X-Flame hoses - flame-resistant solutions for industrial applications

Generation XFlame®

... remains steadfast, even when sparks fly - throughout the entire production process!

Did you know that a car body today has more than 5,000 spot welds? Welding guns, among other things, are responsible for their production. In combination with robots, these are guided pneumatically, i.e. by compressed air, with rotating and axial movements to the optimum welding position. Electrodes then place the welding points precisely and with constant force. To increase the service life of the electrodes, they are permanently cooled with water.

This is precisely where the XFlame® hoses from Novoplast Schlauchtechnik come into play. The hydrolysis and pressure-resistant hoses are used for the compressed air supply and for the cooling water supply and return in the direct welding area. For the XFlame® hoses, proximity to high heat and flying sparks is not a problem: Due to their flame-retardant design in accordance with UL94-V0/V2, sparks and welding beads have no chance of igniting the hose material. In addition, the self-extinguishing properties of the high-tech plastic used prevent the hoses from burning. This was also confirmed by tests carried out by Underwriters Laboratories (UL): in the so-called vertical burning test, the hose extinguishes in less than five seconds. It therefore also complies with the UL94-VO directive up to V2 (depending on dimensions and wall thickness). In addition, hoses from this series are approved for use in the automotive industry thanks to their OEM(Original EquipmentManufacturer) approvals.

The possible applications of XFlame® hoses are not limited to use with welding guns. All known welding processes in which sparks fly are potential areas of application for this product. The XFlame® hose is used equally successfully in welding processes in steel construction and in ventilation duct construction.

Flexible use in drag chains

It is not uncommon for drag chains to be used in welding systems for longer travel distances. In a drag chain, cables or hoses are installed on machines in such a way that these cables and hoses can be moved over distances, but must not be damaged in the process in order to avoid machine downtime. This places heavy mechanical loads on the hoses used and places high demands on flexibility, torsion resistance, abrasion resistance and bending radius. Not to mention the high number of bending cycles that the product has to withstand without damage. Thanks to the properties of the high-performance polyurethane plastic used and the special cross-section of the hoses from the XFlame® generation, all requirements for use in drag chains are met. This means that all Generation XFlame® hoses are suitable for use in drag chains.

LABS-free guaranteed!

In many areas of the production chain in the automotive industry, high demands are placed on the materials and components used.

Special guidelines are applied in the painting process in order to guarantee high-quality processing of the body parts. Due to increased environmental awareness and the associated regulations on pollutant emissions, solvent-free paints and varnishes are also used when painting components. To ensure optimum adhesion of the paints to the substrate, certain conditions must be met throughout the entire production chain, both for the material properties and for the components used: All machine components used in the preceding manufacturing process - and therefore also the XFlame® hoses - must be "LABS-free", i.e. free from paintwettingimpairmentsubstances. These control mechanisms in the production chain ensure that the material surface is absolutely clean, dry and free of oil and silicone in the subsequent painting process. Silicone in particular can have a negative effect on paint wetting. This is therefore an important advantage of XFlame®: all XFlame® generation hoses can be used without hesitation as machine components in a production system, as they are LABS-free, i.e. free from substances that inhibit paint wetting.

Small hose with a big effect

The XFlame® generation hoses are made of polyurethane, which has significantly better product properties than the PVC-coated hoses that are often used.

Whether laser welding, MIG welding or spot welding, sparks fly in all directions and do not stop at hoses. No problem! All XFlame® generation hoses are characterized by their UL94-V0/V2 class flame resistance.

In the past, hoses that were used in areas close to welding had to be replaced regularly, as flying sparks or welding beads would burn into the hose and cause leaks. Long downtimes were the result. This was reduced with the birth of the XFlame® hose generation: With a combination of flame-retardant plastics and an optimized wall thickness, the spark-resistant XFlame® generation of products has minimized the need to replace hoses, enormously reducing set-up and assembly times on welding systems. This has led to a noticeable increase in productivity, particularly in automotive production. The small hose has a big effect here!

The XFlame® generation essentially consists of 3 types

• The robustXFlame® is the conventional version for flame-resistant applications. The rigid version allows operating pressures of over 20 bar.
• The flexibleXFlame hydro® is the logical further development of the robust XFlame® variant. As a result of the increased flexibility, the handling of the hoses has been significantly improved. This makes inserting the hoses into connectors and push-in fittings noticeably easier.
• The elasticXFlame soft® is used in particular for tight installation situations. The highly flexible hose is characterized by its excellent kink resistance.

Due to the wide range of possible applications, it should be possible to differentiate between the hoses in the application. This is why, in addition to the standard black version, the range also includes blue, red, green and white XFlame® hoses. This means that a cooling water line can be distinguished from a compressed air line at first glance.

In view of the wide range of applications, it is important to know that the hoses of the XFlame® generation are not only produced in the usual roll form, but can also be produced in roughly straight individual and inline cut hose lengths. In addition, extendable spiral hoses with working lengths of more than 20 meters can be produced for highly flexible applications. To ensure compatibility with commercially available connection systems, all XFlame® generation hose dimensions and tolerances have been matched to standard plug-in and screw connection systems.

In a nutshell: Generation XFlame® hoses withstand the mechanical demands of drag chains, robots and welding guns, are resistant to media such as compressed air and cooling water and extinguish any sparks thanks to their flame-retardant properties.