Application: Pipes
FDC –
Fast Dimension Change
FDC – Fast Dimension Change
Complete lines and modules from single source
• Automatic pipe dimension change during production
• Efficient pipe extrusion line with high througputs
• High flexibility in pipe geometry and production planning
• Low energy consumption and highest productivity by
high-performance extruders with inner pipe cooling system
• Easy handling due to Industry 4.0-compatible control system
• Excellent pipe quality with homogeneous
pipe surface and even wall thickness distribution
Speed and cost efficiency
• Production of several different pipe sizes
with one line without production stop with
fast dimension change FDC
• Modular concept, from changing one adjustable component to an automated scalable
extrusion line, e.g. diameters 200 to 630 mm
Page 2 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change
FDC system applications
• PE-HD single layer, as well as
co-extruded multi-layer pipes
FDC – Fast Dimension Change
Single screw extruder and pipe heads
The FDC system can be delivered as a complete solution or components
can be choosen to retrofit existing lines for automatic dimension change.
Single screw extruder
The solEX, solEX GL and solEX NG extruder series
were designed for high-performance extrusion of
PE-HD and PP. They are ideally suited for large diameter pipe extrusion thanks to their high troughput
rates. With a processing length of 40D, they are
powerful extruders that enable gentle plastification
with a large processing window.
Advantages:
• Diameters from 45 to 150 mm, L/D ratio 40:1
• High throughputs from 100 to 2,750 kg/h
• Extremely space-saving thanks to high
performance with smaller screw diameters,
therefore also well suited for co-extrusion in
combination with the proven uniEX machines
Pipe head with adjustable melt gap
The adjustable melt gap enables adjustments while
the extrusion line is running. There is no change of
sleeve and mandrel needed, which is usually necessary with every change in the pipe dimensions.
The sleeve of the die is pushed in axial direction
over a conical mandrel and depending on the sleeve
position, a wider or a narrower melt gap is formed.
This concept suits mono-extrusion and co-extrusion.
Advantages:
• Adjustable melt gap with an electric motor
available in sizes from 63 to 1,600 mm
• SDR classes of 11-33 possible, additional versions
(e.g.: SDR 9-26) on request
• Adjustment independent of melt pressure,
as only the die/mandrel area is being adjusted
• Large diameter ranges with changeable die and
mandrel extensions
• Can be used in combination with the effective
melt cooling system Optimelt to reduce sagging
• Retrofit possible for existing pipe heads
Helix 800-4 with 4-layer pipe
head with maximum melt gap
• Optional integration of outer layer distributor in
the adjustable melt gap for faster color changes
• Customization to your production on request
4-layer co-extrusion line with solEX 75
and three uniEX single screw extruders
for the inner and outer layers
Page 3 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change
Adjustable FDC melt gap 800 with
an electric motor and an adjustment
range from 200 - 800 mm
FDC – Fast Dimension Change
Calibration sleeves and vacuum tanks
The FDC calibration sleeve and the vacuum tank vacStream
enables excellent pipe quality by high line speeds.
Adjustable FDC calibration sleeve
The FDC calibration sleeves are availabe for four
dimension ranges. The sleeve body is based on the
principle of a rolled steel sheet. In form and surface
this comes close to the design of a conventional
calibration sleeve that is usually used for these
dimension ranges. The uniform water cooling in
the inlet section of the calibration sleeve enables a
homogeneous pipe quality without water marks.
Vacuum tank vacStream
In the vacuum tank, the pipe is placed on roller supports that can be height-adjusted. This ensures centred pipe positioning moving through the tank and
evenly cooled. Thanks to the pipe support along t
he circumference, perfectly round, high-quality
pipes can be produced. An addition for automatic
dimension change is the direct control of the
vacuum pump. This ensures energy savings of up
to 40% for vacuum pump performance.
