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Peak performance

Flexible covers for machine toolsand linear guide systems

MöllerWerke GmbHmöllerbalg®

KupferhammerD-33649 BielefeldPhone: +49 (0) 5 21-44 77 0Fax: +49 (0) 5 21-44 77 [email protected]

3www.moellerwerke.de2 www.moellerwerke.de

The MöllerGroup 3

The MöllerWerke 4

Standard way covers and folding aprons 6

Large way covers and combination folding walls 10

Equipment with scales 12

Stahlflex® covers 14

Complete units 18

Box and polygonal bellows 20

Disc bellows made of elastomers 22

Bellows and form components made of molerit® 24

Contents

The Kupferhammer in 1907 and in 2008.Headquarters and main administration of the MöllerGroup.

Data and facts

Year of foundation: 1730

Product and service areas:Flexible constructional components, plastics engineering

Operative units: 12

Möller Joint Ventures: 3

Number of employees: 1.800

Headquarters and main administration:

Bielefeld/Germany

Locations: 30 world wide

Status 2008

The CompanyThe MöllerGroup is a company with tradition: Family owned for seven generations, it canlook back on a history of 278 years, in which period the factory has developed into an inter-nationally successful production and service enterprise. Sectioned into two business divisions– plastics engineering and flexible structural components – the MöllerGroup today deliverspeak performance products throughout the world.

The MöllerGroup world wideAs an international enterprise, the MöllerGroup thinks and acts across frontiers. With itsown operative companies or joint ventures at 30 sites world wide, we produce where ourcustomers are. Thus customers throughout the world can rely on our know-how and onour competence on site.

With international partners to world wide success.The MöllerGroup

LocationsMöllerGroup GmbH & Co. KGMöllerWerke GmbHKupferhammer, Bielefeld


MöllerWerke is a competent development partner for the industry. Under the brand name ofmöllerbalg® flexible constructional components are developed and manufactured for a widediversity of applications. In addition to machine tool construction, special vehicles and railwayengineering, the products from MöllerWerke are utilised in hydraulic systems, pneumaticsystems, electrical engineering, medical technology and in many other industrial fields.

Our customers profit from the direct consultory service on site as well as the long-term expe-rience and the know-how of our sales engineers. The MöllerWerke offer optimally designedproducts, high economic efficiency, constant product quality and unrestricted service. Theown materials development with corresponding released mixtures and material combinationscan fulfil almost any technical requirements.

The close cooperation with our customers and the material and product development in thehouse of the MöllerWerke leads to new solutions and new products

Materials: diversified and flexible

Our many years of material and productdevelopment experience as well as numerousspecial technical problem solutions consti-tute significant advantages for the benefitof our customers.The following factors are decisive for thequality of our products:• The particular application• The boundary conditions• The selection of materials• The manufacturing method

We have our own test beds and a technol-ogy centre. In addition, we can access thelaboratories of the MöllerGroup.

Coated technical fabrics:• Polyester fabric coated with polyure-thane, in various thicknesses

• Aramid fabric with and without coating• Fabric with anti-adhesive coating• Rubber coated fabric• Hybrid fabric• Tarpaulin material, Trevira high strength,coated with PVC on both sides

• Aluminium vapour deposited on fabric• Polyester fabric

Elastomer types:• CR chloroprene• CSM hypalon• NBR nitrile• ECO epichlorhydrin• ACM acrylate caoutchouc• MVQ silicone• FKM fluoro caoutchouc

Other materials:• Leather• Insulating materials (e.g. textured glass)• Steels• Aluminium• molerit®

• PVC• Polyamide• PolypropyleneAnd numerous other materials on inquiry.

Methods: individually plannedand implemented

The MöllerWerke utilise a number of specialproduction methods which have mostlybeen developed by us for industrial pro-duction of bellows. Machines, systems andproduction lines are special plants whichhave emerged in the course of numerousyears of experience with bellows produc-tion. MöllerWerke owns internationalpatents for many of these methods.

• Welding automatons for way covers• HF welding automatons for bellows• Dip moulding methods and dipautomaton for molerit®

• Radiation crosslinking

• CNC mould drawing• Manual mould drawing on specialmoulds

• Automated scale production• Automated cutting on plotter, millingand water jet systems

Research and development at MöllerWerke

The market imposes continually growing demands on us and our products. Thereforewe permanently monitor the market developments and devise corresponding innovativesolutions on the sector of new products, materials and methods.

