Equipment: Part 2 by Wire Journal International, Inc.

WIRE JOURNAL SEPTEMBER 2010

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I N T E R N A T I O N A L w w w. w i r e n e t . o r g

part 2

Equipment OFFICIAL PUBLI-

OFFICIAL PUBLICATION OF THE WIRE ASSOCIATION INTERNATIONAL

Compact and Robust

for more installation flexibility

CenterScan 2010 Non-Contact, Eccentricity Measurement System CenterScan 2010â&#x20AC;&#x2122;s compact design enables you to install the system at a wider range of locations on the production line

and eccentricity of conductors, during extrusion and insulation processes. CenterScan 2010 also includes robust electronics

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Wire China, Booth W1E63

WIRE JOURNAL

I N T E R N A T I O N A L

Editorial . . . . . . . . . . . . . . . . 6

CONTENTS

Volume 43 | Number 9 | September 2010

F EATURES

Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Asian Focus . . . . . . . . . . . . . 28 People . . . . . . . . . . . . . . . . 30 Fiber Watch . . . . . . . . . . . . . 32 Fastener Update . . . . . . . . . 34 WAI News . . . . . . . . . . . . . . 36

Equipment: Part 2 . . . . . . . . . . . .48 This feature, the second of two parts, presents more equipment that was displayed earlier this year at the wire Düsseldorf fairgrounds in Germany.

Chapter Corner . . . . . . . . . . 42 Technical Papers . . . . . . . 60-75 Products . . . . . . . . . . . . . . . 79 Classified . . . . . . . . . . . . . . 83 Career Opportunities . . . . . . 83 Advertisers’ Index . . . . . . . . 86

Next issue

T ECHNICAL P APERS High productivity and reliability of XLPE insulated medium-voltage cables Paul Laurenson and Jan-Ove Boström . . . . . . . . . . . .60 Improvement of straightness in rotational blade straightener for superfine wire Masahiro Yoshida, Motoo Asakawa, Satoshi Kajino, Motohiko Urabe and H. Kanaeda . . . . . . . . . . . . . . . .64 Integrated, one-step, high-speed line for the production of low-relaxation, prestressed concrete wire Lorenzo Facchinelli . . . . . . . . . . . . . . . . . . . . . . . . . . .71

October 2010 • The ‘green’ role in

manufacturing

Cover: Close-ups of some of the equipment that was on display at wire Düsseldorf. See p. 48.

SEPTEMBER 2010 | 3

INSIDE THIS ISSUE TECHNICAL PAPER

. .60

AWARD -WINNING

TECHNICAL PAPER

. .64

CONTENTS

AWARD-WINNING

The above figure, which shows electrical breakdown initiated by a vented water tree, is from, “High productivity and reliability of XLPE insulated medium-voltage cables.” The paper by Paul Laurenson and Jan-Ove Boström, presented at WAI’s 2009 International Technical Conference in Istanbul, Turkey, won the Urbain J.H. Memorial Award for best electrical paper.

4 | WIRE JOURNAL INTERNATIONAL

The above figure, which shows a schematic of a rotational blade straightener, is from, “Improvement of straightness in rotational blade straightener for superfine wire.” The paper by Masahiro Yoshida, Motoo Asakawa, Satoshi Kajino, Motohiko Urabe and H. Kanaeda, presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, won the Horace Pops Award for best general paper.

*2,1*)253(5)(&7,21 www.eurollsgroup.com

WE WILL ATTEND WIRE CHINA 2010 - BOOTH # W1 G53-67 - September, 21-24 / 2010 Shanghai, China

Straightening machines

Multiwire drawing machines

Cold rolling lines with cassettes

PC strand machines

Spooling equipment

WIRE MACHINERY DIVISION

EDITORIAL WIRE JOURNAL

EDITORIAL

I N T E R N A T I O N A L

While waiting for the recovery, make sure to take care of the day-to-day business In hard economic times, one looks for signs of hope, of potential, because it is human nature to want to believe that conditions will improve, that loans will be approved and that order books will once again fatten up. Positive economic signs have been hard to come by lately, but the key for any business may be to not lose focus on how to make things work in the conditions that currently exist. One positive sign has been the automotive industry, which has seen a 23% improvement over last year in terms of value of shipments. For companies like Delphi, this is a welcome relief from the sharp declines that the sector has suffered over the past several years. At the same time, most sectors seem to feel better when comparing sales numbers to 2009, an anemic period at best. As 2010 moves along there is a general uneasiness among most sectors, with everyone unsure of the pace of the “recovery.” Fueling the concerns are the sometimes conflicting economic indicators, such as the U.S. Census Bureau’s value of manufacturer’s shipments, which showed a depressed second quarter but a 10.5% increase for the first half of the year. Other barometers, equally uncomfortable, include U.S. unemployment, which was 9.5% in August, and July housing sales, which were 26% lower than June. There’s no lack of statistics to look at, some more gloomy than others, and whether we are in the midst of a slow rebound or a pause, the end result is that much of the wire and cable industry remains under intense pressure. Companies subject to the worst economic downturn in decades have pursued a steady diet of cost reductions, and have done a remarkable job of becoming leaner and more productive. Surviving is essential, but there is also the desire to recreate the revenue curve. Alan Murray recently wrote in The Wall Street Journal about some market-leading companies that missed out on major innovations, such as mainframes to PCs, landlines to mobile and film to digital, all advances that opened up new customers and markets. While those new markets were remarkable innovations, it is the small steps forward that have allowed companies to survive and hopefully position themselves for future innovation. They don’t make the headlines, but it is the day-to-day business of reducing waste, improving efficiency, maintaining employee morale and finding ways to better serve customer demands that should be celebrated while we anticipate for the actual recovery.

Steve Fetteroll WAI Executive Director

WIRE JOURNAL INTERNATIONAL (ISSN-0277-4275) published monthly by The Wire Journal, Inc., is a wholly owned subsidiary of The Wire Association International, Inc., which is located at 1570 Boston Post Road, P.O. Box 578, Guilford, CT 06437-0578, USA, and can be contacted at tel. 203-453-2777; fax 203-453-8384; Internet wirenet.org; e-mail mmarselli@wirenet.org. Address all correspondence concerning advertising production, editorial and circulation to the above address. WJI is printed in USA. Subscription rates: $110 per year, USA; $120 per year, Canada and Mexico; other countries, $140 per year (includes air mail). Back copies: $10 WAI members, $15 non-members. Periodicals postage paid at Guilford, CT 06437, USA, and at additional offices. Wire Journal International grants photocopy permission to libraries and others registered with Copyright Clearance Center (CCC), 21 Congress St., Salem, MA 01970, USA, for a fee of $0.50 per article. Payments should be sent directly to the CCC. Requests for bulk orders or reprints should be sent to the Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA. © 2010 by Wire Journal, Inc. All rights reserved. The Publisher of WJI assumes no responsibility for the validity of manufacturers’ claims made herein. Back issues of WJI are on microfilm and available from University Microfilm, 300 North Zeeb Road, Ann Arbor, MI 48106, USA. Phone: 313761-4700. POSTMASTER: Send address changes to Wire Journal International, P.O. Box 578, Guilford, CT 06437-0578, USA.

6 | WIRE JOURNAL INTERNATIONAL

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CALENDAR

CALENDAR Sept. 21-24, 2010: AWPA Gov. Affairs Conference Washington, DC, USA. Contact: Heather Outhuse, American Wire Producers Association (AWPA) at tel. 703-299-4434. For more details, go to www.awpa.org. Sept. 21-24, 2010: wire China 2010 Shanghai, China. To be held at the Shanghai New International Expo Centre (SNIEC). Contact: Messe Düsseldorf North America, tel. 312-781-5180, fax 312-781-5188, info@mdna.com, www.mdna.com. Oct. 13-15, 2010: SPRINGWORLD Rosemont, Illinois, USA. See p. 15. Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. To be held at the Crowne Plaza Monterrey, this WAI ITC includes a technical conference, tabletop exhibits, tour and networking opportunities. Contact: WAI, tel. 203-453-2777, www.wirenet.org. Oct. 27-Nov. 3, 2010: K 2010 Düsseldorf, Germany. To be held at the Düsseldorf Fairgrounds, Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com. Nov. 7-10, 2010: 59th IWCS Conference™ Providence, Rhode Island, USA.To be held at the Rhode Island Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990.

