Fiber blowing machines
Fiber blowing machines
The fiber optic cable blowing machines are designed and built in our factory located in Poland (Europe), there are also patented and are affixed with the CE marking. We run warranty and non-warranty services, as well as organize training sessions explaining proper use of these machines (operation is very simple and intuitive) Our fiber optic cable machines are fully professional machines for air blown fiber and microcables, fiber optics cable, copper cables, etc. in the HDPE pipe. The most important advantages of the fiber optic cable blowing machines is its patented construction, design and production technology. We hold from our customers reference that they can blow / jet more than 4800 meters of cable fiber in one piece but our blowing machine is designet to do much more. These machines are versatile, reliable, fast, powerful and most importantly very easy to use.
For the period of 11 years of experience in the sector of fibre optic cables and cooperation with customers, who are participants of a technical dialogue and with whom current experience is exchanged, another idea emerged. The idea involving designing a state-of-the-art generation of fibre optic blow moulding machines, duplicate type casing pipes and so-called packages was implemented throughout 2019. The company worked, designed and did tests in order to make operators’ work smoother and more efficient. For a long period of time the company was informed that our fibre optic blow moulding machines are machines that fulfil expectations of customers. Letters of reference provided and clients informing us on the telephone about new records broken as regards the length of fibre optic cables and reliability of machines motivate us to conduct further activities and develop. We asked ourselves a question, what was the purpose of electronic systems in our machines. The answer was one – we always wanted to provide as simple and reliable structure as possible and ensure reliability. The assumptions were appropriate, however, contemporary technologies allow for implementation of new solutions and ideas. Machines constructed in our times should not only be reliable and failure-free, but also smart and able to control the process of blowing. If we create precise mechanic systems made of appropriate materials using precise machine tools and current state-of-the-art and add a smart controller with a touch panel, we will be able to say that we have opened an new era of machines. The most recent models of machines comply with all European and even more other requirements. The offer for the 1st half of 2020 includes MAH-4, MAH-4 Uniwersal series models. The models may be configured depending on requirements of an ordering person and company.
Automatic work of blowing machine, full printable blowing report
All language support
- Versatility - working range of the machine allows blowing cables from a diameter of 0.8 mm to 35 mm.
- Smart touch controller: two operation modes:
manual – allowing for manual operation, which means that an operator controls settings during operation
automatically – after entering of appropriate data and switching on automatic mode the machines controls the cable feeding process independently and with appropriate force and does not allow a fibre optic cable to be damaged.
- Recording of blowing parameters - cable pressing force measured in Newton (N), fibre optic carrying pressure (bar), blowing speed (m/min), blowing length (m) creation of a chart during operation of the machine
- GPS of the machine location on a map
- Reading of weather parameters - temperature, atmospheric pressure (Hpa), humidity (RH%)
- Wireless connection - machines with ancillary equipment such as a tablet, laptop, telephone etc., date and time
- Report - on moulding is served through an Internet browser, which includes prepared information tables.
- Reliability - The machine is very reliable because: it has a unique design, is very accurate, most advanced production technology, the best selection and quality materials, large amount of bearings resistant to dirt. From the beginning of production we have not received any complaints.
- Speed - The machine is capable of blow aprox. 100 m of cable per minute.
- Power (force) - With the arrangement of the profiled rollers that gird the cable at 90%, we can press it with great force and speed at the same time avoid slipping cable or even his chafing (damaged) or break. In addition, each of the rolls has its own drive, which is passed through the pneumatic gear motor.
