WCA May 2009

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Components from wire

The components are then checked for accuracy to the correct dimen- sions and specification using high technology inspection equipment. William Hughes has been making bent wire components and springs for over 200 years and continues to expand its range of products, processes and finishes which now include shot peening, and the Delta ® Tone and Delta ® Seal coating processes. The company also offers an electrophoretic paint process, which provides the black, gloss finish popular in the automotive industry. William Hughes has the technical resources to help its customers design and manufacture a range of bent wire components, as well as helping to solve a wide range of engineering and design challenges. A rapid design and prototyping service is available for wire products including springs and bent wire components. Quality systems to ISO 9001:2000, ISO/TS16949: 2002, ECC 701 coating systems from Nordson Corporation provide precise process control for applying powders for high quality, reproducible cable coating. The system maintains an even flow of powder to consistently produce the desired coating thick- ness. The new dual-filter system and improved pump technology help reduce material usage, lower production costs and allow handling of abrasive materials. ECC 701 systems fluidise and charge various powders, including talcs and superabsorbent powders (SAPs), to spray on to cable. The systems precisely control all process parameters for repeatable coating, and parameters can be easily adjusted to meet changing application requirements. Use of Versa-Spray ® guns optimises performance of various powders using the corona process to charge powder particles. Versatile, industry-proven Versa-Spray guns process a wide variety of materials from talcs to abrasive substances such as SAPs. The new dual-filter system recovers material not applied to cables and returns it to the hopper.

William Hughes Ltd specialises in making complex wire components and was recently asked to manufacture a threaded linkhook with many bends, for use in the diesel pumps used in lorries and cars. The small component is formed from a piece of wire just 117.4mm long and has to meet precise dimensional tolerances. Based on a 2.6mm diameter length of annealed steel wire, the component passes through five different processes before it is ready for use. The first stage is to form a hook at one end and a chamfer on the other using a rotary table, six-stage blanking machine. The partly formed component then moves to a thread cutting machine where a 20mm long thread (4 x 40 UNC) is cut on the chamfered end. The partly formed linkhook is then subject to a press bend and two hand bends to form the precise shape required before being case hardened in a special sealed quenched furnace. Direct electrical heating system for subsea installation Nexans has been awarded an €11 million contract by BP Norge to supply a direct electrical heating (DEH) system for the Skarv field subsea production pipeline in the Norwegian Sea. Nexans is believed to be the only supplier with experience of this technology and has already supplied this type of system for 17 subsea pipeline installations. A number of methods may be used for maintaining flow, such as chemical injection, but DEH has proved to be both a reliable and eco-friendly solution to the problem. Nexans will supply all cables and dedicated subsea equipment for the DEH system. The cables will be manufactured at Nexans’ Halden factory in Norway and are scheduled for delivery in the spring of 2010. Nexans – France Fax : +33 15669 8484 Email : nexans.web@nexans.com Website : www.nexans.com

❍ Linkhook for a diesel pump

the latest automotive standard and AS9100 for aerospace ensure consistency and accuracy of supply. William Hughes Ltd – UK Fax : +44 1963 363377 Email : sales@wmhughes.co.uk Website : www.wmhughes.co.uk

Powder handling for coating systems

❍ Handling system, ECC 701

This results in high transfer efficiency while also providing a clean produc- tion environment. The modular system design has flexible inputs and out- puts for easy integration into existing production lines.

Nordson Corporation – USA Website : www.nordson.com

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Wire & Cable ASIA – May/June 2009