flocking systems for low and high volume production · 2018. 4. 10. · page 12/13 lines for...

Flocking systems for low

and high volume production

maag f lock

*maag_maschinenprospekt_E_Ti 21.04.2006 10:02 Uhr Seite 3

Competence “Made in Germany”

With decades of experience, Maag Flock-maschinen supplies concepts, lines andequipment for flocking an extremely broadrange of products around the world – fromhand flocking units for model and prototypeconstruction to customized, fully automatedlines for high volume production of three-dimensional molded parts. No other manu-facturer anywhere in the world offers asimilar range of products and services fromconsulting to its own metrology.The systemsand machines of the market leader are allproduced in the region.They testify to topquality and competence – because they are“Manufactured in Germany”.

Flock material consists of close cropped textile fibers.When electrostatically charged,millions of these fibers – in some cases withpneumatic support – are enclosed verticallyin a substrate coated with adhesive.Thisresults in functional, durable, high-qualityseamless textile surfaces. Such production isinexpensive and reliable.

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*maag_maschinenprospekt_E 21.04.2006 9:51 Uhr Seite 2

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Contents

Page 4/5Customer examples:Fully-Automated Line for Flocking Glove Boxes

Page 6/7Fully-Automated Lines for Flocking Glove Boxes

Page 8Semi-Automated Lines for Flocking Molded Parts

Page 9Lines for Flat Surface Flocking of Blanks

Page 10Lines for Flocking Greeting Cards

Page 11Lines for Flocking Ribbons

Page 12/13Lines for Flocking Profiles

Page 14/15Lines for Flocking Rubber Profiles

Page 16Control and Switch Cabinets

Page 17Machines for Flocking Textiles

Page 18Machines for Flocking Textiles,Floor Mats and Blanks

Page 19Machines for Cleaning Flocked Textiles

Page 20Lines for Flocking Small Objects

Page 21Transfer Lines for Flocking Molded Parts

Page 22/23Hand Flocking Units

Page 24Manual Units for Flocking Molded Parts

Page 25High-voltage Generators

Page 26/27Testing Equipment


4

Fully-Automated Line

for Flocking Glove Boxes

Molded parts with large recesses, like gloveboxes, act like a small Faraday cage, and therefore do not permit purely electrostaticflocking. A large part of the flock used wouldnot reach the inside of the box. As a result, acombination of air and electrostatic is used in such cases.The flock is automatically dosedin an air stream, charged when it passes ahigh-voltage electrode and blown to theobject.The flock quantity, air stream and high-voltage can be infinitely adjusted.

Three-dimensional molded parts can beflocked both with hand flocking units and infully-automated lines.The necessary degreeof automation is developed together withthe customer depending on the product.Corresponding flocking lines are completelycontrolled over all automation stages andadapted in their modular design to the indivi-dual needs of the customer. Whether it isauxiliary electrodes, nozzle or movementadjustment – extensive detailed knowledge isrequired for a customized design. However,the engineering and consulting competencewhich forms the basis for comprehensiveknow-how in the areas of technology, orga-nization and process planning remains decisiveduring the entire project planning phase.


5

Roberto Schuster, CEO of Schuster GmbH,

“At Maag I stood at the door more or less with a glove

compartment under my arm. Soon thereafter a complete

flocking line was installed at my company. It enabled me

to comply with my customers’ closely calculated economic

specifications regarding the reliable production of high-

quality parts.”


6

Fully-Automated Lines for Flocking Glove Boxes

High volume requirements in productionalso make comprehensive automationimperative for flocking.The customer´srequest for absolute process reliability isbest fulfilled with a practical interlinking ofautomated line modules. On the otherhand, the smallest possible amount ofmanual labor is required for flocking pro-cesses of this kind. All order parametersare specified, verifiable and can be recor-ded with error logs via PLC. In addition,the flocking quality is checked in final inspection with our testing equipment.

C

C D E

F

B


7

Pre-TreatmentAdhesiveApplication Flocking Pre-Cleaning Drying Final Cleaning

A. Widely varying requirements are placedon technical molded parts. Many sub-strate materials require appropriatepre-treatment.

B. The adhesive is applied in a spray booth:either manually, via manually-guidedsystems with partially automated move-ment sequences or fully automatically by robot.