Advantages:
• Uniform pipe surface independent
diameter and line speed
Advantages:
• Continuously adjustable pipe support
• Cylindrical form of calibration sleeve for smooth
surface and round pipes
• Large adjustment range without manual adaption
(e.g.: 110 - 630 mm)
• Excellent wall thickness distribution
• Perfect support for 180° of the pipe circumference
• Fast change between FDC calibration sleeves is
possible (e.g. from 250 - 400 mm to 400 - 630 mm)
• Partial influence in single areas possible
• Perfect cooling in the calibration sleeve enables
excellent pipe quality at high line speeds
• Less haul-off forces due to pipe scrolling support
• Possible retrofit in lines that use BMCtouch control
FDC 630 calibration
sleeve (400 - 630 mm)
Page 4 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change
• No marks on the pipe surface
• Even and i ntensive spray cooling due to optimal
distribution of the spray nozzles
Adjustable pipe support in the vacuum tank
(top maximum to bottom minimum)
FDC – Fast Dimension Change
Vacuum sealing and cooling tanks
Safe and relaible vacuum sealing and equal spray cooling bathes
complete the cooling length perfectly.
Continuously adjustable vacuum sealing
The continuously adjustable FDC vacuum sealing
consists of a rubber membrane formed like a double cone and set in a casing. A vacuum is created
between the rubber membrane and the casing.
Depending on the vacuum, the sealing can be
opened wider or smaller and thereby adjusted to
the different diameters within the range.
Cooling tank coolStream
The cooling tanks are fitted with adjustable pipe
support rolls that can be set to the required pipe
diameter via a central control unit.This ensures
pipes are always centered in the cooling tank,
independent of pipe diameter.
Advantages:
• Simple design without moveable mechanical parts
• Pipe support with form rolls optimized
for the diameter range
• Wear-resistant cloth on the inside prevents direct
contact between pipe and rubber membrane,
thus increasing the sealing‘s lifetime; thanks to
the low friction, the pipe runs very smoothly
• Spray tank connection via connection tunnel
Advantages:
• Spray bath made from stainless steel
• Flexible inlet and outlet sealing
• Easy operation thanks to separate control terminal
• Retrofit possible in existing extrusion lines
• Adjustment ranges of the vacuum sealing are
identical to the ranges of the calibration sleeves
Adjustable vaccuum
sealing inside view
Adjustable vacuum
sealing with cloth
coolStream 800-6 cooling tank with a length
of 6 m for pipe diameters up to 800 mm
Page 5 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change
Pipe support roll
(form roll) in the tank
FDC – Fast Dimension Change
Caterpillar haul-off and control system
All downstream components are designed for automatic dimension change
and are adjusted to the new diameter via the BCtouch UX control.
Caterpillar haul-off pullStream
In the pullStream multi-caterpillar haul-off, lower
caterpillars are adjusted by electrical drives and
upper caterpillars are pressed against the pipe by
pneumatic pressure for automatic range change.
Advantages:
• Adjustment of both lower and upper caterpillars
by electrical drives as option for thin pipes
• Optional separate adjustment of caterpillars in the
inlet and outlet area for secure grip of pipe cone
• Security function by cone monitoring
BCtouch UX line control
The BCtouch UX enables automatic dimension
change according to a specific process stored in
a recipe. The control system coordinates all line
components that need to be adjusted for a pipe
dimension change. The process starts with the adjustment of the melt gap, the calibration sleeve and
the working point of extruder and haul-off. Then,
all other components are adjusted to the new pipe
diameter upon entry of the pipe cone.
Advantages:
• One control terminal for extruder and FDC system
• Overview of beginning and end of pipe cone
Cutting unit cutStream with FDC function
The cutStream cutting devices are available prepared for automatic dimension change. All pipe
supports and central clamping unit are adjusted
automatically to the new pipe diameter.
