Ideal connections - MöllerGroup GmbH...The Kupferhammer in 1907 and 2014. Headquarters and main administration of the MöllerGroup. The Company The MöllerGroup is a company with

Ideal connections

Flexible solutions for construction equipment,agricultural machinery, railway engineering,omnibuses/road trucks and special vehicles

2 www.moellerwerke.de

The MöllerGroup 3

The MöllerWerke 4

Air hoses in the motor compartment 6

Air feed systems for rail vehicles 12

Compensators 15

Bellows and form components made of molerit® - TAUCHPERFORM® 16

Contents

http://www.moellerwerke.de/

3www.moellerwerke.de

The MöllerGroup

With international partners to world wide success.

The Kupferhammer in 1907 and 2014. Headquarters and main administration of the MöllerGroup.

The Company

The MöllerGroup is a company with tradition: Family owned since eight generations,

it can look back on a history of more than 280 years. Since then the company has

become an internationally successful production and service enterprise. Sectioned into

two business sectors – plastics engineering and flexible structural components –

the MöllerGroup today delivers peak performance products throughout the world.

The MöllerGroup world wide

As an international company, the MöllerGroup thinks and acts across frontiers. With

own operative companies or joint ventures, we produce where our customers are.

Thus customers throughout the world can rely on our know-how

and on our competence on-site.



The MöllerWerke

Flexible solutions from a single source.

Production hall

MöllerWerke is a competent development partner for the industry. Under the brand name of

möllerbalg® flexible constructional components are developed and manufactured for a wide

diversity of applications. In addition to machine tool construction, special vehicles and railway

engineering, the products from MöllerWerke are utilised in hydraulic systems, pneumatic

systems, 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 designed

products, high economic efficiency, constant product quality and unrestricted service. The

own materials development with corresponding released mixtures and material combinations

can fulfil almost any technical requirements.

The close cooperation with our customers and the material and product development in the

house of the MöllerWerke leads to new solutions and new products

Order processing centre



Materials: diversified and flexible

Our many years of material and product

development experience as well as nume-

rous special technical problem solutions

constitute significant advantages for the

benefit of our customers.

The following factors are decisive for the

quality of our products:

• The particular application

• The boundary conditions

• The selection of materials

• The manufacturing method

We have our own test beds and a techno-

logy centre. In addition, we can access the

laboratories of the MöllerGroup.

Coated technical fabrics:• Polyester fabric coated with polyuret-

hane, 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

• FMVQ fluoro silicone

Other materials:• Insulating materials (e.g. textured glass)

• Steels

• Aluminium

• molerit®

• PVC

• Polyamide

• Polypropylene

And numerous other materials on inquiry.

Fertigungsverfahren bei MöllerWerke:

Laboratory Production of a wound hose

Methods: individually planned and implemented

The MöllerWerke utilise a number of special

production methods which have mostly

been developed by us for industrial pro-

duction of bellows. Machines, systems and

production lines are special plants which

have emerged in the course of numerous

years of experience with bellows pro-

duction. MöllerWerke owns international

patents for many of these methods.

• welding automatons for way covers

• HF welding automatons for bellows

• dip moulding methods and dip

automaton for molerit®

• radiation crosslinking

• CNC mould drawing

• manual mould drawing on special

moulds

• automated scale production

• automated cutting on plotter, milling

and water jet systems

Research and development at MöllerWerke

The market imposes continually growing demands on us and our products. Therefore

we permanently monitor the market developments and devise corresponding innovative

solutions on the sector of new products, materials and methods.

Modern research facilities are available to our chemists and engineers. Important

CAD systems, innovative experimental technology and continuous online data exchange

between the individual work groups produce efficient application-oriented results.

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

Production methods at MöllerWerke:



Secure air ducts in the complete motor compartment.

Air hoses in the motor compartment

MöllerWerke is a specialist for suction and charging air ducts. Own special production

methods have been developed for these applications, permitting efficient manufacturing

and thus economically attractive design of the desired geometries. Careful production

on our special machines and continual checks ensure constant very high quality of our

products.

We develop the air routing solutions and installation concepts together with our customers.

