008

We make no guarantee for the correctness and completeness of all technical information in this

document. Printed in Germany on paper bleached without using chlorine.

Directory

Metzner Professional Version

Completely automatic manufacturing system for the

machining of up to twelve different hose diameters.

The Metzner Professional Version provides the right solution if

large quantities of PA hoses with different diameters are

needed every day. The word “Professional” represents the

program-controlled, automatic change between different

hoses with simultaneous very high output quantities.

As well as the integration of diverse lettering and marking

processes, Professional systems are also equipped for auto-

matic storing or coiling and for all available Metzner solu-

tions for unwinding and feeding. Therefore, the Professional

systems guarantee maximum automation and constantly

high production output, independent of operating person-

nel.

A production example (Photo 1) illustrates the performance of

the Professional machines: 65 different hoses with a total

length of 138 m and 41 automatic material changes are pro-

duced in 225 seconds. The same process with storing and

bundling only takes 97 seconds longer.

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control. With the installation of an optional automatic hose

changing unit, the Professional Plus machines become genu-

inely completely automated, selecting and feeding the re-

quired material automatically.

Automatic manufacturing system for up to four differ-

ent hose diameters with integrated second cutting

technology for steel-reinforced hoses.

Metzner Professional Plus is distinguished from all other

Metzner PA machining systems by its “Plus”. The Plus stands

for the additional configuration with a circular knife for the

precise cutting of steel-reinforced hoses. These machines thus

also provide a Plus for versatility and are used everywhere

where steel-reinforced hoses as well as standard hoses are

regularly machined.

The circular knife cut is performed in an enclosed protective

casing with extractor. The Metzner-developed extraction sys-

tem, is doubly effective, as cutting dust is removed from both

outside and inside the hose. Using the material properties

stored in the software, the machine automatically selects the

correct cutting technique for each material.

In the basic version, the hose is inserted on the input side of

the machine by the operator, while all machining parameters

and cutting guides are changed automatically by program

Metzner Profi Plus Version

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Manufacturing system for different hose diameters

with integration of up to two inkjet printers.

The Economy Version provides an efficient solution for hose

manufacture. With the standard PC equipment and the

Metzner software (see page 10), complex machining jobs

are optimised for setting-up times and processed just-in-

time.

Changes to hoses and the associated cutting guides are

performed manually with the basic version. With the

“Automatic Mode” expansion option, both the material

change as well as the change of the product-specific guides

are performed under program control.

The Economy Version is equipped with a length measuring

wheel which provides exact cutting lengths for the PA

hoses. The cut is performed using a hose cutting module.

The Economy systems are combined with one or two inkjet

printers for lettering and marking which are controlled by a

database program and apply freely programmable text,

Metzner Economy Version

logos or markings at any positions. The printing is per-

formed at throughput speed so no time is lost. When using

two inkjet printers, the machines are positioned exactly

opposite each other in order to facilitate good all-round

recognition of the lettering.

Metzner provides the two “Basic” and “Economy” decoilers

(see page 7) for unwinding the PA hoses. A feeder unit and

loop controller give good, even material feed, ensuring ten-

sion-free transport of the PA hoses to the cutting machine at

high processing speeds.

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ensures faultless material feeding. The material change is

always performed manually for the Basic Version.

As standard, the Basic Version is not equipped with lettering

or PC terminal. However, an inkjet printer and PC are option-

ally available at customer request.

The low-cost entry into machine processing of your

hoses.

The Metzner Basic Version provides a good solution for ma-

chine processing of hoses for all tasks where the hose mate-

rial only has to be cut to the right length.

As standard, the machine does not have a PC and database

software and is therefore controlled using the operating

panel. With this recipe control, up to 200 machining pro-

grams can be stored, called up and started at the press of a

button. All machine parameters are also selected using the

operator panel. After completion of a machining process, the

next machining job is ready at the press of a button.

The built-in slip measurement ensures exact cutting lengths of

the PA hoses. The cut is performed using the hose cutting

module. Different hose diameters can be quickly and easily

changed to due to the use of quick change guides.

The PA hoses are unwound using the “Basic” or “Economy”

decoilers. A feeder unit combined with a loop controller

Metzner Basic Version

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Even material feed to the cutting machine is the basic require-

ment in order to achieve high length accuracy at high process-

ing speed.

The Professional Decoiler consists of a completely enclosed

decoiling platform with electric brake, a feeder unit and an

integrated loop controller with a particularly large reserve for

high processing speeds. Automatic threading of the hoses

from the decoiling platform through the complete hose ma-

chining system, eases the task of inserting new hose reels

and enables significant time savings to be achieved.

The Economy Solo and Duo decoilers also provide the

completely enclosed decoiling platform with electric brake and

attached feeder unit. In this version, the loop controller is

placed between the feeder unit and the decoiling platform.

The Duo version is used in very cramped spaces or if more

than six different hoses are to be processed.

With the Basic decoiler, Metzner provides a very economic

and robust decoiler. The braking device is an adjustable, con-

tinuously-acting dynamic (rheostatic) brake.

Dereeling and Feeding

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After the machining, the PA hoses must be stored, coiled or

bundled. Metzner provides two methods for this process.

The coiling machine Metzner CRC 750 coils the cut hoses

quickly and effectively. The coiling speed operates synchro-

nously with and completely drag-free to the processing

speed of the machine using an interface to the cutting ma-

chine. The PA hoses are inserted in the coiler using a guide

tube; the retractable guide pins ensure easy removal after

the coiling process. Coiling is not recommended below a

hose length of 2.5 metres.