• Option for manual operation of FDC components
• Modular set-up enables different extension stages
• Retrofitting of FDC function possible for existing
BMCtouch terminals
Advantages:
• Pneumatically operated central clamping device
• Swarf-less pre-cutting unit and main cutting arm
• Separate adjustment of inlet and outlet during
range change to secure grip of pipe in cone area
• Integration of cutting program in the process
cutStream cutting unit with
central clamping function
Page 6 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change
pullStream R 800-VEZ haul-off
with startStream start-up aid
FDC – Fast Dimension Change
Overview of FDC line
1 Extruders
• solEX / solEX GL / solEX NG single screw
extruders
• For co-extrusion lines uniEX and coEX single
screw extruders are used in addition
3 FDC adjustable calibration sleeve
• Change of calibration diameter during
production
• Cylindrical calibration sleeve with
repeatable water adjustment
2 Pipe head with adjustable melt gap
• Enables adjustment of melt outlet gap
during production
• No time-consuming changing of tooling
4 Vacuum tank vacStream with
adjustable pipe support
• Automatic adjustment of pipe support
during dimension change
• Perfect pipe support over 180°
1
2
5 FDC adjustable vacuum sealing
• Adjustment of sealing diameter during
dimension change
• Secure sealing of vacuum tank
6 Downstream components
• Cooling tank coolStream (6a)
• Haul-off pullStream (6b)
• Cutting unit cutStream (6c)
• Tilting table (6d)
• All downstream components are designed for automatic dimension change and
are adjusted to the new diameter at the
right time via the BCtouch UX control
3
4
5
6a
6b
6c
Overview FDC line
6d
Adjustable melt gap
Diameter range (mm)
Extension set Diameter (mm)
160
90 - 160
63 - 90
250
140 - 250
75 - 125
400
250 - 400
140 - 250
630
400 - 630
200 - 355
800
450 - 800
250 - 400
1200
900 - 1,200
500 - 800
Note: standard version SDR 11-SDR 33 (diameter/wall thickness ratio); additional dimensions available on request.
Adj. calibration sleeve 160
Diameter range (mm)
90 - 160
Supersize Diameter (mm) 75 - 125
250
400
630
Adj. vacuum sealing
160
140 - 250 250 - 400 400 - 630 Diameter (mm)
90 - 160
200 - 355 Supersize Diameter (mm) 75 - 125
Note: combination of two sleeves in one line possible
250
400
630
140 - 250 250 - 400 400 - 630
200 - 355 -
Note: additional sizes available on request
Adjustable pipe support in the vacuum tank
Diameter (mm)
Type
160
20 - 160
Half shells
250
400
630
800
1000
63 - 250
75 - 400
110 - 630
200 - 800
315 - 1,000
Roller support Roller support Roller support Roller support Roller support
Adjustable pipe support in cooling tank
Diameter (mm)
160
20 - 160
250
63 - 250
400
75 - 400
630
110 - 630
800
200 - 800
1000
315 - 1,000
Haul-off (pullStream)
Diameter (mm)
Speed (m/min)
Haul-off force (N)
R160-3 VE
20 - 160
0.4 - 20
9,000
R250-6 VE
63 - 250
0.2 - 10
30,000
R400-6 E
75 - 400
0.1 - 5
30,000
R630-6 EZ
75 - 630
0.07 - 3.5
30,000
R800-6 VEZ
160 - 800
0.07 - 3.5
60,000
R1000-8 VEZ
315 - 1,000
0.05 - 2.6
80,000
Note: additional haul-offs available on request
Cutting unit
Diameter (mm)
Max. speed (m/min)
RTAplus 160 RTAplus 250 RTAplus 400 PTAplus 630 PTAplus 800 PTA 1000
20 - 160
20 - 250
63 - 400
110 - 630
110 - 800
280 - 1,000
20
20
10
6
6
2
Note: additional cutting units available on request
Page 7 – © battenfeld-cincinnati Group 2019 – Product Datasheet: FDC – Fast Dimension Change