Modern research facilities are available to our chemists and engineers. ImportantCAD systems, innovative experimental technology and continuous online data exchangebetween the individual work groups produce efficient application-oriented results.

Flexible solutions from a single source.The MöllerWerke

Production methods at MöllerWerke:

MöllerWerke – ultra-modern production methods and productionquality on the highest level.

Cutting centreOrder processing centre

Production hall

Pleating machine


möllerbalg® way covers are carefully produced, quickly available for delivery, have highperformance and are keenly priced. They convince with high quality materials, perfect work-manship and prevent ingress of chips, dust and liquids. The machine operates in the longrun with undiminished precision, requires fewer replacement parts and suffers less downtime.

These covers afford best possible personnel protection against injury. Ultimately, they convincenot only through their functionality, but also serve as visually attractive design elements.

möllerbalg® way covers

• protect employees against injury• protect machines against wear causedby dirt

• combine design and functionality ofyour product

Structure of the möllerbalg®

way covers

The product systematics developed byMöllerWerke and the production techniquesbased thereon permit economically efficientsolutions tailored to suit the individualapplication.

The MöllerWerke®

development department

• equipped with ultra-modern IT technology• 2 and 3 D CAD systems• facility for FEM-analysis

• technology centre with universal teststand and latest laboratory technology

• innovative solutions for new products andapplication engineering improvementsof existing products

Welded-in guide frames patentedby MöllerWerke

• the cover follows the guide track withhigh accuracy

• long flanks do not kink• homogeneous liquid-sealed connectionto outer cover

New proven materials makepossible

• high speeds and accelerations of the cover• service life of up to 10 million cycles• resistant to aggressive coolant-lubricants

The range of materials is continuallyupdated, tested and adapted to thecustomer requirements.You have the machine. We have the cover solution.

Standard way covers and folding aprons

The most common geometric forms

Design of way covers, minimised collapsed dimension per fold

Folding apronsStandard

way coversCombinationfolding walls

U-shape

U-shaped with rear grip

desk shape

folding wall

folding wall L-shaped

combination foldingwall Z-shaped

roof shape

standard

double pleat

outer cover

supporting frame

welded connection

end flange

way cover – standard

Ft = depth of foldFz = = number of foldsLmax/F = maximum length per foldLmin/F = minimum length per fold

Lmax = maximum extended lengthLmin = minimum compressed length,

also block measurementE = thickness of the end flange

Lmin/F Lmax/F

stroke E

35

back

rear gripFt

leg

Lmax

Lmin

Length calculationsThese formulae are intended as helpfor the length calculation of möllerbalg® waycovers. The results are approximations. Inmost cases desired deviations therefrom canbe realised. Please contact our applicationengineers.

Lmax = stroke + Lmin

standard depth of foldfrom 15 mm to 70 mm

Lmin = (Fz x Lmin/F) + (2 x E)

Fz =Lmax

Ft x VZ

Fz =stroke

Ft x VZ - Lmin/F

VZ = Ratio of Lmax/F to Ft

VZ = 1,3 at Ft ≤ 15 mmVZ = 1,5 at Ft = 16-39 mmVZ = 1,6 at Ft ≥ 40 mm

Lmax/F = Ft x VZ

Folding aprons Way coversstandard

PUR fabric0,20 1,8 3,00,40 2,2 4,5

Nomex fabric 0,30 2,2 4,0fabric + Teflon 0,30 2,2 4,0fabric + PUR 0,30 2,2 3,5EM-Nomex 0,50 3,5 5,5Pyresit-Plus 0,40 2,2 4,5

Example of Lmin per fold in mm with a supporting framethickness of 1 mm depending on the outer cover

Constructional principle and designationsCover in a milling machine

Detail views

materials for way covers properties/suitability

No. material type utilisation thick- base bottom top colour dust imper- water cooling resistant flame weld max. cont.ness mate- side side protect- vious to restistant emulsion to retarding sputtering chip operating

rial coating coating ion liquids resistant chemicals resistant resistant temp.°C(*)

FR 1 PUR polyester fabric Standard quality with long service life with regardblack RAL 9011 to cyclic flexural stress; impervious to liquids;

0,2 PES PU PU black -20 to +100resistant to cooling emulsions as well as oil andgrease for smaller size slide track protectionsor folding aprons with smaller fold depths

FR 2 PUR polyester fabric Standard quality with regard to media likeblack RAL 9011 position 1 0,4 PES PU PU black -20 to +100