Consultation of the MöllerWerke specialists already in the vehicle development phase leads

to pioneering concepts that point the way ahead. Thus, knowing the boundary conditions,

the raw, clean and charging air is integrated in three dimensions within the aggregate. This

procedure permits system optimising even before installing the first prototype. As a matter of

course, we always manage the new products until the start of production by our customers.

Production of a wound hose



• Large range of materials suitable for all

mechanical and thermal stress situations

• Mixing, calendering and friction-glazing of

the utilised elastomers on modern

production plants in our factory

• Material and product development in

development department, laboratory and

test shop

• Constructional design with SolidWorks®

and AutoCAD® MECHANICAL. Data can

be processed in the formats STEP, IGES,

ACIS, DWG, DXF and others.

• Prototype testing on our own test stands

• Customer service and product consult -

ation locally by competent production

engineers

Raw airArea between

air intake and filter

Schematic depiction of the air feed systems

Clean airArea between filter outlet and

engine connector or

turbo supercharger

Turbo supercharger charging airArea between turbo supercharger and

engine inlet or charging air cooler

Charging air (cooled)Area between charging air

cooler and engine inlet

Filter

Connection M 10 x 1Maintenance switch

Compressor line

Turbo supercharger

Exhaust gas line

Charging air cooler

Crankshaft housing ventilation

Motor



The following fabrics are utilised for reinfor-

cing the various elastomers. Their tempera-

ture resistance corresponds to that of the

utilised elastomer:

• mixed fabric CO / PET (cotton / polyester)

• polyester (PET)

• polyamide (PA)

• aramid (Nomex)

• aramid (Kevlar)

The choice of the right hose type is

determined by:

• the spatial circumstances in the motor

compartment

• the chemical/physical requirements, such

as: movements, pressures, temperatures,

resistance to oil and fuels

material

properties/suitability

Table of materials

CRchloroprene caoutchouc

CR-fl(flame retarding)

black

black

densitycolour hardness in Shore A

tensilestrength inMpa accord -

ing to DIN 53504

fractureelongationin % accor-ding to

DIN 53505

residualcompressivedeformation

flame retardingand self-extinguish -

ing

oil andgrease resistant

weather-proof

cold flexibility

max. contin -uous tempe-rature (shortperiod tem-perature)

1,48

1,48

>8

>10

>350

>350

-40

-40

100(125)

100(120)

1,19 >10 >450 -1290(110)

1,2 7 >250 -30125(140)

1,41 >10 >300 -40120(135)

1,24 65

60

60

>11 >350 -35150(170)

1,21

1,34

60

60

60

70

60

>6,5

>6,5

>300

>300

-50

-50

240(260)

180(220)

1,37 68 >6 >180 -50180(220)

1,85 83 >15 >250 -25240(260)

1,1860(60)

>7(>17)

>350(>40)

-3570(100)

black

black

black

black

red

pink

red

black

black

NBR (1)

nitrile caoutchouc

EPDMethylene-propylene-diene

caoutchoucECO

epichlorhydrin caoutchouc

ACMethyl acrylate caoutchouc

MVQsilicone caoutchouc

MVQ-fl(flame retarding)

FMVQfluoro-silicone caoutchouc

FKMfluoro caoutchouc

Molerit PVC-P(partially radiation-

crosslinked)

good satisfactory moderate

Charging air hose in the motor compartment



möllerbalg® charging air hoses

MöllerWerke processes exclusively high quality materials. such as:

• high temperature resistant silicone caoutchouc + fluorosilicone

• fluorocaoutchouc as oil barrier

• CR, NBR, ACM (VAMAC) for suction hoses and cooled charging air

• fabric reinforcements such as aramid fibre fabric (Nomex or Kevlar)

Material, material structure, wall thickness and geometry are determined according to the

individual requirements. The technical data for möllerbalg® charging air hoses conform to

the specific motor stipulations.

Sleeves

Elastic connections of charging air lines

• tools for the standard sizes are available

Single wave hose

Utilised like sleeves, but can additionally

take up slight axial and/or lateral movements,

compensation of small constructional

tolerances ranzen

Multiple wave hose with sleeve

• Take up of axial, angular and lateral move-

ments. Pressure stabilisation by external

wire rings. Reduced pressure stabilisation

optionally with internal wire rings. The

movement take up is determined by the

number of waves.