C. In a complex line, flocking can be carriedout either with a mechanical swivelingunit and moving axis systems or with afreely-programmable robot.

D. For special product requirements, the parallel use of different flock types is necessary. This places the highestdemands on planning, construction andinstallation of the line. We develop reliable solutions with separate materialcircuits for this purpose.

E. In the pre-cleaning stage excess flockmaterial is vacuumed off and returned forre-use in the circulation system.

F. Fully automatic drying process with suspension conveyor system.

G. The results of final cleaning are ready-to-install components which are virtually freeof loose flock fibers.

A

C

E

B

D

F

G



8

Semi-Automated Lines for Flocking Molded Par ts

Even in semi-automated lines, the entire core process is automated. Flocking takes place with PLC support, controlled and free of manual influences.

A. Flocking is carried out via blowing nozzles with a PLC-controlledmovement arrangement.

B. As the next step in the cycle, pre-cleaning is controlled via programming.

C. A mobile extraction unit is used to collect the excess flock material. It vacuums off the entire line with permanent vacuum, which ensures minimized flock carry-over to the outside.

D. As in fully-automated lines, the modern, high-voltage supply, whichis also PLC-supported, ensures process reliability.The high-voltageconnected to the actual parts has a crucial effect on the qualityof flocking.

A

B

C

D

DA B


Screen printingAdhesiveApplication

Flocking Pre-Cleaning Drying Final cleaning

9

Lines for Flat Surface Flocking of Blanks

E. The entire process is completely controlledvia PLC and enables permanent fault moni-toring and traceability; all processing and voltage parameters are recorded continuously.

A

C

B

E

A

C

B

E

D

Lines for flocking surfaces are usually usedfor the continuous flocking of fabric yardgoods, films or paper, however can also be used for flocking metal, plastic or woodpanels and flat objects.The design of the line depends on the substrate to be flocked,the planned production speed and the flocktype.

A. PLC-controlled DUO dosing boxes ensurean even flock application and provide forhigh process reliability.

B. A pneumatic flock recovery system assures gentle material transport into themachine circuit.

C. The vacuum technology in the central flockcollection and extraction unit removesexcess flock material continuously undervacuum.

D. Pre-cleaning unit


Screen printingAdhesiveApplication

Flocking Pre-Cleaning Drying Final cleaning

10

Lines for Flocking Greeting Cards

In the line shown, folded greeting cards areflocked at high speed while being passed.In this case a standard line was modifiedfor flat surface flocking on the customer’sspecific request.

A. The adhesive is applied in one or tworows with a screen printing machine.

B. Flocking is carried out via several DUOdosing devices. Excess flock from themachine and the pre-cleaning unit is con-tinuously collected by an extraction unitand fed back into the flock dosing units.

C. The pre-cleaning system is an encapsu-lated system in order to not erect thecards. Excess flock is blown off and ex-tracted under vacuum.

The transfer dryer is designed individuallydepending on the product, the produc-tion speed and the adhesive used.

A

B

C

B

C



11

Lines for Flocking Ribbons

Ribbons are continuously flocked whilebeing passed. Flocking can be one or multi-row up to a ribbon width defined by the customer.

Examples:

A. Gift wrapping ribbons

B. Flock tape

A

B


12

Lines for Flocking Profiles

Continuous profile flocking basically is fea-sible for a big variety of profiles. Depen-ding on the substrate, line systems withdifferent characteristics are employed, forexample for EPDM and TPE profiles, orhard profiles of aluminum or PVC. Flockingis electrostatic and electrostatic-pneumatic,even enabling high-quality flocking ofrecesses and undercuts.

A. Customer-specific integration of profileflocking machine

B. Flocking aluminum profiles

C. Machine combination for rubber flocking

A

B

C


13

Line Components for Profile Flocking

A. Pre-treatment is carried out via mechanicalroughening.The abrasion brushes can be continuously moved and swiveledhorizontally and vertically, which allow to match them to all profile shapes.

B. As an alternative pre-treatment method,plasma-treatment (electrochemical pro-cess) is used.

C. The adhesive is applied with rollers,brushes or micro nozzles.

Pre-TreatmentAdhesiveApplication Flocking Pre-Cleaning Drying Cooling Final cleaning

A

B

C


14

Lines for Flocking Rubber Profiles


Depending on the type of profile used,the separate line components arecombined practically and individually.

