![](https://ahp-makina.com/wp-content/uploads/2017/04/cnc-wire-winding-f.gif)
Electrofusion Fittings Solutions from AHP PLASTIK MAKINA
Manufacture of Electro-fusion Fittings Using the AHP Engineering Systems and Production Methods
Production Methods
>EF Fittings=> 1.Socket Fittings 2.Saddle Fittings
>Socket Fittings Production=>
1.(Injection of Insert Part)+(Wire Winding of Insert)+(Injection of the Body of the Fittings)
2.(Winding of Metal Insert)+(Injection of Body of the Fitting)
3.(Injection of the Body of the Fitting)+(Wire Laying)
>Saddle Fittings Production=>
1.(Injection of Pad Insert Part)+(Wire Winding of Insert)+(Injection of the Body of the Fittings)
2.(Injection of Pad Insert Part)+(Wire Laying of Insert)+(Injection of the Body of the Fittings)
What is Socket Wire Laying?
>Internal Diameter is Sized
>A helical groove is formed in the internal surface of a moulded fitting or section of pipe(for making PE couplers from PE pipe)
>Resistance wire is laid in the groove
Whole process will be done in one CNC machine
Wire Laying Benefits
Reduced injection moulding <> Increased utilisation of cycle times moulding machines
Moulded fittings are in a stable <> Produces high tolerance condition during wire laying products
Improved welding tolerance <> Increased strength of weld between pipe and fitting
Computer controlled process <> Giving flexibility and reduced setting time
Process reduces capital <> Reduces setting times and set-up costs is easy to operate
Production Overview
Fittings are designed in accordance with:
>ISO Standard 8085-3-2001 (E), EN1555-3:1999 and EN12201
>Fittings are socket and saddle type with resistance wires inserted into contact faces
>Equipment is CNC controlled so the design specifications can be changed during testing
Electrofusion Terminology
Types:
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-180841-1-2-1024x468.png)
Socket Coupler
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-180953-1-2-1024x681.png)
Tapping tee
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181039-1-2-1024x768.png)
Equipment Description
>Horizontal wire laying machines with FANUC or SIEMENS CNC controllers
>Design layout allows easy access for set-up and component loading using hydraulic grips or pneumatic grips
>3-axis CNC control system enables optimum production cycle times and repeatability
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181154-1-2.png)
Basic Machine Operation
>Special fixtures located on main spindle of wire laying machine
>Moulded fittings or pipe sections are manually loaded into fixtures and automatically gripped by hydraulic or pneumatic system
>Each fixture is suitable for a range of fittings by only changing end holders of main fixtures
Boring and Wire Laying
In 3 main steps:
> Boring and Chamfering
> Wire Laying Cycle
> Final Boring
Control System
>The CNC system is pre-programmed for the production of each fitting
>Changes can easily be carried out by the operator to incorporate any modifications required in production cycle
>Machines have a memory to store each fitting data
Operating Sequence
>The fitting is manually loaded into the main fixture
>The boring cycle starts at high speed to bore the internal diameter
>The machine is programmed to stop the laying tool at the first termination point
>The wire is manually hooked through the termination hole
>A program is then run which lays wire into the inside surface of the fitting
>The cycle stops when the laying tool reached to the second termination hole
>The wire is manually pulled through the second termination hole
>The boring bar finishes boring to remove any excess material
Snap Ring
>The boring bar is doing 3 jobs at the same time: boring+making the slot for stop ring+wire laying
>The snap ring is pushed into the bore of the fitting until it engages with the machined groove
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181527-1-1024x640.png)
Terminal Pin Mounting
Procedure for Socket Fittings
1.Load terminal pin into press tool
2.Trim wire to length inside terminal housing
3.Place fitting onto mandrel
4.Press terminal pin into fitting
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181647-1.png)
AHP WL200 Horizontal Wire Laying
Typical Fitting Capacity
sockets / couplers : 25 to 180mm I/D |
elbows : 25 to 90mm I/D |
tees (equal) : 25 to 90mm I/D |
reducers : 25 to 180mm I/D |
Metal Mandrel Process
•Mandrel Winding
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181758-1-1-1024x387.png)
•Mandrel put in the mold
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181859-1-1-1024x383.png)
•Take out the mandrel to cooling station and taking mandrel out from injected coupler
![](https://ahp-makina.com.tr/wp-content/uploads/2023/05/Screenshot-2023-05-24-181947-1-1-1024x391.png)
Technology Consultancy
AHP can offer an electrofusion technology consultancy program
a comprehensive guide to producing electrofusion fittings, and includes CAD design of fittings and relevant components, as well as preliminary electrical data
Package Includes
Component Design
> Fittings design drawings
> drawings of terminal pins, snap rings and other associated items
> initial electrical characteristics, including wire type and size, fusion details and fitting resistance details
> finished drawings of components
>AHP Barcode Creator Software
> software for creating 24-bit barcodes (coding is carried out according to ISO/TR 13950)
>Technical Support
> 12 months technical support by fax or e-mail
![](https://ahp-makina.com/wp-content/uploads/2023/05/wire-laying.gif)