Nov. 18-20, 2010: Wire & Cable India 2010 Mumbai, India. Organized by Messe Düsseldorf and the the Confederation of Indian Industry (CII), this event will be held at the Bombay Exhibition Centre in Goregaon. Contact: Eva Rowe, Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180. May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. WAI returns to the Georgia World Congress Center for the trade show and the Association’s 81st Annual Convention. Contact: WAI, tel. 203-453-2777, www.wirenet.org. June 19-23, 2011: JI Cable Versailles, France. This international conference on insulated power cables, which has multiple organizers and was last held in 2007, will present a comprehensive forum about power cables as well as exhibits. Contact: J1Cable 11, www.jicable.org. Nov. 6-9, 2011: 60th IWCS Conference™ Charlotte, North Carolina, USA. To be held at the Charlotte Convention Center. Contact: Pat Hudak, IWCS, www.iwcs.org, phudak@iwcs.org, tel. 732-389-0990. March 26-30, 2012: wire Düsseldorf 2012 Düsseldorf, Germany. To be held at the Messe fairgrounds. Contact: Messe Düsseldorf North America, erowe@mdna.com, tel. 312-781-5180. ■

WIRE ASSOCIATION I NTERNATIONAL EVENTS For more information, contact the WAI, USA. Tel. 001-203-453-2777; fax 001-203-453-8384; www.wirenet.org. Sept. 16, 2010: New England Chapter 16th annual Golf Tournament Boylston, Massachusetts, USA. This event will be held at the Mount Pleasant Country Club. See p. 42.

Oct. 25, 2010: Western Chapter 10th Annual Golf Tournament Rancho Palos Verdes, California, USA. This event will be held at the Los Verdes Golf Course. See p. 43.

Oct. 14, 2010: Southeast Chapter 9th Annual Golf Tournament Conover, North Carolina, USA. This event will be held at the Rock Barn Golf and Spa. See p. 42.

March 3-5, 2011: Modern technologies and modelling of drawing and manufacturing processes of metal products Zakapone, Poland. Contact: Dr. Sylwia Wiewiórowska, wiewior@mim. pcz.czest.pl, www.konferencja.mim.pcz.czest.pl.

Oct. 18-20, 2010: WAI International Technical Conference Monterrey, Mexico. See main listing.

8 | WIRE JOURNAL INTERNATIONAL

May 2-5, 2011: Interwire 2011 Atlanta, Georgia, USA. See main listing.

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INDUSTRY NEWS

INDUSTRY NEWS Germany’s Leoni AG will supply cable harnesses for new Fiat diesel engines Germany’s Leoni AG reports that it has won a contract to supply Fiat with the cable harnesses for a new diesel engine to be used for both Fiat and Chrysler cars. A press release said that the contract amounts “to a mid single-digit million Euro sales volume per year.” The harnesses, it said, will be used for Fiat’s new two-liter MultiJet turbo diesel engine, and have to meet the latest emission requirements according to the Euro 5 environmental standard, that applies to all new cars sold in Europe from February 2011 on. One of the first cars to use the Leoni cable harnesses is the new Dodge Journey, it said. Leoni AG reports is supplying wire The engine harnesses for a new Fiat engine. cable harness employs 57 wires with a total length of around 110 meters that have more than half a kg of copper content, the release said. Per Fiat requirements, they must be able to properly function at a temperature of 150ºC. The harnesses production is scheduled for the fourth quarter of 2010, it said, adding that Leoni will deliver between 100,000 and 150,000 units per year from one of its Tunisian plants. The release noted that Leoni has been supplying the Fiat Group for 30 years, and has supplied wiring harnesses for the Fiat Punto Classic, Lancia Y and other automobiles.

Alcan Cable to consolidate North American cable production facilities Alcan Cable, a business of Rio Tinto, announced that it will consolidate its cable production facilities to improve the performance of its cable business. A press release said that the company plans to close its U.S. facility in Roseburg, Oregon, by the end of the year. “This decision is difficult, but has been made necessary

by the prolonged poor market conditions and outlook in the market,” said Alcan Cable President Jack Miller. “Moving forward, Alcan Cable will focus on its North American production at its remaining cable facilities and continue to provide high-quality cable products and service to our customers.” Alcan Cable, which notes that it is recognized as the only fully integrated aluminum cable supplier in North America, will focus on making a seamless transition during the plant closure process, the release said. “The realignment of manufacturing operations will address the realities of the current and projected market conditions and provide Alcan Cable the flexibility to expand production capacity at its remaining cable plants,” it said.

Nexans wins US$81.4 million cable deal from Greek utility company Nexans announced that it has won a US$81.3 million contract from Greece’s Public Power Corporation (PPC), the country’s largest electrical power utility, to design, manufacture and install a new high-voltage AC power link between Evia and the region of Attika on the mainland. The project, a press release said, will further development of wind power projects totaling around 400 MW on Evia, the second largest of the Greek islands, by enabling the power they produce to be exported directly into PPC’s national power transmission grid. The 150 kV link will interconnect the Nea Makri substation on the coast of Attika with the Polypotamos substation on Evia, it said. The deal will require Nexans to install three subsea cable circuits that will take a 21 km route across the Gulf of Evia in waters reaching a maximum depth of 85 meters, the release said. Nexans, it added, will also supply the underground power cables (2.7 km) to provide the land connections at each end of the submarine cables together with associated accessories such as transition joints and outdoor terminations, it said. “The key factors in winning this contract were our wealth of experience in many similar projects, combined with our capability to provide a complete in-house service from design and manufacture of the subsea and underground cables to installation and commissioning,” said Nexans Senior Corporate Executive Vice President Yvon Raak. The 150 kV submarine cables, to be manufactured in Nexans’ specialized submarine cable facility in Halden, Norway, will feature XLPE insulation and comprise three power cores with a copper cross-section of 630 sq mm, the release said. It added that three cable circuits will be installed across the Gulf of Evia to provide two circuits in

Does your company have news that belongs here? E-mail it to the WJI at editorial@wirenet.org.

10 | WIRE JOURNAL INTERNATIONAL

Underwriters Laboratories warns of fraudulent communication cable

A Nexans submarine cable.

Composite Technology reports 3rd South African ACCC conductor order U.S.-based Composite Technology Corporation announce an order for its subsidiary, CTC Cable Corporation, for its ACCC® 611 kcmil conductor and associated hardware to be used for reconductoring an 88kV, 135 km portion of a 60-100 MVA transmission line for City Power Johannesburg in South Africa. A press release said that the order, from Allteck Line Contractors, a Quanta Services company, stems from “the exponential demand growth and resulting strain on the electrical grid in the Johannesburg region of South Africa.” City Power Johannesburg chose to modernize its grid through Quanta Services, which selected CTC Cable’s ACCC conductor to increase capacity over 100% while reducing both line losses and thermal sag on existing structures, it said. The order, the release said, follows last year’s order for 210 km and another emergency replacement order in June 2010 for 23 km for the company’s composite core conductor technology as the best solution for the severely constrained electrical grid in Johannesburg. To date, CTC Cable has supplied approximately 9,000 km of ACCC conductor that was commercially deployed at more than 140 installations, it said. City Power in Johannesburg contracted Quanta through a local South African partner, Edison Jehamo Power (EJP), to upgrade the existing 88 kV network around Johannesburg, using Quanta proprietary LineMaster™ energized robotic arm technology, the release said. The Quanta Team selected high-temperature composite core conductors for the replacement wire because it can operate at 200ºC under peak loading conditions, it said.

U.S.-based Underwriters Laboratories (UL) has issued warnings about communication cable fraudulently bearing its logo that has been sold through three Internet sites (Cables.com, Jack2Rack.com and CableLot.com) and at Datacomm Cables Inc. in Hauppauge, New York. The cable in question is marked as follows: “VERTICAL CABLE UL C(UL) 4PR 24AWG CMP FT6 - ETL VERIFIED TO TIA/EIA-568-B.2 CAT 5E 350MHZ VID:H1 RoHS COMPLIANT 0992FT.” The announcement did not specify how much cable had been sold, but a sales representative for Datacomm Cables told WJI that he was surprised by the news. “We do handle (Vertical’s) products,” said Dominic Millaci, who recalled that the product used to carry the UL mark about a year ago but added that at some point it no longer did. He said that the company still has Vertical cables in inventory, but that the boxes it comes in do not carry the UL mark as shown in the UL photo. Miko Chiu, product manager for www.jack2rack.com, said that his company has removed the product from its website.

