OUR TECHNOLOGY

COMPACT FIBRE FORMING STATION

An ideal platform for fibre and sizing development for universities, institutes and companies working with composite materials. The COMPACT FIBRE FORMING STATION can re-melt pre-melted glass in the form of pellets, marbles or broken glass and process it into continuous filaments. A bushing with 200 tips is available for this purpose, which can produce a yarn of approx. 58 tex. The basic version is equipped with a central control system for setting and recording all parameters. The bushing is resistance heated. The measuring and test chamber can be adapted to your needs with modules or functions.

TECHNICAL DATA

Length x Width x Height:
Weight:
Bushing height:
Production chamber (Width x Depth):
Melting capacity (@ C-Glass / Pellets):
Electrical connection:
Cooling water connection (Circulation):
Compressed air connection:

280 x 128 x 228 cm
approx. 2600 kg
190 cm
112 x 78 cm
5.5 kg/h
3~ 400 V, 50 Hz, 63 A
120 l/min (Δt=5 °k) 2 bar
350 l/min (8 bar)

DESCRIPTION OF THE BASE MODULE

The COMPACT FIBRE FORMING STATION consists of a partially powder-coated stainless steel frame. The panels are also made of stainless steel and can be easily opened with a release tool. All elements required for the operation of the station are housed behind the panels, ensuring a tidy and protected design.

The production chamber is equipped with doors made of safety glass that can withstand thermal shock and can be opened completely, ensuring optimal accessibility to the chamber for assembly and maintenance work. The remelting bushing is located centrally in the upper area of the production chamber and positioned so that it can be easily operated. It is supplied with power by a resistance heating circuit, the temperature of which is precisely controlled by sensors. An integrated automatic heating up and down system enables a time-controlled start-up of the bushing and thus ensures optimal use of the operating personnel’s working hours.

The system is designed for continuous operation and is specially optimised to reliably produce small production quantities.

A central control unit monitors all sensors and actuators, whose status is clearly displayed on the swivelling control panel. All measured values and settings are continuously logged to enable a detailed evaluation after production.

For maximum flexibility, recessed aluminium system profiles are integrated in the production chamber to enable secure attachment of the equipment. In addition, a well-thought-out cable duct ensures that the cabling inside the chamber is neat and safe.

MODULES

BUSHING

The bushing is the central element of the fibre production and is located at the top in the middle of the production chamber. There are basically two different types of remelting bushings in our standard programme: the low-melting and the high-melting series. In the low-melting version, the remelting bushing is supplied with one heating circuit, while two heating circuits are used in the high-melting series. Both series are made of a platinum-rhodium alloy that has proven successful in the glass industry. Depending on the glass to be melted, the bushing has a melting capacity of 5.5 kg/h, from which high-quality fibres can be drawn. For example, a 200-tip bushing with a single fibre diameter of 12 µm can be used to spin a yarn of 58 tex. All bushings are equipped with several thermocouples and measuring devices to ensure optimal control and monitoring. If you have special requirements or wishes regarding single fibre diameter or thread weight, we also offer customised solutions. Just get in touch.

GLASS LEVEL CONTROL

To relieve the operating personnel in the production of small series, we offer an automatic feeding option for both the low- and high-melting base model. Marbles, pellets or glass cullet can be filled into the material hopper.

An automatic conveyor system transports the material to a scale, where the mass is precisely recorded. The weighed cups then transport the glass to the bushing and dispense it with precision. To ensure an even temperature distribution in the bushing, there are two discharge points that are approached in a targeted manner. This allows the amount of material fed in to be controlled very precisely, guaranteeing a consistently high thread quality.

In combination with a filling level sensor, the automatic feeding system can also perform fully automatic readjustment. This not only reduces the workload for the operating personnel, but also enables precise control of the thread diameter produced.