- How to operate - By dint of the transparent shield the operator during operation can adjust the pressure force of the cable and chain tension
New model of fiber blowing machines MAH-4
|MAH-4 ELEKTRONIK||MAH-4 UNIWERSAL ELEKTRONIK||MAH-4 PAKIET|
| Fiber blowing machine MAH-4 ELEKTRONIK
High power and lond distance
Fiber diameters 3-18mm
HDPE pipes 5-50mm
|Fiber blowing machine
MAH-4 UNIWERSAL ELEKTRONIK
All fiber diameter in one machine: 1-18mm
HDPE pipes 5-50mm
| Fiber blowing machine MAH-4 PAKIET
Fibers, pipes, pakiets 3-35mm
HDPE pipes 5-50mm
Older models of fiber blowing machines we produced in tree types
|MAH-3||MAH-3 UNIWERSAL||MINI MAH-3|
| Fiber blowing machine MAH-3
High power and lond distance 3-17mm
|Fiber blowing machine MAH-3 UNIWERSAL
All fiber diameter in one machine: 0.8-17mm
| Fiber blowing machine MINI MAH-3
Fiber cable blowing machine functioning
The optic cable is inserted via a set of profile rollers, depending on its external diameter. Each roller is equipped with a mechanical drive conveyed through gears and a chain. The machine has an aluminum rollers with a specially designed rubber. Each roller has an undercut groove adapted to the diameter of the fiber. The optical fiber is pressed over the entire circumference and is introduced with great force. The use of rubber eliminates slippage and tear of optical fiber. The use of rolls with special rubber forgiving operator fault for using too much pressure.
The driving force of the mechanical roller system is a pneumatic gear-motor. The process of cable jetting is assisted not only by the feeder, but also the machine’s head, which receives the compressed air. This is the "piston type” method of cable jetting. A piston is attached to the front of the cable, which fits tight to the pipe. The compressed air pushed the piston, which in turn pushes the cable. The so called mechanical feeder turbine serves as the head. Each machine comes with a set of rollers and nozzles for any cable diameter and can be adapted to any optic or micro cable.
ESSENTIAL INFORMATION ON OPTIC AND MICRO CABLE JETTING TECHNOLOGY (HDPE PIPES)
In order to jet a cable, enough force must be applied, which overcomes its weight and friction force. Fig1. presents a simplified model of this situation.
Fig.1 Forces applied to the cable
The cable will travel through the pipe as long as the friction force doesn’t equalize itself with the pulling and pushing forces.
Fig.2 Distribution of forces in a straight pipe
The friction force is defined by the following equation:
F= m * l * g * u
m – cable absolute mass, l – cable length , g- gravitational force, u – friction factor
Let’s consider an example: a 2000m long cable with a mass of 0.2kg/m and a friction factor of 0.08
F=0,2 kg/m * 2000m * 9,81 m/s2 * 0,08 = 314 N
Assuming that the pipe is straight, a force equal to 30 kG is necessary to overcome the friction force when jetting a 2000m long cable.
Nonetheless, a pipe can never be perfectly straight, so we must also consider a distribution of forces in a curved pipe. This situation is presented in Fig.3. The force applied to the cable with α arc just after the bend equals t: F2 = F1 * eam
Where: e - the basis of a natural logarithm, a u – friction factor.
eam for a 30° arc equals 1.04
eam for a 60° arc equals 1.09
eam for a 90° arc equals 1.13
Fig. 3 Distribution of forces in a curved pipe
For example, for a 90° arc, the force before the bend equals 500N, but after the bend it is 565N – that’s a 13% increase. This fact is worth to remember when planning out cable routes. Another thing worth considering is the fact that our calculations account for effects occurring in a dynamical system. The cable travels through the pipe with a substantial velocity which mostly equals 60m per minute. In the case where the cable stops travelling and needs to me moved again, static friction appears which can be twice as strong as regular friction.
Fig. 4 Piston type method
Now that we know the resistances, let’s consider the forces which enable cable travel.
We can distinguish two basic methods of cable jetting: the piston and streaming types. The piston type uses a piston attached to the front of the cable. Compressed air moves the piston, which in turn moves the cable. The streaming method doesn’t utilize any piston. The pulling force comes from the friction between the compressed air and the walls of the pipe.
Piston type jetting is shown in Fig.4
The force applied to the piston is defined by the following equation:
F = (D2 - d2) * p/4 * P
Where: F – pulling force, D – pipe internal diameter, d – cable external diameter, P – air pressure vs. proper excess pressure (Note: A very common mistake can be made when calculating pressure. If the pressure gauge shows, for example, 10 bars, this amount is considered during calculations. The fact is that there’s atmospheric pressure (about 1 bar) at the front of the piston. It is essential to remember this fact during calculations and subtract the pressure gauge readings accordingly.