FR 3 PUR polyester fabric coated For stress with aggressive media, anti-adhesivewith PTFE, RAL 9011 (e.g. utilisation for grinding machines) 0,3 PES PU PTFE black -20 to +100

FR4 PUR polyester fabric coated For stress with aggressive media, anti-adhesivewith PTFE, RAL 9011 (e.g. utilisation for grinding machines) 0,5 PES PU PTFE black -20 to +100

FR 5 PUR nomex fabric, black High flame protection. Complies with the AmericanRAL 9011 (Laserflex 2) standard UL94 HB (utilised e.g., for laser beam guides 0,3 nomex PU PU black -20 to +100

FR 6 nomex one-sidedFor radiant heatmetallised silver colour 0,5 nomex – Alu silver -20 to +180

FR 7 kevlar two-sided For radiant heat metallised silver colourmetallised silver colour 0,8 kevlar Alu Alu silver -20 to +180

FR 8 pyresit plus Mixed fibre Kevlar/Preox with flame-protected PURkevlar/outer coating. Application: for protection against 0,4preox

– PU black -20 to +150slag sputter

F 1 PUR polyester fabric Material with long service life with regard tosuper black RAL 9011 cyclic bending; utilised for linear guides 0,2 PES PU PU black -20 to +100

F 2 PUR polyester fabric Same as FR 2, but colour whitewhite RAL 9002 0,4 PES PU PU white -20 to +100

F 3 PUR polyester fabric Base fabric like position 1, but on one side openone-sided HT black fabric structure (HAT = high temperature dyed), 0,2 PES PU HT black -20 to +100RAL 9011 PUR coated. Utilisation for measuring machines coloured(small end forces).

F 6 PUR polyester fabric Material like position1, but coated internally withwith PUR film black PUR film. Utilisation for grinding machines when 0,3 PES TPU film PU black -20 to +100

perfect confinement is required

F 8 PUR 0,65 F2 with coated-on TPU film (as wear protectioncremeRAL 9011 layer in the case of severe exposure to chips).

Very resistant to abrasion and wear0,6 PES PU TPU film white -20 to +100

F 9 TopResist Enhanced resistance to coolant-lubricants and oils.Utilised for milling machines, lathes and grindingmachines.

0,4 PES PU NBR black -20 to +100

F 10 Laserflex 3 Flame retarding /self-extinguishingUtilised, e.g. for laser beam guides 0,27 PES PU PU black -20 to +100

F 11 Laserflex 4 Flame retarding /self-extinguishingUtilised, e.g. for laser beam guides 0,33 PES PU PU black -20 to +100

Material matrix


standard front mounted projecting

support frame outer shell

end frame of the covering – cleat strip felt

machine face/device surface – cleat strip feltAttachment/mounting

Several possibilities exist for attaching theway covers to machines or devices:

End flanges:• steel sheet, powder-coated• stainless steel• plastic• special materials

Mounting possibilities:• standard• front mounted• projecting

End flanges are delivered with stipulateddrilled holes pattern or without drilled holes.If absolute sealing between the cover/endflange and the machine is demanded, wedeliver corresponding reliable variants.

The alternative: Quick mounting withcleat fastener.The cleat strip is attached captive on theway cover, the opposite strip is bondeddirectly to the degreased machine surface.

end flange

= well suitable = conditionally suitable(*) = maximum temperature applies to the material. Depending on the guide frame materials used, theadmissible temperature for the overall way cover can be lower.

Order your individual product solution now.

quick mounting with cleat fastener

Geometric form of the cover please mark the relevant items

Desired cover specificationsplease fill in measurements in mm

Dry processing

Wet processing

Back width

Leg height

Rear grip

Stroke

Lmax

Lmin

Fold depth

Attachment type

Ft = fold depthFz = number of foldsLmax = maximum extended lengthLmin = minimum compressed

length, also block measurement

Lmax/F = maximum length per foldLmin/F = minimum length per foldE = thickness of the end flange

Lmin/F Lmax/F

stroke E

35

back

rear gripFt

leg

Lmax

Lmin

Inquiry/order order No. date signature

your company

your name

your fax No.

your phone No.

Please send your fax to: MöllerWerke GmbHKupferhammer • 33649 Bielefeld • Fax No.: +49 (0) 521-44 77 333

Folding aprons

Attachment type please mark

Standardway cover

Combinationfolding wall

U-shape

U-shape with rear grip

desk shape

folding wall

combination folding wall L-shape

combination folding wall Z-shaperoof shape

standard

double plead

Advantages:

• quick mounting and dismounting• secure attachment at temperatures inthe range from -20°C to 80°C.

