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Our core business

Our core business are customer-specific solutions for the dimensioning, constructing and manufacturing of any kind of special equipment which we manufacture for you according to your material specifications and individual requirements.

This includes:

  • thermoforming and laminating units for the production of textile components (automotive use)
  • plants for the production of fiber-moldings (automotive use)
  • foaming plants
  • various types of sliding and rotating table solutions
  • complex automation technology

 

Thermoforming and laminating systems

Our first goal is to compile modular plant segments to practical solutions. The core of each plant is the multifunctional system of clamping tongs, clocking the materials which have to be laminated through the system, from the lay-up station to the automatic parts removal .

Here, it is possible to add the cut raw material from the roll or the board. Depending on the material requirements, a wide variety of heating systems are used. By means of a spreading system integrated in the clamping tong unit, it is possible to spread the cutting sandwich during the feed of the pliers.

In the downstream forming station, the heated material is brought into its 3-dimensional contour by means of cooled forming tools. During this process, it is possible to allow the material to flow back over the spreading system. By further developing of the clamping tong system, we are able to dispense with the material clamping frames which are otherwise necessary for the deformation on the forming tools. This task is now taken over by the material clamping tong of the plant.

Thus, it is possible to save material and reduce cycle times which has a cost-reducing effect on the entire production process. The placement of a secondarily acting cooling procedure in the field of forming tools optimizes the cooling process and thus realizes a further process time reduction.

Fiber-molding plants

HMP systems are used to produce three-dimensional fiber components in several process cycles. In this process, a wide variety of fibers are opened and mixed in the fiber preparation system upstream of a basic plant, from the delivered bale to the high-preparation fiber.This fiber mixture is fed into the core of the process, the HMP segment, by means of air flow via pipeline systems. Depending on the component design, component size as well as the necessary physical and acoustic properties, various HMP modules are used for the actual part production. After the production of the blank, the product is taken to the final trimming process via a calibration process. This can now be executed variably and independently from the pre-process (water stream or laser cutting unit, overrun or mounted punching and cutting tools). Fiber components are primarily used as counterpart to a PUR foam solution in the area of front wall or floor insulation.

Foaming plants

Due to their versatility, foaming units can be used in all application areas of PUR processing. There is a wide range of types of foaming systems such as high – pressure systems, piston pump metering systems, low – pressure systems, multi – component systems, spray systems, refrigerator systems and carpet backfoaming systems, to mention just a few types. For the serial production, molded foam parts are manufactured on stationary systems with one or several mould carriers, rotary table systems, overhead or oval conveyors , etc. . Polyurethane components can be found almost everywhere: whether as insulation, upholstery furniture, refrigerator, car seat, headrest, steering wheels, bumpers, spoilers, door trim, carpets, instrument boards, skis, surfboards, ice hockey sticks, letterboxes, computer cases, beer drums etc.

RAT-Spezialmaschinen GmbH builds plants for the high and low pressure reaction areas. The performance spectrum includes: integral, hard, semi-hard, soft foam and insulating foam units. Our many years of experience in the polyurethane sector provide us with the decisive advance in the realization of customized solutions, such as the design, modernization, relocation and expansion of your production facilities.

The centerpiece of each foaming machine are the mixing heads which must be designed for the respective application in order to be able to manufacture the products.

Sliding and rotating table solutions

Sliding and rotating table solutions were designed to optimize time-consuming machine single processes with subsequent manual component handling.

The component produced by means of a combined solution is thus driven through the process clearly fixed onto a lower tool adapter with two or more identically or differently designed upper tools.

A typical example is the RRIM / PUR production of front wall insulations. This sliding table system is a combination of 3 parallel-connected downstroke pressure transducers which are equipped with a sliding-plate mimic. The medium pressure sensor has a closing force of approx. 1,500 KN and is equipped with an injection mold upper part for the production of RRIM parts. The two outer ones have a closing force of 500 KN and are equipped with PUR molded parts. The lower mold parts are located on two independently movable sliding tables. In this plant insulation parts are produced the latter of which consist of an RRIM film and a PUR foam insulation after the end of the process. Since the reaction time during the curing of the PUR backfoaming in the external pressure transducers is greater than in the RRIM process in the medium-pressure transducer, the optimum plant utilization is achieved by alternate feeding.

As a rule, four-column pressure transducers are used in all kinds of possible applications with regard to pressure force and table sizes.

Complex automation technology

This means in general the connection of individual operations to complete processes by means of any kind of automation objects (robots, gantries, manipulators as well as all known basic elements of the general conveyor technology). As a rule, an comprehensive cost-based assessment of the existing situation with regard to the required degree of automation is necessary, taking into account many secondary variables such as production process, quantity, variants, logistics concepts, wage structures, etc.

 

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