WCA January 2011

Reducing cost in manufacturing compact conductors using roll form stranding By Sean Harrington, sales and marketing manager for Ceeco Bartell Products

Abstract The roll form stranding process com- bines the advantages of two highly productive processes, namely roll forming and double-twist stranding. These two systems are forged together to create one high-speed continuous manufacturing cell. This system not only produces compact strand at high speeds, but also allows significant savings to be made throughout the stranding process, from wiredrawing all the way through to the extrusion process. Introduction Recent years have presented a great challenge to the cable industry, especially through the current world

Process steps

Double twist

Roll forming

Coil payoff

Assembly into compact conductor

Roll formed profiles

Round wire

Process steps ❍ ❍

Smaller input wire storage area X. 75% more energy efficient than a typical rigid strander XI. The roll form stranding process combines the advantages of two highly productive processes: roll forming of shaped wire and double twist stranding of conductors. These two systems are forged together to create one high-speed continuous manufacturing cell. This system not only produces compact strand at high speeds, but also allows significant savings to be made throughout the stranding process, from wire drawing through to the extrusion process. Round wire is paid off from stem-type payoff packages allowing up to 1,000kg (2,000lb) of aluminium or 3,000kg (6,000lb) of copper conductor material to be staged behind the roll form strander. The stem package allows continuous operation and is the preferred solution for this process, maximising productivity when the single input wire method is an integral part of the manufacturing process. The round wire passes into the external roll forming section, an integral part of the roll form strander.

recession when demand for cable has reduced, in some cases, by 50 per cent. At the same time raw material prices and energy costs have continued to rise. This has made the competition between manufacturers increasingly aggressive in terms of product range, product quality and costs. The aim of this paper is to present a cost saving technological solution for the wire drawing process. This is the use of the roll form strander, which allows the use of a single input diameter wire to be utilised throughout the stranding process giving significant process savings and advantages, including: Higher stranding productivity (typically 40 tonne/day I. compact Al) Higher productivity in wire drawing II.

Lower drawn wire scrap III. Lower insulating costs IV. Lower capital investment V. Improved return on investment VI. Quicker set-up VII. Reduced work in process VIII. Shorter cycle times IX.

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Wire & Cable ASIA – September/October 2007 Wire & Cable ASIA – January/February 11