• many mounting and dismounting cycleswithout performance deterioration ofthe cleat strip connection


With us you are the greatest.

Because of their dead weight very largecombination folding walls are always achallenge for the constructional designwith respect to the desired running charac-teristics. The inertial forces produced bythe large dead weight in response to therequired accelerations must be skilfullydiverted or dissipated to keep the mechan-ical stress to which the components aresubjected as small as possible.

In order to achieve a safe and functionalsolution, new large combination foldingwalls are tested on our own linear motortest stand. Thus the customer can be surethat a proven system is delivered forhis machine.

Combination folding walls

möllerbalg® combination folding walls are special cover systems from the MöllerWerke,which are assembled from large bellows and other bellows. They can serve as wall coversfor the rear part of the machine or as a roof cover. Thus a hermetically enclosed workingcompartment can be achieved without requiring particularly great effort for designing themachine housing. With the help of special safety systems these bellows systems can alsobe made puncture-proof. In the case of a tool breakage, the kinetic energy of the ejectedfragment is dissipated without endangering persons or systems in the environment.

The new guide frames guarantee special form stability. By consistent weight optimisationand utilisation of lightweight moving systems, möllerbalg® combination folding wallsachieve high travel speeds and accelerations.

Large way covers and very large way covers

Very large way covers

MöllerWerke GmbH devises economically efficient solutions appropriate for the particular machinedue to a comprehensive know-how. In close cooporation with our customers we constantlysupplement our knowledge.

MöllerWerke produces covers which can completely seal off the processing compartmentof the machines. This means that no chip or coolant lubricant can penetrate to the sensitiveparts of the machine. The guide elements as well as the electric and electronic parts ofthe machine are reliably protected. This is also true in particular for very large travel standmachines, portal milling machines and processing centres. Large way covers having aheight greater than 4 m and an extension of 25 m are among our proven products.

For the design criteria and materials, please see the tables in the front section.

Large bellows are convincing

• high stability achieved by crimpingand/or with reinforces supportingframes

• uniform extension with scissor elementsor special damping systems

• lightweight moving systems permithigh speeds and large accelerationswith low friction and little noiseproduction

• stabilising and damping elementsensure parallel extension with low wear

• long service live with maintenance-freeoperation

Large bellows on a portal machine Combination folding wall in a long bed machine

Combination folding wall in a machine


Protective shield against hot and sharp chips.Equipment with scales

For further improvement of the resistance with respect to hot and aggressive chips, smallas well as large way covers can be equipped additionally with metal scales. The scales canbe mounted partially or on all sides. Even the most difficult geometries are possible withFlexecke scales developed and patented by the MöllerWerke.

Length calculationsThese formulae are intended as helpfor the length calculation of for möllerbalg®

way covers with spring steel scales. Theresults are approximations. In most casesdesired deviations therefrom can be realised.Please contact our application engineers.

For every application the right scale

Folding wall with scales in a processing centre

Application exampleBellow with scales Detail view in the machine Cover with spring steel scales

The advantages of metal scales

• less accelerated mass than withtelescopic steel covers

• low vibration travel of the coverwithout impacts

• almost totally closed surface

Niro scale

3-sided scale

Aluminium scale

Flexecke

Spring steel scale

one scale oneach fold

scalewidthFt Lmax

scalewidth Lmax

B 2xFt-20 B 2xFt-20

one scale on eachsecond fold

20 75 2821 75 3022 75 3223 90 3424 90 3625 90 3826 90 4027 100 4228 100 4429 125 4630 55 40 125 4831 55 42 125 4832 55 44 125 5233 55 46 125 5434 65 50 125 5635 65 5037 65 5237 65 5438 65 5639 75 5840 75 6041 75 6242 75 6443 75 6644 90 6845 90 7046 90 7247 90 7448 90 7649 90 7850 90 8051 100 8252 100 8453 100 8654 100 8855 100 90

Spring steel scalePermanent pre-tensioned surface, lowweight, for high travel speeds and acceler-ations, low mounting height due to theflat scale geometry, particularly suitablefor vertical and overhead mounting aswell as for covering large areas.

Niro scaleRobust, impact tolerant, acid resistant, bareor brushed surface, can be folded open.