• Connection type optionally possible as

sleeve or as V-clamp; it is also possible to

combine both connection variants.

Multiple wave hose with V-connection

• positive connection

• utilisation under higher pressure

conditions

• fixed defined mounting situation

• reduced mounting dimension compared

with multiple wave hose with sleeve

• compensation of larger constructional

tolerances

Multiple wave hose with sleeve Multiple wave hose with V-sleeve

Charging air solution

Single wave hose



Rigid and flexible zones in a piping hose

Bend with single piece charging air solutions

• with the same or different connecting diameter

• introduction of waves with additional movement take up

• single piece three-dimensional hose solutions

• minimising interfaces in the charging air system

• limited diversity of parts

Piping hose

• bending radius 0.8 x D

• stability under reduced pressure produced by internal wire spiral

• wire-free and thus non-leaking connection area

• various connection diameters are possible

• connections for maintenance switch and crankshaft housing

ventilation can be integrated

• tools for standard sizes available

• production lengths up to 2,000 mm

Form hose, extrusion mandrel method

• three-dimensional formable

• various connection diameters possible

without fabric insert up to 130 mm, with

fabric insert up to 76 mm

• economically efficient batch sizes up to

50 pieces

Form hose, press and injection

moulded method

• external and internal contour depiction,

e.g. ribs to enhance the stability under

reduced pressure

• economically efficient when large

quantities are required

Extrusion part Injection moulded form part

möllerbalg® suction hose variants

Rigid zone

by additional rubber

layer

Flexible zone

with pre-formed folds



Double bend crosslinked Bend crosslinked

Air ducts crosslinked

Form parts by dip method

• stable under reduced pressure by

crosslinking

• soft plug-on regions by partial

crosslinking

• complex geometries with strong

cross-section changes possible

• no direct connection on the turbo

supercharger

• insertion of indicators such as M10x1

possible

• permit ambitious design also for

functional parts

Pressure mbar bar Pa Kpa MPA N/mm² mm WS

1 mbar 100

10 5

1

1000

10 6

10 6

10

10 -4

0,1

10 -6

10 -3

1

1

10 -5

10 -4

0,1

10 -6

10 -3

1

1

10 -5

10

10 4

0,1

100

10 5

10 5

1

0,1

100

10 -3

1

1000

1000

10 -2

1

1000

10 -2

10

10 4

10 4

0,1

10 -3

1

10 -5

10 -2

10

10

10 -4

1 bar

1 Pa

1 KPa

1 MPa

1 N/mm²

1mm WS

Overview of pressure measuring units

Bend



Air and air conditioning engineering in locomotive

and wagon construction.

Air feed systems for rail vehicles

MöllerWerke is a competent partner for ventilation and air conditioning engineering.

For many vehicle types in railway engineering we deliver a wide range of flexible air guiding

systems.

Together with the leading manufacturers of rail vehicles, MöllerWerke develops

and tests air guiding bellows and compensators and is experienced in all

production methods involved.

Advantages for MöllerWerke partners:

• many years of experience and know-how

for the technical design

• constructional design with SolidWorks®

and AutoCAD® MECHANICAL. Data can

be processed in the formats STEP, IGES,

ACIS, DWG, DXF and others

• Möller technology centre equipped with

test facilities for movement sequences,

also under pressure and thermal stress

• customer service on site by competent

application engineers

• on request MöllerWerke performs

documented long-term test runs of the

traction motor ventilation bellows

conforming to the specifications by the

rail vehicle manufacturer.

Traction motor ventilation bellow



Traction motor ventilation bellows

möllerbalg® traction motor ventilation bellows are products specially developed for the

particular application. The connections can be designed depending on the particular

installation situation on the wagon body or on the bogie. The connections (flanges) of the

folding bellows have circumferential sealing surfaces. Backing flanges attached to the

folding bellows by vulcanisation provide a homogeneous self-sealing secure connection.

The number of folds is determined according to the distance between the bogie and

the wagon body and according to the expected movement sequences. The geometry of

the traction motor ventilation bellows is determined by the connections and the pressure

losses. The basic parameter is thereby the volume flow rate of air through the bellows.