PA hoses are often stored in bundles. This is usually per-

formed by a gripper arm which grips the hose after the

cutting and stores it in a bundle magazine. The PA system

operates without interruption when two bundle magazines

are used, the operator removing the hoses from the first

magazine while the second is being filled. Very short hose

lengths can also be stored without problems in the maga-

zine for bundling.

Storing and coiling

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Labelling and Marking

PA hoses must often be lettered or marked for identification

and determination of installation positions. Due to the differ-

ent requirements, Metzner currently provides four different

methods for lettering and marking.

Inkjet printers can apply freely programmable text, logos

and markings during passage through the machine with no

lost time. Inkjet printing is a relatively low-cost process but

the print quality is not as high as with laser printing.

Laser printers also apply freely programmable text, logos

and markings to the hose without loss of time. The print qual-

ity is first-class and this is reflected in the price, which is

higher than for inkjet printers.

As well as text, plastic labels can also be colour-coded. The

print quality of the thermal transfer printer is first-class.

The prices are comparable to those of laser printers.

Coloured marking bands are used for specifying the as-

sembly points. They let the installer quickly recognise at which

places the PA hoses have to be attached to the body shell.

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Metzner provides practically-proven, comprehensive software

solutions for efficient machining of PA hoses. All software

packages provide functions such as the management and

processing of complex parts lists with different hose lengths

and diameters and individual lettering and marking.

Local Mode

Software solutions in Local Mode control the machining proc-

ess of the system and all associated peripheral applications.

All machining parameters are recorded using an intuitive,

logical and easy-to- use control panel and are stored in a

database. Proven data input wizards and help menus support

the data input. Data recording is performed independently

from the production machinery which can continue uninter-

rupted.

Integration in existing IT networks

Many companies control their production using internal IT

networks. In this case, Metzner provides consistent integration

into the existing IT network. All production orders are trans-

ferred online with their own data structure to the machine

controller and are processed. In the other direction, the ma-

chines provide information for the production control. The

company thus obtains a real-time overview of the current

machine state, the production process and all completed and

pending processes. All systems fitted with IT integration can,

of course, also be operated in Local Mode.

Monitoring and optimisation

As an option, each hose can be examined for possible mate-

rial surface defects before the PA hoses are processed in the

machine. In the case of a defect, a signal is sent to the ma-

chine controller which recalculates and optimises which cut

lengths are still possible up to point of the material defect. In

this way, material waste is minimised.

Software solutions

PA Machine

Max. numbers of tubes 12 4 1 1

Automatic change of tubes O ▲ ▲ —

Dereeling & Feeding

Dereeler Professional O O — —

Dereeler Economy Solo O O O O

Dereeler Economy Duo O O — —

Dereeler Basic — — O O

Labelling & Marking

Ink-Jet printer O O O ▲

Laser printer O O — —

Thermal transfer printer O — — —

Marking with coloured bands O O — —

Storing & Coiling

Material feed-out O O O O

Bundle und feed-out O O — —

Coiling O O — —

Software

Local mode O O O O

IT-Integration O O ▲ —

Monitoring and optimisation O O — —

• Based on many successful customer projects, Metzner has

high expertise for automatic PA hose machining and excel-

lent solution competence for your requirements.

• Different solutions: we provide the four machine concepts

presented above for machining your hoses matched to

individual requirements of capacity, budget and degree of

automation.

• You can rely on our wide experience with different letter-

ing and marking requirements such as inkjet and laser

printing, label printing and the application of marking

bands.

• Depending on the requirements, we provide solutions for

destacking, bundling or coiling PA hoses after the machin-

ing.

• Our powerful software packages provide completely auto-

matic hose manufacture in any quantity, length and letter-

ing and integration in internal company IT networks with

integrated quality and status monitoring.

Your benefits

O = available, ▲ = optional, — = not possible

Configuration

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Professional

Version

Profi Plus

Version

Economy

Version

Basic

Version

www.metzner.com

many years for many machining tasks, ideally satisfying cus-

tomer-specific requirements by innovative and well thought

out ideas. As well as the various PA cutting machines, you

can also find numerous solutions from us for:

• Profile machining

• Brake pipe machining

• Hydraulic hose machining

• PUR cable machining

• Corrugated tube machining

Our international sales network in more than 30 countries

provides you with competent advice and fast, effective service.

Make use of our experience and knowledge and talk to us.

Strong collaboration – world wide

With Metzner, you receive quality and competence from one

source. We have been doing our own in-house development

and production for many years. This means you can be certain

that the design is carried out as you have planned with our

development team – faultless, on time and matched to your

requirements.

Due to our many years of experience, we can consider your

requirements from different viewpoints. Potential savings and

productivity increases are thus determined from the technical,

organisational and commercial aspects. The proposals result-

ing from this are implemented by our design team in close

collaboration with you.

After delivery of the machine, we are happy to also train your

employees in order to ensure a smooth production start-up.

Due to our simple and intuitive machine controls, it is often

the case that only a few hours are required for this. For inte-

grated IT applications, we also ensure that your employees are

familiar with all important functions and processes.

We have been a reliable partner to the automotive industry for

Metzner Maschinenbau GmbH Messerschmittstraße 30 | 89231 Neu-Ulm | Germany Phone: +49 731 40199-0 | Fax: +49 731 40199-33