TELE-FONIKA reports cable contracts Poland’s TELE-FONIKA Kable updated and reported on several contracts made earlier this year. TELE-FONIKA Kable has begun the delivery of a complete 110kV cable system for the construction of a double-fed electric power supply line for the National Stadium in Warsaw within the framework of the investment project of RWE Stoen Operator Sp. z o.o. implemented by ZWSE MEGA-POL S.A., a press release said. The project calls for the construction of two supply lines for the National Stadium, one of which will be a reserve line. The cable line running between the District Supply Point and the District Supply Point Stadium has a designed length of 1.5 km, including approximately 510 mt that will be laid under the Vistula River, the release said, adding that the second line has a designed length of 4.35 km. Both cable lines will be constructed with the use of the XRUHKXS FIMT 1x1000RMC/120 110kV type

Correction The last portion of a news item that ran in the June issue, “EU extends duties for Chinese products,” cited three sources of information, one of which was Europa, about “a recent” joint investigation of Chinese steel wire rope that enabled Spanish authorities “to recover several million euros of import duties.” The news attributed to Europa was accurate, but it was about events that happened in 2006. SEPTEMBER 2010 | 11

INDUSTRY NEWS

normal use with one spare to ensure continuity of operation. Each circuit is designed for a nominal capacity of 200 MVA. Installation is planned to be carried out by Nexans’ own cable ship, the C/S Nexans Skagerrak, with the cables to be buried approximately 1 meter below the seabed, the release said. The project is scheduled for completion within 36 months.

INDUSTRY NEWS

cables and Pfisterer cable equipment. “This will be the first Polish electric power line with a fiber-optic module built inside the cable, used to monitor its temperature during use,” the release said. The cable is manufactured in the Bydgoszcz Plant. Another press release said that the company’s U.S. subsidiary, TELE-FONIKA Cable Americas, will supply 40 km of TorsionFlex® type cable to Horizon Wind Energy LLC Houston for two major wind energy projects: TOP CROP in Illinois and MEADOW LAKE in Indiana. TorsionFlex, it noted, is a group of cables with a flexible multi-wire copper core with insulation and a rubber coating, used for wiring of a wind tower, e.g., to connect a generator turbine with a transformer. The cable is produced at the company’s plant in Krakow, Poland. TELE-FONIKA Kable also reported the signing of a contract for supply of 110 kV cable system for PKP Energetyka S.A. Lodz Plant, which will require approximately 12 km of the cable (XRUHAKXS 1x240/95 sq mm 64/110 kV). The 150 kV submarine cable link across the Gulf of Evia will facilitate the development of wind power projects totaling around 400 MW on Greece’s second largest island.

E-mail: fukaseco@ja2.so-net.ne.jp http://www.fukase.co.jp

12 | WIRE JOURNAL INTERNATIONAL

Nexans to supply range of cable for nuclear power plant in China Nexans announced that it has been awarded a contract worth US$9 million from China Nuclear Power Engineering Co., Ltd. (CNPEC) to supply specialized low-voltage (LV) power, control and instrumentation cables for the 1,660 MW Taishan EPR nuclear power plant currently under construction in Guangdong Province. A press release said that Nexans is supplying K3 type (not safety classified) cables for the Taishan project that have been specifically designed and tested to deliver exceptional performance, reliability and safety in nuclear power installations. The cables for the Taishan nuclear power plant will be manufactured in the Nexans Mehunsur-Yèvre plant in France. Deliveries to the site in China will commence at the end of 2010 and are scheduled for completion by the end of 2011, it said. Typical duties for the LV power cables will be to power the pumps that transfer water between the reactor vessels and the steam generators; the control cables will provide primary control for primary pumps, safety valves, ventilation and air-conditioning and more; and the instrumenta-

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INGOT CASTERS Wheel & Belt Track & Belt

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FRANCE DIVISION Properzi Properzi France Parc d’activité du Vert Vert e Galant Parc Avenue v 78 Avenue du Château F 27745 Saint Ouen l’Aumône, France Phone: +33. 1. 34 32 34 80 Fax: +33. 1. 34 32 34 89 properzi.fr info @ properzi.fr

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INDUSTRY NEWS

tion cables will be used for constant system surveillance by measuring parameters such as steam pressure, water and component temperature, liquid levels, flow rates and vibration, the release said. “China is a very important market sector for Nexans, so we are very pleased to be involved in this key development in the country’s growing nuclear power industry that already has 25 reactors under construction and many more in the planning stages,” the release said.

Magnetic Analysis Corporation notes its plans to relocate to larger plant Magnetic Analysis Corporation (MAC), a U.S. manufacturer of sophisticated test systems for metal manufacturers worldwide, reports that it is relocating this year to a larger plant in Elmsford, New York. A press release said that after more than 40 years in Mount Vernon, New York, the company had grown out of its facility. “The new facility will provide an 80% increase in space, greatly expanding our ability to manufacture and assemble large inspection systems and demonstrate them for customers,” said company President Joseph Vitulli. “This move is critical to our strategy of offering the highest quality test equipment to meet the growing demands for inspecting tube, bar, wire and other metal components throughout the world.” The new plant, which has approximately 47,000 sq ft of space, is well located to facilitate shipment of large test systems through New York-area airports and seaports to domestic and overseas destinations, the release said. For more details, go to www.mac-ndt.com.

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14 | WIRE JOURNAL INTERNATIONAL

SPRINGWORLD organizers hope return to Rosemont will lead to better times SPRINGWORLD organizers report that despite a generally soft uncertain market economy, expectations are good for the biennial spring event, which is scheduled to be held October 13-15, 2010, at the Rosemont Convention Center in Rosemont (Chicago), Illinois, USA. “We have had an excellent [response from] exhibitors and suppliers around the world,” said Thomas Renk, executive vice president of the Chicago Area Spring Manufacturers (CASMI), which puts on SPRINGWORLD. “In addition to U.S. based spring making equipment companies, we have companies from Canada, Germany, Italy, Great Britain, Turkey, Japan, China, Taiwan, and India represented. In general, show management and the exhibitors are optimistic that industrial production is on the rise and that manufacturers are much more interested in making equipment purchases after holding back for the past two years,” he said. Renk said that overall, he has not seen a downturn in space reservations for 2010.

INDUSTRY NEWS

Most 2008 exhibitors are returning, and have booths similar in size, but some with multiple booths have reduced the total number, he said, noting that this represents an exhibition trend for manufacturing as a whole, especially for heavy equipment. That said, there will be plenty of equipment at the show, although a few exhibitors will have less on display to save money on space and shipping costs, he said. “Many companies have stated that the equipment they are showing has already been sold and will be delivered right from the show floor.”

KEIR - BackBone™

SPRINGWORLD 2010 will include some new exhibitors coming Europe, Turkey, China and India that want to expand their market reach into the U.S., Renk said. “The real unknown for SPRINGWORLD is what kind of attendance can be expected,” he said. “With companies having cutback on personnel over the last two years, and with the lingering travel expense limitations, we are hopeful that we will see a strong attendance and interest in exhibitor equipment. Currently we are tracking about 10-15% behind the 2008 show pre-registrations, at 60 days out from the show. We have seen a strong uptick in recent weeks as we have gotten closer, suggesting that people may be sitting on the fence a bit longer before making any decisions. Hotel reservations have been strong (and based on the volume to date seem to indicate that a good number of people) are still planning to attend.”

Flyer Bow

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16 | WIRE JOURNAL INTERNATIONAL

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Show registration is free up until September 20, at which time there is a $25 fee. The event will feature a first-time onfloor education during show hours, Renk said. Exhibitors have been invited to put on technical programs, new product announcements and machinery repair classes, all of which will be offered free for exhibitors and attendees. Wire Journal International will be among the exhibitors at the event. Renk also noted that the Spring Manufacturers Institute (SMI) will sponsor a reception Wednesday, October 13, from 5 pm to 6:30 pm in the Convention Center. See the SPRINGWORLD ad on p. 9. Contact: Tom Renk, CASMI, tom@casmi-springworld.org or tom@associationenterprise.org.