A. P/F-800-L flocking machine for mere electrostatic profile flocking with auto-matic flock return.

B. P/F-E/P flocking machine:The electrostatic-pneumatic flocking guarantees that evenwith complicated shapes, undercuts andrecesses can be reliably flocked.

C. Excess flock material is vacuumed off in the pre-cleaning section.

D. Flock extraction and collection unit withrefilling option for fresh flock.

A B

C D


15

Drying

Hot air in combination with an IR heatingsection at the dryer entrance guaranteesfast heating up of the profile surface andthe uniform drying of the adhesive.

A. THL-IR-1,8 G dryer

B. Temperature monitoring

C. Dryer open with radiator in operation

D. IR transfer dryer

E. Control panel

Cooling

F. The adhesive is solidified in a cooling section to prevent the flock surfacebeing damaged during final cleaning.At the same time, the profile cools forimproved handling.

Final cleaning

G. In the final cleaning section, adhering particles are brushed off from all sidesand vacuumed off via a cyclone.


A

B

D

F

G

C

E


16

Control and Switch Cabinets

A higher-level control system with a wellthought-out control concept reflects onthe line control of the entire line; all command values are transferred by meansof bus systems.The integration in largerproduction lines is based on customer re-quirements to the greatest extent possible,however the control system also operatesindependently if necessary. Basically, allcommon signals can be adopted on thecustomer side. Illustrated menus simplifyoperation and provide for high user friendliness.

Screens of the line control system

A. The HST high-voltage controller is an important component of every line con-trol system.

B. Great importance is placed on safety.Programmable monitoring limits of thehigh-voltage supply ensure smooth operation. A

B


17

AdhesiveApplication Flocking Pre-Cleaning Drying Final Cleaning

Machines for Flocking Textiles

Flock is particularly well-suited for use onjerseys,T-shirts, work clothing and othertextiles.The velvety surface has a highcovering capacity even on dark fabrics, isvery durable and retains its color brillianceeven after frequent washing. For motifflocking of T-shirts and sportswear, theadhesive is applied with the screen printingmethod. For smaller lots, textile flocking isvery economical when applied with handflocking units, and for medium volume pro-duction with semi-automated devices.

A. Adhesive application with KDM-4/4

B. Manual flocking with HEK 100

C. RF 500 flocker

D. TRUS-160 KT dryer

A

B

C

D

C



18

Machines for Flocking Textiles,

Floor Mats and Blanks

A

B

C

A. The RF 500 has proven to be outstandingfor flocking textiles and flat parts. It con-sists of a high-voltage electrostatic unit, thecontrol unit and the actual flocking unitwith a round flock container and rotatingbrush. Both the rotating speed of thebrush and the dosing time, height andduration of the connected high-voltage canbe individually set-up.

B. When combined with a screen printingcarousel and supplemented with a screen-ing frame, the RF 500 can also be usedas a multi-color flocking unit.

C. The FF 380-430 flat flocker was engi-neered for integration in screen printing carousels.The ultra-flat design enablesoperation even in tight spaces.


AdhesiveApplication Flocking Pre-Cleaning Drying Final Cleaning

19

Machines for Cleaning Flocked Textiles

After drying of the flocked textiles, theexcess flock is removed with the TS-Cmachine.This is carried out by a combi-nation of vacuuming off with strong tur-bulence and brush support.The surface is brushed off by the upper and lowerbrush at the inlet slit. In addition, a special airguidance with a strong air flow causes theflocked textile to vibrate. Excess flock isvacuumed off into a collection bag.Variousattachments, e.g.VR-TF for transfer cleaning,are available as expansion options.



20

Lines for Flocking

Small Objects

The range of possible applications forflocking lines is extremely wide. Flockingsolutions can be matched to the individualcustomer requirements and realized at anyautomation level. Correspondingly highengineering competence is required foreach individual line design.


Pre-TreatmentAdhesiveApplication Flocking Pre-Cleaning Drying Final cleaning

21

Transfer Lines for Flocking

Molded Par ts

An electrostatic flocking system is com-bined with an electrostatic-pneumaticflocker for flocking complicated objects.

We also supply flocking systems for laterintegration in existing lines at the custo-mer's plant.