3-sided scaleThis alternative for the telescopic steelcover, with all advantages of the springsteel scale protects the guide track on allaccessible sides and is impervious to liq-uids.

Aluminium scaleLow weight, can be folded open, weldingsputter does not adhere.

FlexeckeThe Flexecke developed and patented bythe MöllerWerke pioneers a quite newapplication field. Every conceivablegeometry can be covered with the helpof the Flexecke.


Stahlflex® – high speed engineering.Stahlflex® covers

Ultra-modern engineering achieves high speeds and accelerations in machine tools, entailingmechanic stress magnitudes at the absolute limit or beyond the capabilities of conventionalcover systems. Thus there is a demand for solutions with maximised wear resistance andminimised mass combined with extremely steady travel behaviour. The reply to this challengeis Stahlflex®.

This innovative cover system from the MöllerWerke in lightweight construction consists ofmetal and plastic connecting elements. The low mass of the cover permits very high travelspeeds and accelerations. The mechanical stress of the components and the machine is thussmall, achieving steady uniform motion. The almost closed metal surface of the cover, whoseelements show a wiping action, to protect the machine against hot sharp-edged chips.

Our new covering system is maintenance-free, long-lived and attractively priced. Individualelements that have been damaged can be easily replaced due to the modular design.Furthermore, with the help of a plugging system patented by the MöllerWerke, existing cov-ers can be complemented with additional covers in almost any spatial orientation.These properties make Stahlflex® the optimum solution for modern machine tools.

The advantages at a glance are

• suitable for large accelerations• suitable for high speeds• small mass• resistant to chips• maintenance-free• possible with various geometries• practice-proven protection system• cost favourable for procurement andmaintenance

• long service life• can easily be complemented

Stahlflex® covers – modular design for overhead or vertical installation

65 mm 40 mm 50 mm 6 mm

75 mm 45 mm 60 mm 6 mm

85 mm 50 mm 70 mm 6 mm

100 mm 60 mm 85 mm 6 mm

115 mm 70 mm 100 mm 6 mm

Scale Lmax /scale Lmin/scale

scale scale bevel extension per block dimensionwidth B A scale per scale

FZ = Lmax / Lmax per scale

Lmin = FZ x Lmin per scaleplus scale over-run

Scale

Cover for vertical installation

Cover for overhead installation

View of a travel stand machineView of processing centre

width

width

opposite scale

scale over-run

scale over-run


Stahlflex®covers as system solution – single piece or modular design for wall and roof

LmaxLmin

Stahlflex®covers – single piece or modular design for large area vertical installation

BB

Stahlflex® cover rear view Stahlflex® cover front view Stahlflex® cover corner solution rear view

Detail view of plugged system

Detail view of exchangeable scales

Plugged system

The plugged system developed by the MöllerWerke makes it possible to firmly couplethe nevertheless be detached. The plugged spring element latches into a pocket-shapedholder in which it is locked into position. To break the connection, the plugged springelement must be pressed together to release it out of the locking device. This can berepeated any number of times, because the deformation of the spring element takesplace in the elastic range.

Exchangeable scales

A further development step of the Stahlflex® covers is the modular system design withexchangeable scales. In this system the spring steel elements of the cover are connectedto plastic elements. The special feature of this system: The connection is devisedsuch that individual elements can be mounted and dismounted. This makes it possibleto replace destroyed scales individually. This advantage is welcomed by the machineoperators, because it means that the repair effort and the costs for replacement partsare significantly reduced.

65 mm 40 mm 50 mm 7,5 mm

75 mm 45 mm 60 mm 7,5 mm

85 mm 50 mm 70 mm 7,5 mm

100 mm 60 mm 85 mm 7,5 mm

115 mm 70 mm 100 mm 7,5 mm





Scale

65 mm 40 mm 50 mm 7,5 mm

75 mm 45 mm 60 mm 7,5 mm

85 mm 50 mm 70 mm 7,5 mm

100 mm 60 mm 85 mm 7,5 mm

115 mm 70 mm 100 mm 7,5 mm





Scale

height

height

width

scale over-run

scale over-run


Supporting machine components – complete systems.Complete units

Thus the MöllerWerke decided a few years ago not only to take up this trend, but alsoto set own standards. Today machine manufacturers tend to require complete modules,as modern machine tools are based on modular design. The task amounted to developinga multifunctional complete unit.