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INDUSTRY NEWS

Asia Pacific Wire reports contracts being by its subsidiary in Thailand Asia Pacific Wire & Cable Corporation Limited (APWC) announced that one of its Thai subsidiaries, Siam Fiber Optics, Co., Ltd. (SFO), signed several major contracts earlier this year and before with local companies and state-owned telecommunication companies for a total value of approximately US$18.4 million. A press release providing a periodic update of orders

included a US$5.7 million contract with Marubeni Thailand Co., Ltd., to deliver 5,650 km of fiber-optic cable over a seven-month period through October 2010; a US$3.8 million) contract to deliver 2,794 km of fiber optic cable to TOT Public Company Limited, a stateowned telecommunications company, which commenced in May 2010 and would run for four months; and two contracts from Thai Transmission Industry Co., Ltd., to provide 4,130 km of All-Dielectric Self-Supporting Optical Cable (ADSS) and 4,324 km of drop wires to be used to link the telecommunication network for all the domestic universities in Thailand totaling approximately US$8 million over 14 months that commenced in January 2010. The company noted in its release that Siam Fiber Optics is 60% owned by Charoong Thai Wire and Cable Co., the latter of which is 51% directly or indirectly owned by APWC. The other three non-controlling interest parties own rest of the 40% of Siam Fiber Optics Co., Ltd., it said. “Asia Pacific Wire and Cable Corporation is pleased by the strong demand for the telecommunications products in Thailand and optimistic about experiencing a continued recovery in our business,” the release said. “These contracts represent a healthy pipeline and stable growth in our telecommunications cable business. The company expects to see continued strong demand for our wire and cable alongside the expansion of telecommunications and electrical infrastructure in the growing Asia-Pacific region.”

Saudi Arabia plans major energy projects Saudi Electricity Co., a statecontrolled utility, reports that its board has approved projects worth US$3.9 billion that will help it meet demand for more power in the region. A Bloomberg report said that the Riyadh-based company, in a statement to the Saudi bourse website, cited the following projects: expanding the Rabigh power plant; building a power link

18 | WIRE JOURNAL INTERNATIONAL

INDUSTRY NEWS

between Hail and al-Jawf; and installing power cables in Mecca. The article said that power demand in Saudi Arabia, the worldâ&#x20AC;&#x2122;s largest oil supplier, is set to increase 8 percent a year as the population expands and the government invests to spur economic growth. It also noted that, earlier this year, the Saudi Press Agency said that the Kingdom has implemented tariffs for electricity from July 1 as it seeks more efficient energy use. The rates, it said, will be applied to government, industrial and commercial clients.

Dubai Cable reports more UAE cable orders from gas development project Dubai Cable Company reports that it has won a second contract to work on the UAEâ&#x20AC;&#x2122;s Abu Dhabiâ&#x20AC;&#x2122;s Integrated Gas Development (IGD) project, which is slated for commissioning in 2013. Gulf News reports that Dubai Cable Company won an order from Japanâ&#x20AC;&#x2122;s JGC Corporation to supply custom power cables to the new Habshan 5 gas processing plant. It noted that this news follows the companyâ&#x20AC;&#x2122;s recent contract with Hyundai Engineering and Construction. The contract calls for Dubai Cable Company to support the utilities and offsite part of the development, a deal â&#x20AC;&#x153;that could see it supplying up to 70 percent of the associated facilityâ&#x20AC;&#x2122;s power cable requirements,â&#x20AC;? it said. â&#x20AC;&#x153;The Habshan 5 gas processing plant will require thousands of km of high-quality cables with special materials that can withstand Habshanâ&#x20AC;&#x2122;s harsh environment and comply with stringent safety and project requirements,â&#x20AC;? the release said. â&#x20AC;&#x153;These kinds of projects and the growth of the oil and gas sector in UAE, and the GCC in general, were the motivation for us to launch the Special Cables Unit at the end of 2009,â&#x20AC;? the story said. It noted that the company has two factories in Abu Dhabi and one in Jebel Ali, with the capacity to fill very large and very specific orders.

New ew Patente Patented Pate ented te e Break-Down ed Bre eak-Dow wn Reels wn Reels

WCISA notes changes to board of directors

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20 | WIRE JOURNAL INTERNATIONAL

The Wire and Cable Industry Suppliers Association (WCISAÂŽ) announced the following changes to its board of directors. Rahul Sachdev, executive vice president, Wire & Plastic Machinery Corp., is the new WCISA president, serving a threeyear term. He succeeds Thomas Copp, president of REELEX Packaging Solutions, Inc., who will remain on the board of directors, serving a three-year term as immediate past president.

INDUSTRY NEWS

Continuing board members elected to new three-year terms include: William E. Crowle, president, QED Wire Lines Inc.; Rob Fulop, vice president & general manager, Wire Lab Company; David B. Kiddoo, global business manager, AlphaGary Corp.; Rene Mayer, technical sales, Mossberg Reel LLC; Mike Patel, industry manager-wire & cable compounds, Teknor Apex Co.; Joseph Snee, sales manager, Amaral Automation Associates; and John Zachow, business area manager, Davis-Standard Corporation. New board members are: Perry Chattler, president, DCM Industries, Inc., and Drew Richards, CEO, RichardsApex, Inc. WCISA also thanked two board members who have resigned: Neville Crabbe, president, Leoni Wire, Inc., and Terri W. Terry, senior marketing specialist, CommScope BiMetals Product Group. WCISA, a nonprofit corporate membership organization of North American-based suppliers of machinery, materials and accessories used for making all type of wire and cable, promotes its members at wire and cable trade events and conferences.

News in brief Arabian Oil and Gas reports that Saudi Arabia’s MESC Group recently was awarded a contract worth US$14 million from GS Engineering & Construction Corporation of South Korea to supply instrumentation cables for Takreer Ruwais Refinery Expansion in Abu Dhabi. … Pacific Gas & Electric, a California-based utility that is a Fortune 500 company, recently bestowed its first “Green Supplier of the Year” award to Southwire Company. … InnoVites B.V. announces that Siechem Technologies, India, has selected CableBuilder© to further boost the efficiency and quality of their design and quoting processes. Siechem designs and produces a wide variety of specialized cables using technology that includes an electron beam irradiation facility. Siechem is the latest in the long row of cable manufacturers in India benefiting from CableBuilder, it said. … Nexans has signed a Frame agreement with Nordex, a major international manufacturer of high-efficiency wind turbines, to supply customized WINDLINK® power cable sets (dedicated cut lengths according to Nordex specifications) and kits (continued on p. 26)

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22 | WIRE JOURNAL INTERNATIONAL

ISO9001 ISO 9001 REGISTERED

NETWORKING TECHNICAL & OPERATIONAL PRESENTATIONS WORKSHOPS

G L O B A L

CONTINUOUS

CASTING —

F O R U M

—

WAI’s new forum raises the bar on copper continuous casting May 2-5, 2011 | Atlanta, Georgia, USA Information will flow. It’s hot. Molten hot. It’s pervasive. And it’s a new forum for copper continuous casting practitioners in which every major process is well represented: SCR | Contirod | Properzi | Upcast | ESSEX It’s a total immersion in a think tank where industry gurus will greet you. Experts will enlighten you. Legends will lead you. It’s high-viscosity learning that’ll stick with you because you have to be present to access it. Given its fluid format, no matter your level, you’ll leave with a rock solid understanding of what’s new and innovative in continuous casting today. Here. There. And everywhere copper bar and rod is processed—worldwide. It’s a big idea that’s much more than theory. One forum—over four days— at Interwire 2011. It’s convenient. Comprehensive. Compulsory. It’s engineered for you. Go with the flow and learn more at: www.wirenet.org The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

Convention Dates: May 2-5, 2011 | Exhibit Dates: May 3-5, 2011 Georgia World Congress Center | Atlanta, Georgia, USA

INTERWIRE 2011 IS ALIVE WITH POSSIBILITIES. IT IS RENEWED, INVIGORATED, AND TAKING A NEW TACK. WHO’S AT THE HELM? Senior executives from more than 25 key corporations are skillfully guiding major changes to the show. Their interest in Interwire—the largest wire and cable marketplace in the Americas— is resolute. Interwire affects their business and is clearly worth their personal time. The result is a series of carefully considered and nimbly integrated transformations to better Interwire. Location: Atlanta, Georgia. Relocated and familiar, Interwire returns to the city of its origin where it was introduced in 1981. Compact: 3 full days of exhibits. Interwire 2011 offers a concentrated show schedule.