AUTOMATIC FEEDING

WINDER

Our semi-automatic winder is equipped with cardboard tubes for winding the fibres and can reach winding speeds of up to 2300 m/min. The integrated thread guide moves the thread in an oscillating motion over the winding tube, whereby the position and path are freely programmable.

The winding shaft has a separate track for piecing, onto which the thread is manually placed and then brought up to speed. As soon as the required speed is reached, the winding process begins. This ensures that only threads with the correct diameter are wound onto the bobbin.

As soon as the desired winding quantity or winding time is reached, the process stops automatically. The finished bobbin can be removed from the winding shaft without tools, a new cardboard sleeve can be fitted and the bobbin can be prepared for the next winding process.

PHASE CONVERTER

The COMPACT FIBRE FORMING STATION uses single-phase melting transformers that are directly connected to the mains, which can lead to an uneven load distribution. If a balanced load distribution is required, we offer a special option that ensures equal utilisation of all three phases – the AC-to-AC converter.

WATER CHILLER

If there is no cooling water supply in the building, a separate cooling water circuit can be installed. In this case, the waste heat is either discharged into the room or outside via an exhaust air pipe. With this variant, there is no need for a conventional cooling water connection. Only a connection for filling the internal cooling water circuit is required.

AIR CONDITIONING

This option allows precise control of the airflow and temperature in the production chamber. Without air conditioning, uncontrolled air movements and temperature fluctuations occur in the production chamber, which in some cases are not a problem. However, during the production of thin fibres, these fluctuations can cause breaks and disrupt production.

With the air conditioning option, the air in the production chamber can be specifically regulated. It is blown in through flaps at the top of the chamber and sucked out at the bottom. This means that the air moves in the direction of the fibre flow, thus minimising turbulence. The sucked-in air is cleaned by built-in filters and processed in the air conditioning system before it is returned to the production chamber. The air inlets are equipped with flanges that can be individually equipped according to requirements.

LINEAR UNIT

The linear unit is designed for horizontal installation and is screwed onto the mounting frame, with a screw-on surface available for attaching the equipment. The equipment mounted on it can be positioned electronically with an accuracy of 25 µm, whereby the sequence can be programmed via the central control system. The system can support loads of up to 25 kg (max. 50 Nm) and enables high-precision positioning of the equipment relative to the glass fibres.

The flexible adjustment of the position – both before and during the production process – opens up new possibilities for the precise measurement and coating of glass fibres. This not only improves the quality and reproducibility of the measurement results, but also the development of innovative fibre products.

DRIP TRAY

The drip tray is mounted on its own rollers and can be attached to the base module using turnbuckles. This makes it easy to remove if necessary, for example for conversion work in the production chamber. The top side is covered with a walkable grating that safely collects dirt and liquids. For cleaning, the three gratings can be removed by hand without tools. The collected liquid is drained off via a side waste water drain. If required, the collection tray can also be equipped with a pump.

MOUNTING FRAME

The easy-to-install and move mounting frame serves as a base for winders, applicators, linear units or customised devices. The traverses consist of solid aluminium system profiles to which the equipment can be attached with standard bolts.

APPLICATOR

The illustration shows a roller applicator with a ceramic coating that is suitable for a wide range of fibres. It is used primarily for silane-based sizes for fibre diameters of 10 to 30 µm. The applicator is easy to clean and all components can be disassembled by hand without tools.

Our portfolio includes a variety of other applicators, including tape and single fibre applicators with different coatings. If you cannot find a suitable applicator for your application, we will find a customised solution. Just get in touch!

MELTING - FURNACES FOR ALL TYPES OF FIBRE PRODUCTS

Glass melting furnaces are designed and engineered to transform raw materials into molten glass. Molten glass is then transferred through feeder and forehearth to bushings to form fibres. These furnaces are made from special type of refractory material and heated with natural gas, electricity or combination of both.

OUR TECHNOLOGY

COMPACT FIBRE FORMING STATION

TECHNICAL DATA

DESCRIPTION OF THE BASE MODULE