The folding bellows consist of a rugged Nomex silicone fabric. The defined geometries are

set up on specially designed tools and tested when necessary. The folding bellows are

stabilised with wire rings if necessary according to the operating requirements.

möllerbalg® traction motor ventilation bellows are proven, for example, by Siemens AG,

Bombardier Transportation, Alstom Transportation, Stadler AG, AnaldoBreda.

Diesel-electric locomotives

• traction motor ventilation bellows

• compensators

• air conducting hoses in the motor

compartment

Electric locomotives


• compensators

Rail cars, trainsets, waggons


• compensators

• air conducting hoses

Utilisation fields of the MöllerWerke products



MöllerWerke utilises only application tested materials for the traction motor ventilation

bellows, such as Nomex silicone fabric complying with the fire protection classes of most

European railway companies.

Applicable standards

• testing of the fire behaviour of materials

according to E DIN 54837 – classification

according to E DIN 5510-2

• testing of the surface inflammability

according to ASTM E 162

• determination of the smoke gas density

according to ASTM E662-97

• British Standard 476-7: 1997

• determination of the oxygen index

accord ing to EN ISO 4589 -2 : 1999

• testing according to EN ISO 11925-2

with regard to the fire behaviour of

construction products – classification

according to UNI CEI 11170

• determination of the smoke class accord -

ing to NF F 16-101 - smoke gas density

according to NF X 10-702; smoke gas

toxicity according to NF X 70-100

• classification according to the Spanish

Standard RENFE UNE 23.725-90

• fire protection classification according to

CEN/TS 45545

• fire protection classification according to

NFPA 130:2010

Depiction of the deflections

Prototype test

Testing facilities

The maximum stipulated movement of a bellow for a new project is simulated with testing

facilities. The long-term durability of the traction motor ventilation bellows can be tested

before the start of serial production by calculation in testing facilities with pre-defined

movement matrix over a defined period of time. Thereby the wear behaviour with various

installation lengths and deformation sequences is tested too. Such a prototype test includes

on request a detailed documentation. The evaluation considers in detail the appearance

of a case of damage, the abrasion, the pressure and scraping locations as well as the stroke

number dependent effect on the resulting leakage flow rate.

Schematic depiction of the installation of atraction motor ventilation bellows

traction motor

venti -lation shaft

Wagon body

traction motor ventilation bellow

end flange withfeed-in cone andrubber seal

Silicone flangewith backingflange

Silicone flangewith steel flange attachedby vulcanisation



Double compartment compensator

Air conditioner and compensator

Compensator

Perfect is what works.

Compensators are high performance flexible connecting elements for movement take up

and for tolerance compensation in air conditioning and ventilation systems. Specially

designed compensators are utilised in locomotives and passenger train coaches. Extreme

installation variants can be implemented with asymmetric geometries. The connection

to the respective interface is established with self-sealing flanges attached by vulcanisation.

The flanges can be made optionally of aluminium or stainless steel.

Additional insulating materials can be incorporated in the compensators to avoid cold

bridges. The materials utilised for compensators comply with the fire protection classes of

most European railway companies.

Compensators

X

X2:1Installation width

design width

circumferential

sealing lip

steel flange

attached by

vulcanisation

sewn


16

Form components made of molerit®

The advantages of the dip moulding method

• nearly all shapes are possible, including

complex geometries

• small batches can be produced with

low tool costs

• various hardness ranges possible within

one dip moulded component

• 2 colours possible within one dip

moulded component

• surface optionally mat or glossy

• standard colours: black, red, yellow,

grey, transparent; special colours can

be selected if required

• 100 % reproducibility

The worldwide unique, automated system offers designers new opportunities in the design

of plastic moulded parts with different geometries. The manufacture of injection moulds is

often uneconomical for small to medium series. The tool production for TAUCHPERFORM® is

associated with significantly less effort and cost.

For quantities up to 15,000 pieces, TAUCHPERFORM® offers a flexible and efficient alterna-

tive to other moulding processes. After just three weeks, the first sample is available.

So products can be modified and optimized quickly with little effort. Mouldings and bellows

made with TAUCHPERFORM® can be found in the entire industry, such as electrical engineer -

ing, mechanical engineering, sanitary engineering, medical and automotive technology.

