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Innovations in pipes cutting and belling  #6(112), 2012

Since 1962 the Italian company Sica S.p.A. is engaged in development and supplying of effective solutions for extrusion of plastic pipes. In May, at the exhibition Plast-2012 held in Milan, Sica presented the latest models of equipment for haul-off and belling of pipes.

Cutting and haul-off pipes with Combo
At the exhibition was presented a special version of combined equipment Combo 110K for pulling and swarfless cutting of plastic pipes, including unplasticized PVC. Combined equipment has a single base and a common electric drive. Machine can be supplied in two versions: with one haul-off and one saw (2x1 model) for single extrusion lines, or with two haul-offs and two saws operating in parallel (2x2 model) for double extrusion lines. Each haul-off has 2 caterpillars: an upper tilting unit positionable pneumatically, and a mechanically height-adjustable lower unit. Caterpillars have chains with high-friction, low-wear neutral vulcanized rubber pads, and there is also the option for belt haul-off configuration, suitable for handling material particularly subject to the risk of deformation and marking.

Constant pulling power at different extrusion speeds is guaranteed by vector drive systems controlled via a closed-loop control system with a speed transducer. The cutting units are synchronized electrically with the haul-off. With the 2x2 version, the two cutting units are driven and controlled independently, enabling the machine to compensate for any difference in speeds of the double-extrusion lines, while their electric drive system ensures high production rates for short pipes even at fast extrusion speeds. Combo 110K is capable to handle pipes with outside diameter of 12 mm to 110 mm and is equipped with rotary cutting units with blade type tools. Exhibited model also incorporates some other special accessories (patent pending).

The Combo range comprises a variety of models differing in terms of the type of obtainable cut and the maximum diameter of workable pipe.

Cutting machine Duet 200
Duet 200 is an innovative automatic inline planetary cutting machine in the Duet series. It cuts and chamfers PP, HDPE and unplasticized PVC pipes with diameters up to 200 mm, performing automatically double-cycles of simultaneous cutting at high extrusion speeds.

In addition to the standard model equipped with disc and chamfer, there are also the Duet/K (for swarfless knife cut) and Duet/C (for chamfering and knife cut without producing chips and dust inside the pipe) versions. The latter versions are particularly ideal for high productivity PP lines and those producing double-socketed pipes. The accurate testing performed directly in extrusion lines and continued product development have allowed the Duet models to attain a new standard of performance efficiency and reliability. The machines are equipped with innovative low-wearing cutting tools that maintain an extremely high quality and consistent cut over time and that reduce drastically maintenance operations. Innovative design and cutting method are Sica-patented and allow the Duet to achieve elevated hourly production rates. For example, the Duet 125 version can produce 2000 cut pieces 150 mm long + socket per hour and can achieve an hourly production rate of over 2300 pipes/hour of length 500 mm long + socket). The Duet 200 can produce 1650 cut pieces/hour of length 150 mm + socket, and 1250 pieces/hour of length 1000 mm + socket.

Belling machine Multibell 75
Multibell 75 is an automatic in-line belling machine that sockets by means of an oven with recirculated and thermoregulated hot air. Machine is designed for double-extrusion lines for unplasticized PVC pipe with 16-75 mm in diameter and 1-6 m in length. It can form solvent cement sockets in a multisocketing process with external cooling by pre-cooled compressed air and internal cooling by water in the mandrel.

Ring seat sockets are formed by air-blowing against external molds, external cooling of the socket with water circulation in the molds, and internal cooling of the socket with water circulation in the mandrel. Version Multibell 75 Plus has a new pipe handling system for double-extrusion lines with productivity that is independent of the extrusion and pipe-feed speed, which makes possible the handling of extrusion speeds of up to 25 m/min with no waste, achieving
maximum productivity of 1100 sockets/hour with solvent cement sockets in the 4 pipe version that processes an external diameter of 32x1,8 mm. The pipe is heated in a high-capacity thermoregulated hot air oven with a built-in device for the final positioning and alignment of the pipes; that guarantees the uniformity of the socket dimensions in multisocketing processes, thanks to the setting of the pipe portion length to be heated for socket forming, and the perfect lengthwise alignment of the pipes after heating and before the forming stage.

Belling machine Unibell 200JW Plus
Demonstrated at the expo Unibell2 200 JW Plus represents a new range of Sica “Unibell J” belling machines, designed for pipes of unplasticized PVC (version with Rieber cycle is also available). These belling machines feature new processing technology for socket moulding in pipes, significantly increasing production capacity, taking up less space and reducing running costs, while offering operational simplicity and reliability. Exhibited machine processes pipes with a diameter of 32 mm to 200 mm and a length of 0.5 m to 6 m, achieving productivity for SN4 110 x 3.2 PVC-U sunken waste pipes of 300 sockets/hour with a mechanical mandrel cycle. The side of 1900 mm length has two heating stations and a molding station. Heating takes place only while the pipe is actually in the heating station and until the end heating temperature has been reached. It makes possible to reduce heating duration and hence - energy consumption. The moulding process uses a Sica patented system which forms the inside of the socket against the mandrel while cooling is taking place with compressed air. The latter is previously treated within special thermodynamic cycle as processing fluid to achieve optimal temperature, pressure and hydrometric conditions.

Due to all these the benefits are achieved  in terms of productivity, socket quality and energy consumption. Productivity is further increased through the injection of pressurised water mist into the processing fluid. The mechanical and system devices destined for quicker and safer pipe format changes are also important; of these, the Sica patented rapid securing system for the socket moulding unit is particularly noteworthy.


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