For example, a 40mm pipe has the following numbers: D equals 32mm, d of the cable is 16mm and excess pressure equals 7 bars. This gives us circa 420N or 40kG of force.
According to the above equation, the lesser the difference between the pipe’s internal diameter and the cable’s diameter, the smaller the force will get. It is best to use the streaming method when dealing with small pipes and thick cables. The distribution of forces is shown in Fig.5.
The pulling force applied to the cable is defined as follows:
F = n/4 * d * (D - d) * P/T * L
Where: F – Force applied to the cable , P – compressor excess pressure, d – cable external diameter , D – pipe internal diameter, T – route length, L – cable length. This equals to roughly 180 N for 32 - 16 mm diameters and cable/route lengths of 2000m.
Apart from the pulling force, there is also the pushing force originating from the mechanical feeder. This force amounts to 500 - 2000N, depending on the machine and cable stiffness.
The theoretical part ends at this point. We hope that it proves useful and provides an understanding of the jetting process. Knowledge of it helps in making crucial decisions, but the reality is of course much more complicated and there are many deciding factors which must be taken into consideration with the application of this technology.
Fig.5 Distribution of forces in streaming type cable jetting
The factors can be divided into three groups:
1. Material-dependant, e.g. dependant on the cable, pipes, connectors or lubricant
2. Equipment-dependant, e.g. dependant on the jetting machine, compressor, air pipes, cable reeler, additional heads, etc.
3. External conditions-dependant, e.g. dependant on the cable’s route, placement of pipes, weather, temperature, etc.
A compressor with 7 bar air pressure and efficiency of 8m3/min (11m3/min for the streaming method) is the basic requirement. The compressor must be small and light – this helps with manoeuvring – and ideally equipped with an air drier and cooler. Under no circumstances can the air be oiled. The air pipes connecting the compressor and the jetting machine must be flexible, must be able to withstand enough pressure and, most importantly, their connectors must be durable and safe, so the airflow is not throttled in any way.
The jetting machine is the heart of the whole system.
Fig.6 Jetting machine diagram
The jetting machine comprises of the head and the feeder.
The head is a device in which the optic cable and compressed air are transferred to a pipe through a system of seals and nozzles. It is important to choose a proper sealing material, so that it does not cause excessive friction to the cable coating. Nozzle geometry is also crucial, as it adjusts the air current, preventing the formation of harmful vortexes. The decisive factor on speed and comfort of working with this machine is the ease with which various head accessories can be adapted to specific diameters of the cable.
It is important to enable free, but steady unreeling of the cable, as too fast speeds of the reeler can damage the cable. The reelers should be placed on axes with bearings, special stands or trailers with brakes which allow for control of unreeling speed.
Another piece of equipment worth noting is the so called ‘roundabout’. If there are 3000 metres of cable on the reeler, it will be impossible to jet the entire length in one direction using only one machine. The solution is to jet 1500 metres only. Then, the feeder can be used to place the rest of the cable into a special basket equipped with an arm which helps in cable placement. We call this tool a ‘roundabout’. Next, we turn around the jetting machine and, this time reeling the cable from the basket, we can jet the rest of the cable from the other side.
In order to extend the range of jetting, a number of machines can be linked together in a cascade, for example, a couple of jetting machines or one jetting machine with a cable booster. This method, however, requires the use of a larger number of compressors (Fig.7).
Fig.7 Cascade jetting
The range of jetting may differ substantially, depending on the designated route. Each curve or hill shortens the range by a fraction.
High temperature of surroundings, especially in the situation where the compressor is not equipped with an air cooler, may result in cable heating which reduces its stiffness and in turn decreases pushing efficiency. The pulling force is also reduced by lower density of hot air. High temperatures may reduce lubricant effectiveness as well.
High air humidity with temperatures in range of about 0°C may lead to serious complications. The air expanding in the pneumatic engine rapidly decreases its temperature, which leads to freezing of water vapour and icing. As a consequence, the engine gets jammed. The interior of the jetting head may also get iced. To prevent this, use of air driers is highly advisable.
Source: GAMM-BUD Sp. z o.o. Szczecin, ul. Harnasiów 4