Special industry theme days. Look for presentations, technical papers, and executive discussions to orbit around these central themes: Metals & Materials Manufacturing Best Practices Green Initiatives Also NEW: The Global Continuous

More operating equipment. Interwire is a machinery show. Visitors can count on more operational equipment in 2011. Renewed energy. Exhibitor participation is on the upswing showing a 14% increase between the 2007 and 2009 events. Networking opportunities, ranked as the #1 reason to attend the show, will be part of the landscape. Expect to see production solution demonstrations and other attendance-building activities on the exhibit floor.

CC Casting Forum.

Uniting worldwide copper continuous casting practitioners for networking, technical and operational presentations and workshops. Fully supported. Show management continues to work with allied organizations, supporting sponsors, and educational supporters to interest a growing number of international participants in the show. Event news is communicated to Wire Journal International readers in 108 countries worldwide.

“Having all or most of the vendors in one location for a face-to-face has always had unmeasured value and still does, especially when times are tougher for travel and the like. Our company believes in the future of the business and that means get out there and find out what is going to take us into new future markets. I’ve already recommended that we return in 2011.” Ed Kozlowski, Senior Design Engineer W.L. Gore & Associates

SAVE THE DATE: MAY 2-5, 2011 AND LEARN MORE ONLINE AT WWW.WIRENET.ORG Interwire 2011 is organized by The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

INTERWIRE 2011 EXHIBITING COMPANIES — AS OF AUGUST 2010 Fil-Tec Inc. Filtertech Inc. Fine International Corp. Fisk Alloy Conductors Flymca Flyro FMS USA Inc./FMS AG Foerster Instruments Inc. H. Folke Sandelin AB Fort Wayne Wire Die Inc. Fortune Machinery Frontier Composites & Castings Inc. Fuhr GmbH & Co. KG Fushi Copperweld Garg Sales Co. Ltd. Gauder & Co. Gauder Group Inc. Gavlick Machinery Corp. GCR Eurodraw SpA Gem Gravure Co. Inc. Genca/Canterbury Engineering W. Gillies Technologies Gimax SRL GMP-Slovakia Golden Spot Industry Inc. Guill Tool & Engineering Co. V. Hagen & Funke Hall Industries Heacock Metal & Machine Co. Inc. Heany Industries Inc. Heatbath Corp. Henrich Maschinenfabrik GmbH Heritage Wire Die Inc. Howar Equipment Inc. Huestis Industrial Huettner Maschinenfabrik GmbH ICE Wire Line Equipment Inc. IDEAL Welding Systems Ideal-Werk INHOL LLC Inosym Intras Ltd. Italian Trade Commission ITO-SIN (Deyang) Wire & Cable Equipment Co. Ltd. IWE Spools & Handling GmbH IWG High Performance Conductors Inc. IWMA - International Wire & Machinery Association JMS Machinery Joe Tools Kalmark Ltd. KEI Industries Ltd. KEIR Manufacturing Inc. Kieselstein GmbH Ernest Koch GmbH & Co. KG Albert Krenn Friedrich Krollman GmbH & Co. KG Lamnea Bruk AB LaserLinc Inc. Leggett & Platt Wire Group Leoni Wire Inc. OM Lesmo Lesmo Machinery America Inc. Lloyd & Bouvier Inc. J.J. Lowe Associates LUKAS Anlagenbau GmbH M + E Macchine + Engineering Magnetic Technologies Ltd. MAGPOWR Maillefer SA

Mapre Belgium SA Merritt Davis Metavan NV MFL USA Service Corp. Frigerio The MGS Group (MGS-HallNorthampton) MGS Manufacturing Inc. Micro Products Co. Microdia USA Millennium Steel & Wire Inc. Morgan-Koch Corp. Mountville Rubber Co. MPI Machines Ltd. NEPTCO Inc. Nextrom Oy Niagara Composites Industries Inc. Niehoff Endex North America Inc. Maschinenfabrik Niehoff GmbH & Co. KG Northampton Machinery NUMALLIANCE Oklahoma Steel & Wire OMA SRL OMA USA Inc. OMCG North America OMCG SpA Paramount Die Co. Parkway-Kew Corp. Pave Automation Phifer Wire Inc. Pioneer Machinery Co. Ltd. Pittsburg Carbide Die Co. Pittsfield Plastics Eng. Inc. Plasmait GmbH Plymouth Wire Reels Polytec Inc. Pourtier - Gauder Group Power Sonics LLC/Magnus Equipment Precision Die Technologies Inc. Premier Wire Die PrintSafe Promostar srl Properzi International Inc. Proton Products QED Wire Lines Inc. Queins & Co. GmbH Raajratna Metal Industries Ltd. RAD-CON Inc. Radyne Corp. Rainbow Rubber & Plastics Rautomead Ltd. Reel-O-Matic Refractron Technologies Corp. RG Attachments RichardsApex Inc. Rizzardi Rosendahl GmbH Rosendahl Nextrom Technologies Roteq Machinery Inc. Saarsteel Inc. SAMP SpA SAMP USA Inc. SAMPSISTEMI Sark USA Inc. Sark Wire Corp. Sarkuyasan AS Schlatter Inc. Schunk Graphite Tech Setic SAS Sictra Srl SIKORA International Corp.

SIMPACKS Sirio Wire Srl Sjogren Industries Inc. Skaltek Inc. SKET Verseilmaschinenbau GmbH Smeets SA Sonoco Reels Spirka Schnellflechter GmbH SPX Precision Components FENN Division STAKU-Anlagenbau GmbH Stema/Pedax Steuler Anlagenbau Stolberger Inc. (dba Wardwell Braiding Co.) Stolberger KMB Maschinenfabrik GmbH T & T Marketing Inc. Talladega Machinery & Supply Taubensee Steel & Wire Co. Taymer International Inc. Team Meccanica Srl Teknikor Teknor Apex Co. Tensor Machinery Ltd. Teurema Thermcraft Inc. Traxit North America LLC Troester GmbH & Co. KG Paul Troester Maschinenfabrik Tubular Products Co. Tulsa Power Inc. UMC United Wire UNITEK Uniwire International Ltd. UPCAST OY US Reel US Synthetic Wire Die Vandor Corp. Vitari SpA Vollmer America Inc. Wafios Machinery Corp. WAI Connection WCISA - Wire and Cable Industry Suppliers Association Weber & Scher Mfg. Co. Inc. Windak Inc. Wire & Cable Asia Magazine Wire & Cable Technology International Wire & Plastic Machinery Corp. wire 2012/Messe Düsseldorf North America The Wire Association International, Inc. WIRE BULLETIN Wire Forming Technology Wire Journal International Wire Lab Co. Wire Machine Systems Inc. Wire World Internet WireCo WorldGroup WiTechs Witels Albert USA Ltd. Woodburn Diamond Die Inc. Worth Steel & Machinery Inc. WTC Wyrepak Industries Inc. Ya Sih Technology Yield Management Corp. Zeus Inc. Zumbach Electronic AG Zumbach Electronics Corp.

INTERWIRE 2011 | THE LARGEST WIRE AND CABLE MARKETPLACE IN THE AMERICAS.