In detail this entailed: Integration of the guides for the covers. A weight-optimisedlight and compact design was required, which can be mounted quickly in the machinewithout great effort. The complete unit performs a supporting function for themachine shrouding.

The complete units are safely delivered to the machine on a transport frame or othersuitable transport device. The scope of delivery also includes the mounting instructionsfor all steps from releasing the transport securing devices to the finished installationin the machine. On request installation of the first complete unit can be managed onsite by our engineers.

3-D depiction of a complete unit

View of a complete unit before mounting in the machine

Top view on complete unit

Bottom view on complete unit

The results are complete units fromthe MöllerWerke.

Convince yourself of the high performanceof our complete units. We are pleased totake over the complete development fromthe first constructional design file to the fin-ished product.


Box and polygonal bellows

Allround protection with corners.

Structure of the möllerbalg® box bellows

Box bellows

Box bellows surround the machine components to be protected or the dangerous areas onall four sides. They are provided as protection against dust, dirt or liquids, to feed fresh airor to safely shield dangerous places (e.g. lifting tables).

Box bellows have manyadvantages

• welded-in supporting frames in eachfold – long flanks do not collapse

• numerous proven materials are available• a divided bellows design facilitates retro-fitting without requiring machine/devicedismantling

• almost any dimension can be produced;MöllerWerke delivers sizes from amatchbox up to a car garage

These formulae are intended as helpfor the length calculation of möllerbalg®

box bellows. The results are approxi-mations. In most cases desired devia-tions therefrom can be realised. Pleasecontact our application engineers.

Lmax= stroke + Lmin

Lmin = (Fz x Lmin/F) + (2 x E)

Fz=Lmax

Ft x VZ

Fz=stroke

Ft x VZ - Lmin/F

VZ = ratio of Lmax/F to Ft

VZ = 1,3 if Ft ≤ 15 mmVZ = 1,5 if Ft = 16-39 mmVZ = 1,6 if Ft ≥ 40 mm

Lmax/F = Ft x VZ

PUR fabric 0,20 3,0PUR fabric 0,40 4,5PUR fabric + teflon film 0,30 4,0PUR fabric + PUR film 0,30 4,0BM nomex 0,50 3,5Pyresit-plus 0,40 4,5Pyresit-plus 0,75 7,0special materials on inquiry

Example for Lminper fold in mm fora support framethickness of 1 mm,depending on theexternal coverStandard materials

Polygonal bellows

Polygonal bellows, like box bellows, provideallround protection. However, no supportingframes are needed. The form stability ofthe folds is achieved by the multiple-layerstructure of the external cover. Polygonalbellows are utilised as cover for piston rodsand guide columns in mechanical engineer-ing. They are used as light-proof camerabellows of large format cameras, reproduc-tion cameras and large format copymachines. MöllerWerke offers polygonalbellows as prism types and conical typesin tetragonal, hexagonal and octagonalversion as well as special versions.

Advantages of polygonal bellows

• attractive design• light-proof• dustproof• excellent extension ratio• largely resistant to oil• in accordance with the NC-production,polygonal bellows are constructed bythe MöllerWerke with CAD support

Laser beam protection bellows asbox bellows or polygonal bellows

MöllerWerke is a development partner ofrenowned laser machine manufacturersand well known for its special solutions andnew developments. The personnel of theMöllerWerke is pleased to assist you withthe design of your laser beam protectionbellows.

– Lmin– Lmax– inner rectangular dimensions of both connecting sides– depth of fold– centre offset of the two connecting sides relative toeach other

B

BB

HH

HB

H

Ft

Ft

d D

Lmin, Lmax, D, d or FtLmin, Lmax, Ft,inner rectangular dimension orouter rectangular dimension

External cover

Welded connection

Supporting frame

End flange

Ft = depth of foldFz = number of foldsLmax/F = maximum length

per foldLmin/F = minimum length

per foldLmax = maximum extended

lengthLmin = minimum com-

pressed length, alsoblock measurement

E = thickness of theend flange

Lmin/F

Lmin

Lmax

stroke

Ft

E

Lmax/F

Length calculations

Required constructional specifications for polygonal bellows

Beam guide bellows in a laser machine

Box bellows in anassembly line


Disc bellows made of elastomers

Smallest mounting dimension – greatest extension.Disc bellows protect personsagainst injury by movingmachine elements

• dust and dirt• wood and metal chips• liquids such as water, oil, emulsionsand chemicals

Disc bellows have a special rank among the bellows. Their mounting dimension is smallerthan that of all other bellows – and their extension ratio is enormous. They are assembledwith individual discs connected alternately at the outer diameter and the inner diameter.Thereby the material makes a homogeneous connection which is inseparable and completelyimpervious. Sleeves or flanges can be mounted on both ends of the disc bellow.

