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Nonferrous topics such as copper and aluminum, annealing, etc. go here.

TOPIC: Wire Buncher Troubleshooting

Wire Buncher Troubleshooting 2 weeks 2 days ago #3058

I am currently investigating a spike in the weight of 4ft samples coming off the bunch strander. Seven reels are utilized to create 7-strand wire of resulting gages 6, 12, and 14. Four reels are created by each set of 7. The issue lies with the fourth reel of each set. The weight of samples typically decreases a little from reel 1 to reel 3, then the 4th reel spikes in weight. My speculation thus far concerns the annealing process and the tension. Is it possible that this is just the result of hard wire present at the inner-most layer of wire on the reel? What others factors might I consider - possibly increasing tension resulting in increased elongation? Readings do show that the flyer tension is not exactly the same among the set of seven.
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Wire Buncher Troubleshooting 2 weeks 1 day ago #3059

Hi There Ms Willson,

Lets go over some of the basics first:

1) If the pay-offs for the single wires on the strander are not driven, then the pay-off brakes create a torque and, as the pay-off reels go down, the individual wire tensions go up. This is all very normal but all the individual wires must have the same metallurgical composition and properties. That includes elongation. There can be no mixtures of hard and annealed wires in the same seven wire strand. Measure each of the wire tensions so that all are typically the same or quite similar.

2) Make sure all the pay-off reels are in good shape, balanced and ready to be used properly.

3) Make sure that the seven wire pay-off reels typically have the same amount of wire on each of them so that the individual wires twist properly when they close at the buncher.

4) It is important that each of the pay-off pintles are completely free turning and that the wires are properly wound on the pay-off reels. Turn each empty pay-off pintle carefully by hand to ensure there are no hang-ups or other strange intermittent torque effects. Have maintenance repair those pintles that are below standard and recheck by hand.

5) Make sure that the wire path to the buncher closing point is smooth and free of spots where the wires could hang up.

6) Make sure that the 7 wire bunched strand has a smooth and free wire path through the buncher and on to the take-up. Everything counts!

Now you are ready to run a trial on your 7 wire bunched strander.
Peter J. Stewart-Hay Principal
Stewart-Hay Associates
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The following user(s) said Thank You: Ms Christel Robin Willson

Wire Buncher Troubleshooting 2 weeks 1 day ago #3060

  • Willy M Hauer
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Hi Christel,

Are you using dynamic(pintle type) pay-offs of flyer?

A double twist machine can be a highly productive machine but requires rather precise input:

Wire diameter
Residual elongation
Wire tension (pls note that a tension differential is required between layer)
Closing die quality
Clear and clean wire path in the machine itself
Correct correlation between pay-off tension and bow speed

Best Regards,

Howar Equipment Inc.
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The following user(s) said Thank You: Ms Christel Robin Willson

Wire Buncher Troubleshooting 2 weeks 6 hours ago #3061

Thank you ever so kindly! My next step is to procure a tension meter that is capable of conducting readings on moving wire to ensure the tensions are consistent.
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