Special-purpose machines for taping, winding and spiraling – from design to commissioning
PNS Sondermaschinen GmbH
Pankstr. 8-10, 13127 BerlinNew on Amplifa
About PNS Sondermaschinen
PNS Sondermaschinen GmbH, founded in Berlin in 2003, is a special-purpose machine manufacturer for winding, taping and spiraling systems. The company develops and manufactures taping machines for insulating formed coils, generator bars and industrial hoses, precision wire winding machines with up to 33 wires per layer, yarn winding machines for aramid, Kevlar and polyester yarns, as well as spiraling machines for steel and yarn reinforcements on hoses and cables. In addition, PNS offers special applications such as boiler interior grinding machines, embossing and cutting machines and hose rewinders. The range of services covers design and development, control automation, manufacturing, assembly, commissioning as well as service with on-site support and training. Customers come from hose and cable manufacturing, electric machine, generator and transformer construction, the basic materials industry, aerospace and robotics. Materials processed include high-strength steel and stainless steel wires, copper bars, aluminum cores as well as rubber, silicone and PVC products. References exist worldwide, among others in Europe, Asia and America.
- Site
- Berlin
- Processes
- Manufacture of taping machines/insulating machines (e.g. BR60, BBS15, BBF28, BBF23, BBF20, BBF4,, Manufacture of wire winding machines (e.g. MCW5-LT33, SSM40, SSB70, MCW4), Manufacture of yarn winding machines (e.g. SYD2, SSB20, SSB10, LH01), Manufacture of spiraling machines (e.g. WFMS4, SPT60D, SPT18, FRS120, SA100-E), Special-purpose machine construction (e.g. PDK250 boiler interior grinding machine, PRB45 embossing, Design and development, Assembly and testing, commissioning, Control automation
- Materials
- Stainless steel, Steel (high-strength), Kevlar, Aramid, Polyester, Plastic strands, Rubber (rubber tapes), Silicone
- Certificates
- CE conformity of the delivered machines
- Founded
- 2003
- Industries
- Hose and cable manufacturing, Electric machine construction, Generator construction, Transformer construction, Automotive/vehicle construction, Basic materials industry
- 01
Consulting and technical concept development
- 02
Design and development
- 03
Control automation
- 04
Manufacturing and logistics
- 05
Assembly and testing
- 06
Delivery and commissioning
- 07
Service, system maintenance and training
Materials
Steel (high-strength)
High-strength steel wires are processed on precision winding machines and magazine spiraling machines into braiding and spiraling bobbins.
Stainless steel
Stainless steel wires in layers of up to 33 wires for demanding braiding and spiraling products.
Copper
Flat copper bars with variable cross-sections are insulated on the bar taping machine.
Aluminum
Aluminum cores serve as carriers when taping rubber tapes onto industrial hoses.
Rubber
Rubber tapes are wound onto hoses to finish multi-layer industrial hoses.
Silicone
Silicone hoses are given yarn reinforcements on spiraling machines.
PVC
PVC hoses are given yarn reinforcements on spiraling machines.
Kevlar
Technical yarns such as Kevlar are rewound with high quality on yarn winding machines.
Aramid
Aramid yarns are wound automatically onto braiding bobbins.
Polyester
Polyester yarns are processed on yarn winding machines in layers of up to 24 threads.
Plastic strands
Plastic strands up to 2 mm Ø are applied helically to stranded material up to 120 mm Ø.