A. Appiani Ace Metal Inc. ACM-KSM AFL AIM Inc. Ajax Turner All Forming Machinery Inc. Amacoil Inc. Amaral Automation Associates American Kuhne AW Machinery LLC AXIS, A Consona ERP Solution Axjo Plastic AB Aztech Lubricants LLC B & H Tool Co. Inc. Balloffet Die Corp. Bartell Machinery Systems LLC/ Ceeco Machinery Bekaert Corp. Bergandi Machinery Co. Besel Basim San Tic Ltd. Sti. Beta LaserMike Blachford Corp. Maschinenfabrik Bock GmbH & Co. KG Bogimac Bongard Machines USA LLC Breen Color Concentrates Bühler-Würz Kaltwalztechnik Butt Welders USA Caballe SA Cable Consultants Corp. Carris Reels Inc. Cary Compounds LLC Cemanco LC Chase Coating and Laminating Clifford Welding Systems Clinton Instrument Co. CM Furnaces Inc. CMEC International Exhibition Ltd. CN Wire Corp./Er Bakir Comapac Wire Machinery Srl Cometo SNC Commission Brokers Inc. Condat Corp. Conneaut Industries Inc. Continuus-Properzi SpA Cortinovis Machinery America Inc. CRU North America Inc. Daloo Machinery Davis-Standard LLC Dem Costruzioni Speciali Srl Die Quip Corp. Domeks Makine Ltd. Sti Dynamex Corp. Ebner Furnaces Inc. Egyptian Galvanized Steel Plant Co. EJP Maschinen GmbH Engineered Machinery Group Inc. Enkotec Co. Inc. ERA Wire Inc. Esteves Group USA Etna Products Inc. Etna-Beechem Lubricants Ltd. Eurodraw Energy SpA Eurolls Group Srl EuroWire Magazine George Evans Corp. EVG Inc. Fabritex Inc. FIB Belgium SA

INDUSTRY NEWS

(pre-terminated sets) for onshore wind farm projects across Europe. … CommScope, Inc., reports that two Japanese wireless operators have made the switch to HELIAX® 2.0 smoothwall cables, the feeder and jumper coaxial cable line solution offered by its Andrew Solutions division that is a global supplier of wireless communications systems and products. “Japan is known as one of the most demanding markets in the wireless industry with high expectations for advanced technology and superior quality,” said Akira Kawada, country manager and president, Andrew Solutions Japan. “We are proud to bring the next generation of wireless cables to Japan.” ... Northwire Technical Cable, a provider of technical and retractile cables, announced that it has formed a government business unit to meet the growing demand from the U.S. government, civilian research agencies, core government suppliers, contractors and affiliate organizations. ... Custom Cable Industries, a U.S.-based supplier of central office, custom, standards based and network cables, has filed for Chapter 11 protection and is looking for a buyer. The company, which provides connectivity solutions that include structured cabling; network, voice and data solutions; and

26 | WIRE JOURNAL INTERNATIONAL

professional services reported assets of between $1 million and $10 million, and liabilities of between $10 million and $50 million. ... U.S.-based C&M Corporation, a manufacturer of bulk cable, coil cords, and cable assemblies, announced that IWI Associates will be its sales representatives in Northern California and Northern Nevada. It noted that IWI Associates’ Midwest group already represents C&M in Texas, Oklahoma, Louisiana, and Arkansas. ... Industrial Electric Wire & Cable reports that it has officially changed its name to IEWC and created a new logo to better reflect the company’s focus on providing supply chain solutions for OEMs and subassemblers around the globe. It said that IEWC’s military/aerospace division, Colonial Wire and Cable, and its location in the United Kingdom, C3 Limited, will also assume the new name and logo. ■

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bunchers, and features considerably reduced noise emission and heat generation. For all strand constructions and less scrap – enabled by the open system.

ASIAN FOCUS

ASIAN FOCUS Furukawa joint venture in China to produce industrial cables Japan’s Furukawa Electric Industrial Cable Co., Ltd., announced the formation of Huatong Furukawa (Tangshan) Cable Co., Ltd., a joint venture it has entered into with China’s Hebei Huatong Wires & Cables Group Co., Ltd. At its website, Furukawa’s announcement said that the venture, to be located in Tangshan, Hebei Province, has US$19 million of capital, and will have about 200 employees that will manufacture industrial wire for mining, oil fields, wind power generation, etc. The cables will offer improved environmental durability and bending resistance, attained by covering the conductive body with rubber, it said, adding that the cables are mainly used in the movable portions of industrial machinery. The Furukawa Electric Group, it noted, has developed a wide range of applications for these cables, which are used for high and low voltages. The products are used in the high-speed trains of Japan and China, and have earned an excellent technical evaluation, it said. The announcement observed that China has a continuing need to expand its electrical capacity “to expand in step with economic growth in recent years, and needs have grown for rubber cables used with excavating machinery for coal mine resources and oil fields.” Windpower generation is another driver for the product, it said. “As the world’s largest emitter of CO2, surpassing the United States, China is investing aggressively in wind power generation. This is likely to lead to growing demand for the cables used by wind power generators.” Further, China is planning an extensive high-speed rail network, which should prompt a rise in demand for cables used with rolling stock, as domestic production advances, it said. “Moreover, in these rapidly emerging markets, machinery with higher output is now being used. This will lead to rising needs for rubber cable products with higher voltage resistance and durability (against high and low temperatures, oil, and other phenomena).”

Vietnam cable quality: what a difference a few days can make Within a three-day spread, Viet Nam Business News had two news stories about electrical wire that some readers might have found puzzling. A July 22 story carried by the news agency said that Vietnam’s Ministry of Industry and Trade reported that wire exports were set to increase, “because the quality was good and the price competitive.” It noted that in the first five months of 2010, Vietnam earned US$487.8 mil-

An electrical power pole and a jumble of wires in Saigon, Vietnam. lion from exporting electric wire and cable, double the same period last year. The two largest importers were Japan ($342 million) and the U.S. ($53 million), both double the same period last year, mainly for electric wire and cable for automobiles, computers and motorbikes, it said, adding that Africa and the Middle East also had potential for exporters. The article said that other factors that helped the results were better support policies, such as reduced export fees and red tape. It added that, “Producers should use local material to cut production costs and invest in research and production technology to add value to products.” The perspective had not been so positive three days earlier, when Viet Nam Business News ran a story that said, “The quality of most electrical wires made in the country is abysmally low in the absence of clear-cut quality standards, consumer’s ignorance, and producers’ need to cut costs in the highly competitive market.” It cited a Ho Chi Minh official as saying that most fires (90 percent) in the city were related to electricity. The July 19 article cited a recent test of electrical cables by the Centre for Studying and Consulting Consumption (CESCON) that found “just one out of 36 samples of electrical wires and the insulation made by 15 companies meeting all quality and safety standards.” The one company whose samples fared well was Viet Nam Electric Wire and Cable Joint Stock Company (CADIVI), which had received certification for quality last May, it said. The conductors in the bad cable, it said, did not have enough copper and some even contained foreign substances. In the article, one cable company director was cited as saying that quality was compromised in favor of low prices because customers, mainly rural, “do not attach too much importance to quality.” Other buyers prefer cheap cables to cut costs, it said, while another executive was

Have news that belongs here? If so, e-mail it to editorial@wirenet.org.

28 | WIRE JOURNAL INTERNATIONAL

Hitachi Cable adds production equipment to plant in Malaysia Japan’s Hitachi Cable has added equipment at Hitachi Cable (Johor) Sdn. Bhd. of Malaysia, which a press release said should have been in full-scale operation as of August to produce photovoltaic wire. A number of wire reports said that the Malaysia plant, which will “take its place alongside Hitachi Cable Fine-Tech, and Hitachi Cable (Suzhou),” will produce “NoWarp” photovoltaic wire. The wire, it said, connects the individual cells that make up a solar cell, serving as a conductor that collects the generated electric power. Hitachi Cable launched production of the photovoltaic wire in 2000 and now sells it under the NoWarp brand name. The company, the reports said, is investing about US$6 million for the project. The NoWarp wire, the reports said, is highly rated for achieving flexibility while maintaining high electrical

conductivity. They added that the wire now has about a 20 percent share of the global photovoltaic wire market. The company also produces the wire at similar facilities in Japan and China. “With this new facility, Hitachi Cable Group is seeking to expand net sales of wiring materials for solar cell use, primarily NoWarp products, from approximately 4 billion yen in fiscal 2009 to 9 billion yen in fiscal 2012,” they said. The articles noted that growing interest in energy conservation and efforts to prevent global warming have led to anticipated annual growth rates for solar cell module output capacity averaging 22 percent. The company was cited as saying that advances in solar cell modules through the development of crystalline silicon solar cells have resulted in slimmer units. That, in turn, has caused problems in that the thinner individual cells are more susceptible to the thermal stress generated when connected to photovoltaic wires, which sometimes results in warp, the reports said. Thus, the photovoltaic wires must be flexible enough to absorb the thermal stress and to resist cell warp, they said. ■