Disc bellows are mostly utilised to protect machines or machine components. The applicationfields are diverse, ranging from hydraulic and pneumatic pistons via threaded and ball rollspindles to processing and measuring machines. The forms of the disc bellows are as mani-fold as the products which they protect. The classical disc bellows are circular, but othergeometries are possible, too, with corresponding tools.

Standard materials:

CSM rubber:If no special requirements are imposed withregard to the resistance to oil, we usuallyrecommend CSM rubber. Its advantages arehigh weather resistance combined withadequate resistance to oil and chemicals.The permissible operating temperaturerange is -20°C to +110°C. Extreme resist-ance to flexural fatigue.

NBR rubber:NBR rubber is particularly resistant to oil,emulsions and fuel. However, it is not asweather resistant as CSM rubber.

Special materials:

Viton:This fluoroelastomer is particularly resistantto acids and of all the materials mentionedhere it features the highest permissiblethermal stress (- 20°C to approx. + 160°C).

PUR:Polyurethane is very resistant to abrasion,torsionally stiff and resistant to acids andalkalis. Furthermore, this material is physio-logically innocuous and therefore eminentlysuitable for utilisation in medical equipmentas well as in the food industry.

Selection of the attachment

Information with regard to the definition of the disc bellows

A) Sleeve for attachment with hosebinders. Combination with flange ispossible.

C) Spacer flange fixing with sheetmetal flange and screws. Combinationwith sleeve is possible.

B) Flange formed from the last fold. Attach-ment with sheet metal ring and recessed headscrews. Combination with sleeve is possible.

Explanation of the abbreviations:Da = external diameterDi = internal diameterFt = fold depthFz = number of foldsAF = extension per foldLmin = length in compressed stateLmax= length in extended stateH = strokeDS 1 = sleeve diameter 1DS 2 = sleeve diameter 2DF 1 = flange diameter 1DF 2 = flange diameter 2b 1 = sleeve width 1

Fold depth Ft = (Da - Di) : 2Extension per fold AF = Ft x 1.1Maximum length L max = AF x FZNumber of folds Fz = L max : AFMinimum length L min = Fz x 2.5

You can request your product solution now.

Inquiry/order order No. date signature

your company

your name

your fax No. your phone No.

Please send your fax to: MöllerWerke GmbHKupferhammer • 33649 Bielefeld • Fax Nr.: +49 (0) 521-44 77 333

Disc bellows

Customised design disc bellows

Di = attachment A B C

Da= DS 1 mm mounting orientation: horizontal vertical

stroke = DS 2 mm for smooth shaft for threaded spindle

b 1 mm the bellows are continually wetted with oil or grease yes no

b 2 mm


Bellows and form components made of molerit®

The MöllerWerke have been able to solve almost all constructional problems with this specialdip moulding method for more than 40 years. All customers profit from this experience andthe continually growing know-how of our specialists.

molerit® is one of our own material developments involving a thermoplastic based on PVC.When demanded by the utilisation conditions or when new specific material information isavailable, the material molerit® is adapted by our personnel in the development departmentand laboratory. The method itself is continually re-checked and optimised regardingeconomic efficiency and quality.

Bellows and form components manufactured by the dip moulding method are utilisedthroughout the industry, for example in mechanical engineering, medical technology, vehicleconstruction, electrical and sanitary engineering as well as for manufacturing prototypes.The dip moulding method is also suitable for coating metallic components.

The material

molerit® is a special mixture based on PVC.Careful selection of the components is madeaccording to the aspects of health compa-tibility, environmental compatibility and tech-nological properties. With PVC as a basis,a polymer with high chemical resistanceis utilised, which is well known through

decades of experience. The properties ofmolerit® depend strongly on the auxiliarymaterials and the production mode, andthey can be adapted to suit a wide diversityof technical requirements. An extensiverange of types with a broad spectrum ofproperties is available: low temperature

suitability, high temperature suitability,haptic, optics, flame retarding, individuallyoptimised media resistance (oil, grease,petroleum ether, salts, acids and alkalis).Furthermore, molerit® can be manufacturedin almost any colour – even as glass-trans-parent component.Any shape for your particular application.