Berlin Location
Berlin
DEHeadquarters, design and manufacturing
- Materials
- Steel, stainless steel, copper, aluminum, rubber, silicone, PVC, Kevlar, aramid, polyester
- Automatic taping system BR60 with industrial robotics
- Hose taping system BBS15
- Multi-axis taping machine BBF28 up to 2.8 m coil length
- Multi-axis taping machines BBF23 and BBF20
- Flat-coil taping machine BBF4
- Bar taping machine BBS20
- Precision winding systems MCW5 series up to 33 wires
- Rewinding system SSM40 for magazine winding
- Yarn winding systems SYD2, SSB10 and SSB20 with dual winding head
- Magazine spiraling machine system WFMS4-FRS120-RFZ150
- Spiraling machines SPT60D and SPT18-YH
- Boiler interior grinding machine PDK250
- Embossing and cutting machine PRB45
- Hose rewinder ATS800
- Constant-tension wire dereelers LT12–LT33-250-T
Machines and Systems
Inside the production
Industries
Processes & technical limits
| Processes | Tolerance | Max. part | Weight | Lot size | Materials |
|---|---|---|---|---|---|
| Manufacture of taping machines/insulating machines (e.g. BR60, BBS15, BBF28, BBF23, BBF20, BBF4,Engineering | – | 2.8 m (coils, expandable) | – | – | – |
| Manufacture of wire winding machines (e.g. MCW5-LT33, SSM40, SSB70, MCW4)Engineering | – | – | – | – | Stahl, Edelstahl |
| Manufacture of yarn winding machines (e.g. SYD2, SSB20, SSB10, LH01)Engineering | – | – | – | – | Kevlar, Aramid, Polyester |
| Manufacture of spiraling machines (e.g. WFMS4, SPT60D, SPT18, FRS120, SA100-E)Engineering | – | 120 mm (stranded material Ø) | – | – | Stahl, Kunststoff |
| Special-purpose machine construction (e.g. PDK250 boiler interior grinding machine, PRB45 embossingEngineering | – | – | – | – | – |
| Design and developmentEngineering | – | – | – | – | – |
| Assembly and testing, commissioningAssembly | – | – | – | – | – |
| Control automationEngineering | – | – | – | – | – |
| System maintenance and service (on-site support, repair, training)Engineering | – | – | – | – | – |
53 Anlagen & Maschinen
| Machine | Manufacturer / model | Quantity | Working area | Year built | Site |
|---|---|---|---|---|---|
| Automatic taping system (industrial robotics) for generator bars/form coils | PNS BR60 | – | – | – | Berlin |
| Hose taping system | PNS BBS15 | – | multi-layer large industrial hoses | – | Berlin |
| Multi-axis taping machine | PNS BBF28 | – | coils up to 2.8 m length (expandable) | – | Berlin |
| Multi-axis taping machine with external support | PNS BBF23 | – | coil lengths up to 2.3 m | – | Berlin |
| Multi-axis taping machine with head support | PNS BBF20 | – | coil lengths up to 2.0 m | – | Berlin |
| Flat-coil taping machine | PNS BBF4 | – | – | – | Berlin |
| Rope taping system | PNS BBSF20 | – | various lengths | – | Berlin |
| Bar taping machine | PNS BBS20 | – | flat copper bars, variable cross-sections | – | Berlin |
| Bench taping machine | PNS BBU3 | – | – | – | Berlin |
| Hand taping machine | PNS BBU2 | – | – | – | Berlin |
| Precision winding system (wire) | PNS MCW5-LT33 | – | layers of up to 33 wires | – | Berlin |
| Precision winding system (wire) | PNS MCW5-LT24 | – | layers of up to 24 wires | – | Berlin |
| Precision winding system (wire) | PNS MCW5-LT16 | – | layers of up to 16 wires | – | Berlin |
| Precision winding system (wire) | PNS MCW5-LT12 | – | layers of up to 12 wires | – | Berlin |
| Precision winding system (wire) | PNS MCW5-LT9 | – | layers of up to 9 wires | – | Berlin |
| Precision winding system, special version | PNS MCW5-FW-LT12 | – | layers of up to 12 wires | – | Berlin |
| Precision winding system | PNS MCW4-LT12 | – | layers of up to 12 wires | – | Berlin |
| Precision winding system, rotating | PNS MCW4-LT12-90° | – | layers of up to 12 wires | – | Berlin |