NEW ENTRIES Machines still installed in a German cable factory, promptly available! Ref. no. 10-7608 STOLBERGER, tubular strander SVR 12/355, 1100 min-1 , encircling bearings Ref. no. 10-7609 STOLBERGER, tubular strander SVR 12/560, GESADUR underrollers Ref. no. 10-7610 STOLBERGER-NIEHAUS, tubular stranders, encircling bearings, 1100 min-1, 2 sets for 1+6 and 2 sets for 1+12 bobbins, 250 mm ø Ref. no. 13-7612 HENRICH, double twist buncher, take-up bobbin 630 mm, with 7 flyer-type pay-off ’s (2 machines available) Ref. no. 61-7619 HENRICH, copper rod drawing machine model 30R13, 13 dies, inlet 8,0 mm, finished ø 1,4 mm, continuous annealer, dual spooler AR 1000 for bobbins 630 mm ø, plus bundle packer / static coiler for bobbins 1250 mm ø Ref. no. 61-7620 HENRICH, aluminium rod drawing machine model 30R13, 13 dies, inlet max. ø 9,5 / 12 mm, finished ø 2,0 – 4,5 mm, spooler max. 1250 mm ø Ref. no. 66-7600 NIEHOFF, 8-wire drawing line, type MMH 101, 21 dies, inlet 1,5 mm ø, finishing size 0,2 – 0,30 mm, continuous annealer R 160, automatic static coiler for 630 mm bobbins Further medium and fine wire drawing machines as well as drawing lines for copper alloys and flat wire.

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SEPTEMBER 2010 | 29

ASIAN FOCUS

cited as saying that low-quality cables remain popular since most customers do not know the dangers they pose and pay more attention to prices.

PEOPLE

PEOPLE SAMPSISTEMI has announced the appointment of Dominique Perroud as CEO of SAMP SHANGHAI, responsible for strengthening and expanding SAMP’s position in China while also integrating other business units belonging to the SAMP group. He has more than a quarter century of industry experience. He joined SAMP in 1997, and since 1999 he had been Dominique managing director of SAMP USA Perroud in Williamsport, Maryland. The current 1st Vice President of Wire Association International (WAI), he holds a degree in electrical engineering from Switzerland’s ETS School and an MBA from the University of Massachusetts. Marco Gerardo has been appointed as vice president of sales & services at SAMP USA, Inc., in Williamsport, Maryland. He joined the company in 1991 as a sales area manager, and in 1997 was named export sales manager, responsible for territories in Mexico and Canada. He was promoted in 2000 to sales and Marco Gerardo marketing manager. Prior to joining SAMP, he worked for O.M. Lesmo and Johnson Controls in Europe. Based in Italy, SAMPSISTEMI is a global supplier of equipment and accessories for the wire and cable industry. Beta LaserMike reported the recent promotion of Dan Norris as director of engineering. He has more than 20 years of management experience with global organizations, including 14 years with Beta LaserMike, and has a diverse background in lean manufacturing, operations, sales, quality, program management and strategic planning. He will take over responsibiliDan Norris ties that had been handled by company President Ken Wright. Norris previously worked for EG&G Mound Applied Technologies and at Amoco Corporation. He holds a B.S. degree in business administration. Based in Dayton, Ohio, USA, Beta LaserMike is a global supplier of precision measurement and control systems for sectors that include wire and cable. Antonio R. Ayala has been named Latin America Sales Manager for Canterbury Engineering and Genca Corporation (CanGen). He will promote the companies’ extrusion technology in Mexico and South/Central

30 | WIRE JOURNAL INTERNATIONAL

America. Most recently he was director, Latin-America sales, at J.J. Lowe Associates, Inc., where he had worked since 1998. Prior to that he was employed by AXA Group (Monterrey, Mexico), Conductores Latincasa (San Luis Potosi, Mexico) and Ericsson (Stockholm, Sweden). The 2009 president of WAI, he has been a primary organizer for the Antonio Ayala Association’s International Technical Conferences in Mexico. He holds a mechanical and electrical engineering degree from The Engineering University at Veracruz, Mexico, and an MBA degree from Ohio University. Based in Atlanta, Georgia, and St. Petersburg, Florida, CanGen supplies engineered and manufactured screw and barrel components, and extrusion tooling and die product lines. Cable Components Group (CCG), has named Barbara Cioffi as customer service manager, reporting to David Braun, vice president, business and product development. She will oversee the company’s inside sales team accountable for daily interactions with customers as well as provide critical support for CCG’s ongoing introductions of FluoroFoam® and FluoroSpun® products for the wire and cable, fiber optic, and industrial non-woven and tubing markets. She previously worked at NEPTCO, where she held positions over 21 years as international customer service specialist, customer service manBarbara Cioffi ager, and product manager of outside plant products. Based in Pawcatuck, Connecticut, USA, Cable Components Group (CCG) designs, engineers, and manufactures high performance extruded products for the wire and cable, fiber optic and industrial non-woven markets. The Extrusion Systems Group of Davis-Standard, LLC, announced that Weijian (Kent) Wang has recently joined DavisStandard as a process engineer working in development in the company’s technical center. He worked for 13 years as a senior process engineer for Pactiv Corporation, and prior to that was with Integrated Bagging Systems, Inteplast Corporation. He holds an M.S. degree in chemical Weijian (Kent) engineering from the University of Wang Cincinnati. Based in Pawcatuck,

Carol A. Jensen has joined Northwire, Inc., as a regional sales manager, with a strategic focus that includes the Midwest and Central regions of the U.S., as well as Canada and Europe. She has 14 years of OEM direct sales and marketing expertise, most recently as vice president of sales and marketing for a Wisconsin-based investment organization. She holds a B.S. degree from the University of Wisconsin-Stout. Based in Osceola, Wisconsin, USA, Northwire, Inc., manufactures technical and retractile cables for diverse applications. C&M Corporation has named Roger Rue as the company’s global supply chain specialist. He has more than 17 years of experience in international sourcing, qualification and procurement, with extensive on-the-ground experience in Asia, India, Europe and Mexico. Previous employers include Guill Tool and Engineering, Bacou-Dalloz and Barry Controls. He holds BS/BA degrees in finance, an MBA degree in marketing from Bryant University and a certification in program management from Boston University. The company also named Bo Oliveira as its

Western regional sales manager. He previously worked for 32 years with American Insulated Wire, where he served at positions that included OEM inside sales manager and national OEM sales manager as well as cable design engineer. He holds a BA degree from Providence College. Based in Wauregan, Connecticut, USA, C&M Corporation is an integrated manufacturer of bulk cable, coil cords, and cable assemblies. Joe Zajac has been named manager, market development, professional broadcast and commercial AV products, for General Cable Corporation. In this role, he will lead the market and business development efforts for both the Gepco® brand and Sheer Wire™ line of products. He has 25 years of experience in the broadcast industry as well as 14 years in manufacturing, product development and field engineering. In 1996 he joined Gepco, where he served as engineering manager, field engineer and operations manager. He previously was managing engineer for 10 years at Columbia College Chicago, where he where he has also been a part-time instructor for the last 20 years. He holds a B.S. degree in radio/sound from Columbia College Chicago. Based in Highland Heights, Kentucky, USA, General Cable is a global manufacturer of copper, aluminum and fiber optic wire and cable products. ■

SEPTEMBER 2010 | 31

PEOPLE

Connecticut, USA, Davis-Standard, LLC, is a global supplier of extrusion technology for sectors that include wire and cable.