The outstanding advantages ofthe dip moulding method are:

• nearly all shapes are possible, includingcomplex geometries

• small batches can be produced withlow tool costs

• various hardness ranges possible withinone dip moulded component

• 2 colours possible within one dipmoulded component

• surface optionally mat or glossy• standard colours: black, red, yellow,grey, transparent; special colours canbe selected if required

• an alternative to injection mouldingand pressing methods for mediumquantities up to 10,000 pieces per year.

The outstanding properties ofmolerit® are

• high resistance to cracking due to ageingor the effect of light

• good resistance to UV radiation• cold stability down to -50°C• thermal form stability up to +70°C, in thecabin area up to +85°C

• with radiation crosslinking up to +100°C• very good resistance to acids, alkalis, seawater and gases

• material types in many hardness grades,see the material table on this page

• special type for enhanced resistance tomineral oil and grease

Dip moulded components – product diversity Dip moulding process

Transformer protective hood

Utilisation in vehicle engineering Application in an ergometer

materialmolerit®

molerit® T 50 M

molerit® T 56 K

molerit® T 56 KS

molerit® T 59

molerit® T 59 FL

molerit® T 60 F

molerit® T 60/60

molerit® T 70

molerit® T 80

hardnessshore A+/-5%

weather(UV1) ozone, water)

mechanicalproperties

oil and grease petroleumether

alkaline washingsolution (1%)

cold fracturetemperature acc.to DIN 53372

max. utilisationtemperature

(°C)2)

flame retardingaccordingto UL 94

resistance against

52

50

50

59

59

60

60A/60D3)

70

80

-50

-45

-52,5

-32,5

-30

-22,5

-40

-22,5

-32,5

70

704)

70

70

70

70

70/1003)

70

70

–

–

–

–

V-0

–

–

–

–

/ /

F = good resistance to oil and grease very good 1) with dark colorationFL= equipped to be flame resistant good 2) short-term stress up to +120°C possibleK = very good cold resistance satisfactory 3) radiation crosslinked (Shore D +5/-10)M = mat surface conditional 4) in vehicle interior also for occasional surface

temperature up to 85°C

/

Material properties of molerit®

www.moellerwerke.de26 www.moellerwerke.de

The method

The heated dip core is immersed in liquidmolerit®. The material gelatinates around thedip core. The core exactly images the inter-nal contour of the dip moulded component.The wall thickness of the dip moulded com-ponent is determined by the dwell time inthe molerit® and by the thermal capacity ofthe tool. The fully gelatinated and cooleddip moulded component is pulled off thedip core.

Dip moulding tools – quick andcost-effective, available alreadystarting at 500 Euro

MöllerWerke constructs dip moulded compo-nents and their tools with the help of 2-D and3-D CAD systems. The tools are produced onmodern CNC machines. If modifications of thetools become necessary during the pilot phase,they can usually be implemented quickly andcost-effective.

Radiation crosslinking afterdipping

This process produces two material proper-ties in one component. The desired flexibilityof the soft plastic component is retained incertain areas, whereas in defined zonesthe form stability and hardness of hardplastic parts is produced. The areas of thedip moulded component which are to becrosslinked are exposed to a dosed beta radi-ation. This alters the material and hard zonesevolve with have greater mechanicalstrength and thermal form stability.

Special versions of the dipmoulding parts:

• can also be combined with each otheras components

• venting or exhaust ventilation of theform components can be provided withadditional air flaps or air screens

• increase of the stability with insertedwire rings

• can be sectioned by sewing-in zip orcleat fasteners

• print marking possible• metal or plastic flanges can beincorporated

MöllerWerke GmbH – customer proximity is our topmost principle!

We have the right möllerbalg® for your machine or application.

Let us solve your cover problems.


KupferhammerD-33649 Bielefeld

Phone: +49 (0) 521 - 44770Fax: +49 (0) 521 - 4477333Email: [email protected]: www.moellerwerke.de

We deliver a large number of diversified products with various properties. The productsand services presented in this brochure as well as the descriptions and specifications areto be understood as examples. They do not constitute guaranteed features or suitabilityfor a particular application. The actual properties and suitabilities can deviate from whatis described here.

www.moellerwerke.de

Peak performance

Flexible covers for machine toolsand linear guide systems


KupferhammerD-33649 BielefeldPhone: +49 (0) 5 21-44 77 0Fax: +49 (0) 5 21-44 77 [email protected]

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