| Wire/yarn winding machine | PNS MCW4-LT6W-4Y | – | 6 wires + 4 yarn threads | – | Berlin |
| Rewinding system for magazine winding | PNS SSM40 | – | – | – | Berlin |
| Semi-automatic wire winding machine | PNS SSB70 | – | heavy-gauge wires | – | Berlin |
| Wire dereeler with unwinder and dancer system | PNS LTA800 | – | – | – | Berlin |
| Wire dereeler with wire break monitoring | PNS TAS800 | – | – | – | Berlin |
| Constant-tension wire dereeler | PNS LT12-250-T | – | 12 individual wire dereeling positions, DIN spools | – | Berlin |
| Constant-tension wire dereeler | PNS LT16-250-T | – | 16 individual wire dereeling positions | – | Berlin |
| Constant-tension wire dereeler | PNS LT24-250-T | – | 24 individual wire dereeling positions | – | Berlin |
| Constant-tension wire dereeler | PNS LT33-250-T | – | 33 individual wire dereeling positions | – | Berlin |
| Yarn winding machine | PNS SYD2-LT6-2-320-Y | – | up to 2x6 threads | – | Berlin |
| Yarn winding system | PNS SYD2-LT12-2-250-Y | – | 2x12 or 1x24 threads | – | Berlin |
| Yarn winding machine | PNS SSB10-LH12 | – | up to 4 braiding bobbins | – | Berlin |
| High-performance winding machine system | PNS SSB20-LT16-250Y | – | 2x8 thread dereeling positions | – | Berlin |
| High-performance winding machine system | PNS SSB20-LT12-250Y | – | 2x6 thread dereeling positions | – | Berlin |
| High-performance winding machine system | PNS SSB20-LT8-250Y | – | 2x4 thread dereeling positions | – | Berlin |
| High-performance winding machine | PNS SSB20 | – | dual winding head | – | Berlin |
| Winding machine system | PNS SSB10-LT12 | – | 2x6 thread dereeling positions | – | Berlin |
| Winding machine | PNS SSB10 | – | dual winding head | – | Berlin |
| High-performance wire dereeler | PNS LT12-250-T-Y | – | 2x6 thread dereeling positions, expandable to 2x8 | – | Berlin |
| High-performance wire dereeler | PNS LT12-250-Y | – | 2x6 thread dereeling positions | – | Berlin |
| Overhead multi-payout system | PNS LH01-250-YH | – | – | – | Berlin |
| Overhead multi-payout system with individual dereeler for strands | PNS LHT01-250-YH-1-250 | – | – | – | Berlin |
| Magazine spiraling machine system | PNS WFMS4-FRS120-RFZ150 | – | – | – | Berlin |
| Magazine spiraling machine | PNS WFMS4 | – | material up to 2 mm Ø, stranded material up to 120 mm Ø | – | Berlin |
| Caterpillar puller/feeder | PNS FRS120 | – | up to 120 mm Ø | – | Berlin |
| Centering device | PNS RFZ150 | – | – | – | Berlin |
| Spiraling machine, double deck | PNS SPT60D | – | – | – | Berlin |
| Spiraling machine | PNS SPT60 | – | 60 plug-in winding stations | – | Berlin |
| Spiraling machine system | PNS SPT18D-YH/A-B | – | – | – | Berlin |
| Spiraling machine | PNS SPT18-YH | – | – | – | Berlin |
| Single-disc puller | PNS SA100-E | – | integrated measuring system | – | Berlin |
| Boiler interior grinding machine | PNS PDK250 | – | – | – | Berlin |
| Embossing and cutting machine | PNS PRB45 | – | slot insulations, interleaves, top sticks | – | Berlin |
| Hose rewinder | PNS ATS800 | – | various diameter and length dimensions, coreless bundles | – | Berlin |
| Taping machine (winding and unwinding of tape material) | PNS BFS5 | – | – | – | Berlin |
Additional services
Quality
PNS delivers taping machines with CE marking and protective equipment and relies on wear-free brake technology as well as sensor and control technology for consistent, reproducible process quality. Products manufactured with PNS machines meet stringent evaluation criteria such as the Catenary Test in aerospace.
| Evidence | Berlin |
|---|---|
| CE conformity of the delivered machines |
Company History
- 2003
Foundation of PNS Sondermaschinen GmbH in Berlin