WCA July 2007

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58 Wire & Cable ASIA – July/August 2007
These specialities comprise a grouping very nearly at
the end of the production cycle, approaching the point
at which the wire maker’s responsibility becomes the
customer’s property.
The providers of the goods and services reviewed here know that
it is at this full stop that the productivity of the entire operation will be
reckoned – and found to be everything it should be, or otherwise. They also know
that, given the razor-thin margins that define the global marketplace, at that juncture
the line between profit and loss is correspondingly fine.
Fortunately, these companies have been operating at this frontier for some time, and
their grasp of a balance sheet is as sure as their command of their technology. They
know that today’s high-speed wire making process cuts no slack for poor tension
control, worn rollers, inconsistent braking, uneven heating, or warped discs. Still less
do they cut themselves any slack in assessing the financial realities of the industry.
Pay-offs, take-ups
& winding systems
Improving productivity and quality
Continuous process with a constant speed, allowing long batch lengths, improves
productivity and quality. But ribbon lines still run with single take-up, resulting
in imitated line uptime. To fill this gap Nextrom has developed a dual take-up,
which can be integrated into any existing ribbon line.
By replacing a conventional single take-up with a dual take-up, the capacity
increases, reducing scrap, as well as decreasing manual costs. The transfer
from full reel to an empty one can be done at production speed, with no need
to reduce the process speed. The longer the pay-off fibre length is, the greater
capacity. Conversely, the amount of scrap is minimised, since there is no need to
stop the line as long as there is fibre left on the pay-offs.
This process also reduces the risk, since the inaccuracy level is greater during
a start-up. The operator interaction is also reduced since threading the take-up
is not needed when changing the take-up spools. The new dual ribbon take-
up is based on well proven high-speed fibre dual
take-up technology, with two identical traversing
take-ups. The transfer mechanism consists of a
gripping and cutting mechanism, and horizontally
moving conveyor pulleys.
The new development is focussed on the gripping
and cutting mechanism, which is optimised for
4 to 12-fibre ribbons. The same mechanism can be
modified for up to 24-fibre ribbons.
Mechanical modifications are mainly related to the
guidance of the ribbon and flange design. The main
focus has been put on 12-fibre ribbons, although
parts of the trials were run with 4-fibre bundles to demonstrate usability with
EPFU (blown fibre). As a result of the development, work at a reliable success
rate has been achieved with line speed of 800m/min.
Nextrom OY – Finland
Fax: +358 95025 3003 • Email: • Website:
Nextrom – improving quality
and productivity
▲
Simple and economical
pay-off systems
Wyrepak, USA, offers a full range
of pay-off equipment featuring
the most simple and economical
pay-off system, with spool caps
and tension brushes, made to fit
spools from size 6" (150mm) to
49" (1250mm).
Installation is easy, and operation
is simple. Cost is less than more
sophisticated pay-off systems,
and often the same result is
achieved with steady back tension
from the selected brush. For
improved tension control a simple
Wyrepak belt wrapped tension
capstan can be added.
Wyrepak Industries Inc – USA
Fax: +1 860 632 5775
Email:
Website:
Tension brushes in a range of sizes ▲
Photo credit: YMD Engineering LLC