TAUCHPERFORM® – Immerging into a new dimension.

www.tauchperform.com

http://www.tauchperform.com/

17

The material

molerit® is a special mixture based on PVC.

Careful selection of the components is made

according to the aspects of health compa -

tibility, environmental compatibility and tech-

nological properties. With PVC as a basis,

a polymer with high chemical resistance

is utilised, which is well known through

decades of experience. The properties of

molerit® depend strongly on the auxiliary

materials and the production mode, and

they can be adapted to suit a wide diversity

of technical requirements. An extensive

range of types with a broad spectrum of

properties is available: low temperature

suitability, high temperature suitability,

haptic, optics, flame retarding, individually

optimised media resistance (oil, grease,

petroleum ether, salts, acids and alkalis).

Furthermore, molerit® can be manufactured

in almost any colour – even as glass-trans -

parent component.

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

hardness

shore A

+/-5%

weather

(UV1) ozone, water)

mechanical

properties

oil and grease petroleum

ether

alkaline wash ing

solution (1%)

cold fracture

temperature acc.

to DIN 53372

max. utilisation

temperature

(°C )2)

flame retarding

according

to 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®

The outstanding properties of molerit®

• high resistance to cracking due to ageing

or the effect of light

• good resistance to UV radiation

• cold stability down to -50°C

• thermal form stability up to +70°C, in the

cabin area up to +85°C

• with radiation crosslinking up to +100°C

• very good resistance to acids, alkalis, sea

water and gases

• material types in many hardness grades,

see the material table on this page

• special type for enhanced resistance to

mineral oil and grease Utilisation in vehicle engineering

Scan code to learn moreabout TAUCHPERFORM®



18

The method

In the TAUCHPERFORM® process a teach

robot determines the geometric parameters

for each new article. These are the basic

data for TAUCHPERFORM®. When the tool

has been inserted into the system, it is heat -

ed and dipped into a basin with the molerit®.

The material gelatinates around the mould

(tool) which exactly images the inner con-

tour of the finished part. The wall thickness

of the product is determined by the dwell

time in the molerit® and by the thermal

capacity of the tool. The fully gelatinated

and cooled dip moulded component is

pulled off the tool.

Dip moulding tools – quick and cost-effective, available already starting at 500 Euro

MöllerWerke constructs dip moulded compo-

nents and their tools with the help of 2-D and

3-D CAD systems. The tools are produced on

modern CNC machines. If modifications of the

tools become necessary during the pilot phase,

they can usually be implemented quickly and

cost-effective.

Radiation crosslinking after dipping

This process produces two material proper-

ties in one component. The desired flexibility

of the soft plastic component is retained in

certain areas, whereas in defined zones

the form stability and hardness of hard

plastic parts is produced. The areas of the

dip moulded component which are to be

crosslinked are exposed to a dosed beta

radiation. This alters the material and hard

zones evolve with have greater mechanical

strength and thermal form stability.

Special versions of the dip moulding parts:

• can also be combined with each other

as components

• venting or exhaust ventilation of the

form components can be provided with

additional air flaps or air screens

• increase of the stability with inserted

wire rings

• can be sectioned by sewing-in zip or

cleat fasteners

• print marking possible

• metal or plastic flanges can be

incorporated



MöllerWerke – Customer proximity is our primary principle.

We have the right möllerbalg® for your vehicle.

Let us find the ideal connection for you.

MöllerWerke GmbHmöllerbalg®

Kupferhammer D-33649 Bielefeld

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

We deliver a large number of diversified products with various properties. The products

and services presented in this brochure as well as the descriptions and specifi cations are

to be understood as examples. They do not constitute guaranteed features or suitability

for a particular application. The actual properties and suitabilities can deviate from what

is described here.

mailto:[email protected]


www.moellerwerke.de

MöllerWerke GmbH

möllerbalg®

Kupferhammer

33649 Bielefeld

Phone: +49 (0) 5 21-44 77 0

Fax: +49 (0) 5 21-44 77 333

[email protected]


mailto:[email protected]

Documents

Ideal connections - MöllerGroup GmbH...The Kupferhammer in 1907 and 2014. Headquarters and main administration of the MöllerGroup. The Company The MöllerGroup is a company with