Online Hose Cutting Machine

The Online Hose Cutting Machine from Ecotech Industries is a cutting-edge, fully automated system designed for yarn hose production and industrial hose cutting applications. Built with a strong stainless steel structure and advanced servo-driven technology, this equipment delivers high-precision, efficiency, and safety for continuous manufacturing environments. It is engineered to meet global industrial standards, making it an essential solution for manufacturers that deal with hoses of varying diameters and lengths.

This system integrates modern automation with PLC controls, ultrasonic sensors, and poka-yoke safety features, ensuring seamless operation while maintaining accuracy and worker protection. With its capability to cut hoses ranging from 20mm to 60mm in diameter, the machine is versatile, durable, and future-ready for industrial production lines.

PLC Controlled Fully Automatic Operation

At the heart of the Online Hose Cutting Machine is a PLC-based control system that ensures precision, consistency, and automation. The programmable logic controller automates every stage of the cutting process, from feeding to measuring and cutting. This reduces human error, increases productivity, and ensures repeatability across thousands of cycles.

The fully automatic nature of the machine allows it to be integrated directly into production lines, where it continuously handles yarn hoses without manual intervention. This results in reduced downtime, improved efficiency, and consistent quality output, which is critical for high-volume manufacturing industries.

Robust Stainless Steel 304 Construction

The complete structure of the machine is manufactured using SS 304 stainless steel, known for its durability, corrosion resistance, and hygienic properties. This ensures that the equipment not only withstands long-term industrial use but also maintains a clean and professional finish. The stainless steel design guarantees structural integrity even in heavy-duty applications, extending the lifespan of the machine.

Caterpillar / Haul-Off Unit with Servo Motor Drive

The hose feeding system relies on a caterpillar or haul-off unit, which is driven by a high-performance servo motor. This mechanism ensures smooth, precise, and consistent movement of the hose during the cutting process.

The unit uses a master-slave servo motor-drive system, where one motor leads and the other follows with synchronized accuracy. This design eliminates slippage, reduces wear, and ensures the hose is fed at a consistent speed for exact length cutting.

By combining servo-driven accuracy with durable construction, the haul-off unit plays a vital role in delivering reliable, high-quality cuts with minimal waste.

PTO Mechanism with Pulse Feedback Provision

The Online Hose Cutting Machine is equipped with a PTO (Power Take-Off) mechanism featuring pulse feedback. This system continuously monitors hose feed movement and provides real-time feedback to the PLC. With this feedback loop, the machine can instantly detect deviations, adjust feed speed, and maintain cutting accuracy within strict tolerances.

Pulse feedback ensures every hose section is cut to the exact length required, supporting quality control and reducing material wastage.

Rotary Cutter Cutting Assembly

For cutting accuracy, the system incorporates a servo-driven rotary cutter assembly. Unlike traditional blade cutters, the rotary cutter delivers smooth, precise, and burr-free cuts, ensuring the hose edges remain clean and suitable for downstream processes.

The servo-driven operation allows the cutter to adapt to different hose materials and diameters, minimizing tool wear and extending service life. This makes the cutting assembly highly efficient, reliable, and cost-effective.

Hose Diameter Range (20mm – 60mm)

The machine is designed to cut hoses with diameters varying from 20mm up to 60mm. By incorporating different die sets, the system can be adjusted quickly to accommodate hoses of varying sizes.

This versatility makes it suitable for a wide range of industries, including automotive, construction, agriculture, and hydraulic applications, where different hose diameters are commonly used.

Ultrasonic Sensor-Based Loop Control

One of the advanced features of this machine is the ultrasonic sensor-based non-contact loop control system. This technology monitors hose loop formation in real-time and adjusts the caterpillar speed accordingly.

Since the system is non-contact, it prevents wear and tear on hoses while ensuring the feeding process remains stable. The result is consistent speed control, better hose tension management, and improved cutting accuracy.

Safety Poka-Yoke Integration

Safety is a top priority in Ecotech’s Online Hose Cutting Machine. The equipment is integrated with poka-yoke mechanisms that prevent unsafe operation. For example, if the caterpillar door or cutter die door is open, the machine will not run.

This safety interlock system ensures that operators are fully protected from moving parts and high-speed cutting assemblies. It also prevents accidental damage to the machine, supporting long-term operational safety and reliability.

Recipe Creation for Operator Ease

The machine allows operators to create and save recipes based on different part numbers, diameters, and lengths. Each recipe stores the required cutting parameters, which can be recalled instantly for future use.

This feature significantly reduces setup time and enhances operator efficiency, particularly in environments where multiple hose specifications are handled daily. By simplifying operations, Ecotech ensures manufacturers can maintain both speed and precision in their production processes.

Applications of Online Hose Cutting Machine

The Online Hose Cutting Machine is suitable for industries where precision hose cutting is critical, including:

• Automotive manufacturing – for coolant hoses, hydraulic hoses, and fuel lines.

• Agricultural machinery – for fluid transmission hoses used in tractors and implements.

• Construction equipment – for high-durability hoses in earth-moving and heavy machinery.

• Industrial hydraulics – for pressure hoses in CRDI, FIP, and fluid power systems.

• General manufacturing – for any production line requiring precise hose length cutting.

Advantages of Ecotech’s Online Hose Cutting Machine

1. High Precision Cutting – Servo-driven rotary cutter and pulse feedback ensure accuracy.

2. Durability – SS 304 stainless steel construction guarantees long-lasting performance.

3. Automation – PLC-controlled operations minimize human intervention and errors.

4. Flexibility – Handles hose diameters from 20mm to 60mm with quick-change dies.

5. Safety – Poka-yoke integration ensures operators are protected during every cycle.

6. Efficiency – Recipe-based programming reduces setup time and increases productivity.

7. Low Maintenance – Advanced servo systems and non-contact ultrasonic sensors reduce wear and extend component life.