22

Hand Flocking Units

Universal units for manual flocking are usedin the hobby and model construction, aswell as in laboratories or in prototypeconstruction.

A. Mini flocking unit

B. Mini flocking unit with various applicatorsand power supply unit

The HEK 100 is designed for industrialapplications.

C. HEK 100 with various applicators

A

B

C


23

A. The FT 1000 flocking table is the idealworkplace when combined with a handflocking unit.The supporting surface isdesigned as a screen so that excessflock falls into the funnel below and theninto a collection container. A spring-loadedsupport serving as a counterweightmakes work even easier.

B. The KFG 800 cabin flocker featurespurely electrostatic operation and leads to a very dense, even surface by flockingfrom the bottom up. First flocking mate-rial is applied to the grounded bottomof the cabin.When the high-voltage isswitched on, the flock jumps upwardand penetrates the adhesive-coated surface of the objects.

A

B


24

Manual Units for Flocking

Molded Par ts

A. EPF electrostatic-pneumatic flocker

Three-dimensional products, hollow bodiesand deep recesses form a Faraday cage.The interiors of these objects can only beflocked with the electrostatic-pneumaticmethod. The EPF is used for universalflocking ranging from individual prototypesto medium volume production. It consists of a flock hopper, flock dosing system, high-voltage generator and a control unit.

B. FK 1200-N flocking cabin

This flocking cabin with extraction offerssufficient working space for the use ofmanual flockers.The main excess flock fallsdown into the collection container, while therest is vacuumed off to the rear. Whencombined with the mobile Dustomat 160extraction unit, this fulfills the valid guide-lines for workplace safety and hygiene.

A

B


25

High-Voltage Generators

An important component of every flockingline is the rugged, high-quality, linkable high-voltage generator of separately operatingcomponents.These are controlled via PLC,and can thus be integrated in fully-auto-mated production. Different devices areused for various performance classes. As asafety-relevant component, the high-voltagegenerator always complies with the latestvalid standards and technology.

A. High-voltage control with HST 01/03

B. HER high-voltage generator

C. High-voltage control, integrated in thefront of a control cabinet

D. HE 2000 mobile high-voltage generator,also suitable for stationary installation

E.Control cabinet for laboratory use withHST/HER

A

B

C

D

E


26

Testing Equipment

For the evaluation and analysis offlocking results we offer a wide rangeof testing equipment.The measuringand test units for all applications havelong proved themselves in user plants,in laboratories of the car manufac-turers and at universities. We offerprecision technology for all commontest standards.

MT 501 tear tester.A proven test method is the tear test. No need for subjective, visualevaluation. A measured value is dis-played in newtons and printed out.Tests can be conducted on even verysmall, uneven parts, like those fre-quently encountered in the automotiveindustry.


27

The DMB 10 conductivity meter measuresthe electrical conductivity of the flock.Withelectrodes available as an option, the conduc-tivity of the adhesive and the ground leakagecurrent of the flocked objects can be measu-red.The temperature is measured with thecontact sensor or contact-free with the IRsensor.

To evaluate the quality of the flocked pro-ducts, the APG 1000 abrasion tester is used.The speed and number of strokes can beselected as desired.The device is also suitablefor testing the abrasion resistance of leatherand painted plastic surfaces.

The HMG-D high-voltage meter with a measuring lance measures the high-voltagepresent at the electrodes of the flockingmachines.The measuring range is 0 -100 KV.

The flock shape provides an optical evaluationof the flock. This is achieved by measuringthe length and shape, as well as by checkingthe cut ends. A sample of the flock is placedon the glass carrier, scanned and opticallymeasured for this purpose.

The SPG 1000 rise time tester examinesthe behavior of the flock in an electric field.In accordance with the standardized testspecification, a sample of the flock is siftedonto the grounded base plate.The time theflock requires to jump from the plate at adefined high-voltage is measured.

Especially with larger lines, the siftability of theflock is an important variable.With the RPG1000 the flock is filled into the sifting drum,the residual quantity is weighed after a definednumber of rotations and visually evaluated.


Maag Flockmaschinen GmbHIn der Braike 16 72127 Kusterdingen / Germany

Fon +49 (0) 7071 - 94 910-0 Fax +49 (0) 7071 - 94 [email protected] www.maag-flock.com

Made in Germany

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