FIBER WATCH

FIBER WATCH News is ‘stimulating’ for optical fiber deployment in Tennessee and Kentucky The states of Tennessee and Kentucky will benefit from recently sanctioned projects as part of the Rural Utility Service Broadband Initiatives Program funded by “stimulus” projects through the American Recovery and Reinvestment Act (ARRA). Kentucky’s McCreary County Record reports that U.S. Secretary of Agriculture Tom Vilsack and Governor Steve Beshear announced the projects, one of the largest of which is the Highland Telephone Cooperative (HTC). The story notes that HTC will receive $66,489,162 to enhance broadband communication options in McCreary County (29% of funding) as well as Scott and Morgan counties in Tennessee (71%). The project, it said, will benefit 52,000 people; 1,800 businesses and 100 community groups. “Not only will this funding help create jobs, it will also help bring much-needed infrastructure to our rural communities, helping them to expand their services, attracting new businesses that will bring economic growth and jobs by providing affordable access to critical 21st Century

32 | WIRE JOURNAL INTERNATIONAL

technologies,” Gov. Beshear said in the article. “Expanding broadband access in these rural communities will make it easier for Kentuckians to receive better health care, quality education and critical small businesses opportunities. This is remarkable news for Kentucky.” A report from Tennessee’s WBIR notes that the money will allow HTC to run broadband fiber to each customer’s home. “It has really opened up all of our territory to get these services which, without stimulus money, would’ve been a long time until we were able to do that,” HTC General Manager Fred Terry said in the report. Per the WBIR story, engineers will soon draft plans for the broadband installation and then contractors will be hired. HTC Plant Manager Roger Galloway estimated that some 500 or more contractors would be needed. The fiber, he said in the report, has to be installed in all three counties within three years. The WBIR report said that HTC won the money by sending an application to the USDA. It added that the federal government is providing $2.4 billion to expand broadband access to rural America.

The countries of Suriname and Guyana officially launched the Suriname/Guyana Submarine Cable System (SGSCS), a US$60 million project that was hailed as representing “a new era” in the region. Kaieteur News Online (KNEWS) reports that the Guyana Telephone and Telegraph Company (GT&T) held its official launch on July 29, with Guyana President Bharrat Jagdeo announcing a government project to outfit some 90,000 poor families with laptops in a three-year project. Two weeks later, it said, Suriname commissioned its service. GT&T has invested US$30M to bring the cable, and it will cost from US$20-30 million to fully optimize the system’s potential, the report said. In it, GT&T Marketing Manager Wystan Robertson said that the SGSCS launch bodes well for the Information and Communication Technology (ICT) development of the two countries and the Caribbean Community (CARICOM). GT&T, KNEWS reported, is working with several partners to introduce cheaper computers and other services, including call centers and banking initiatives. One of the major projects underway is the establishment of a Trade Point at the Guyana Office for Invesment (GoInvest) which will be allowing locals to link-up and talk to overseas businesses, said the KNEWS report, who also noted the following. In terms of collaboration with Suriname, talks are underway to link up the thousands of Guyanese who live and do business with that neighboring country with Guyana using roaming services. In essence, Guyanese and Surinamese, using GT&T and Telesur services can visit the other country and make calls and go online, under new features to be introduced. During the Guyana launch in July, Dirk Currie, CEO of TeleSur, had noted that the collaboration is a new era in telecom for the region, providing not only the high speed Internet, but data, video and increased bandwidth.

Report: FTTH customers love their fiber A new report commissioned by the Fiber-to-the-Home Council has found that consumers continue to experience greater satisfaction with FTTH services than do those who rely on other broadband access technologies such as cable modem and DSL. A press release said that a survey of more than 1,000 FTTH subscribers and 600 other broadband subscribers, drawn randomly from an online panel of more than 50,000 consumers by the research firm RVA LLC, found that 71% of FTTH subscribers indicated that they are “very satisfied” with their Internet service, compared with 53% for cable modem subscribers and 52% for DSL. The numbers are even higher for the polled consumers who have high-definition television, it said. The survey found that average FTTH download and upload speeds continue to stay well ahead of cable and DSL, the release said. Based on these reports, FTTH currently has a median download speed of 16.6 Mbps and an upload speed of 4.5 Mbps, an increase of 219% for download and 350% for upload speeds over the three years RVA has conducted this survey. Compared to tests from consumers with other types of broadband, FTTH download speeds on average are 1.5 times faster than cable modem download speeds, and 5.7 times faster than the median DSL download speeds, the release said. In terms of upload speeds, it added, FTTH is 3.2 times faster than cable modem and 5.7 times faster than DSL. The release said that a total of 13% of FTTH users reported operating a home-based business, with 75% saying that without FTTH, the business would either not be feasible or not be very efficient. Based on survey input from home-based business, RVA estimates that increased efficiencies from FTTH may already add as much as $9.9 billion to the U.S. home-based business economy, it said. As of April 2010, FTTM services were available to more than 16% of North American homes and were connected to nearly six million of them. ■

SEPTEMBER 2010 | 33

FIBER WATCH

Joint venture Suriname and Guyana fiber optical cable system launched

FASTENER UPDATE

FASTENER UPDATE Topura America Fastener plans to expand its plant in Bowling Green Kentucky Gov. Steve Beshear was among those in attendance on June 2 to celebrate the announcement of the expansion of Topura America Fastener, whose 71,966-sqft plant in Bowling Green, will expand by 96,000 sq ft. SouthCentralky.com, the website of the nine-county South Central Kentucky Regional Economic Development Partnership, reports that Topura America Fastener, a manufacturer of automotive and industrial fasteners, will add 30 new jobs in phases over the next three years, raising employment at the Bowling Green plant to 95. It said that the company will invest $9.34 million as a result of the expansion and through continual improvement in processes and technology. “Topura America Fastener is extremely excited about today’s announcement and for the opportunity of organizational growth in a challenging economic time period,” said Darrell Oakley, Topura executive vice president. “The expansion will secure an increase in both job opportunities and process investments for today and long term.” The Kentucky Economic Development Finance Authority

(KEDFA) preliminarily approved Topura America Fastener for tax incentives up to $675,000 through the Kentucky Business Investment program, with up to another $75,000 possible in tax benefits, the report said. In accordance with the new state incentive programs, the city of Bowling Green provided its financial support to this project in an occupational tax abatement for a 10-year period.

Boeing patent a metallic bolt of genius Boeing has been awarded a patent, #7,755,876, for a fastening assembly to be used on composite structures that will reduce or eliminate internal sparking and prevent hot gas from escaping into an aircraft structure when it is hit by lightning. Bloomberg reports that the fastener technology is quite useful to Boeing’s 787 Dreamliner, which uses composite materials that are not as effective as aluminum at evenly dispensing current from a lightning strike throughout the aircraft body. The patented technology includes a special washer that can contain hot gases and prevent arcing, it said. A lightning strike near other types of standard aerospace fasteners, it noted, can produce a high current density entering the airframe of the aircraft through that fastener. ■

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WAI NEWS

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Wire Association International to elect Board of Directors this month The annual election of the WAI’s board of directors, whose members meets twice a year, will be taking place this month. The ballots, which will be distributed by e-mail to members only, will include a slate of four new candidates and three returning directors to serve a second three-year term. The candidates were identified by the Nominating Committee (see below news item) and approved by the Board of Directors, which met for its May meeting during Wire Expo 2010 in Milwaukee.

The following individuals have been nominated to join the board; Sheldon Scott, president & CEO, Whitney Blake; Anthony DeRosa, president, Cortinovis Machinery; Mark A. Thackeray, Senior Vice President, North American Operations, General Cable; William A. Avise, president, Leggett & Platt Wire Group and vice president of Leggett & Platt. Candidates presented to serve a second three-year term are: Malcolm Michael, director/secretary, Australasian Wire Industry Association; Ralph Noonan, sales manager, Etna Products; and Donald Schollin, president, Q-S Technologies. (continued on p. 39)

Volunteer Sp✹tlight This occasional section will provide readers a better idea of what WAI’s committees/board of directors do.

Volunteer spotlight: WAI’s Nominating Committee Every year, the WAI membership votes to elect members of the Board of Directors. The slate of directors which appears on the ballot is the work of the Nominating Committee. The Nominating Committee consists of not less than five members and they cannot be eligible to serve or be nominated for the board of directors. As a result, the committee has historically been made up of past members of the board of directors, as they are familiar with the responsibilities of service. “The Nominating Committee considers multiple factors in the process of identifying candidates,” said WAI Executive Director Steve Fetteroll, who also serves as the staff liaison to the committee. “The committee is very thoughtful in terms of aligning candidates with the Association’s strategic direction and maintaining representation from the many different segments of the industry.” Once the board of directors is elected by the membership, the nominating committee then prepares its recommendation as to who should serve on the executive committee for the upcoming year. The board considers this recommendation at their next meeting. The executive committee consists of the president, 1st vice president, 2nd vice president, past president and generally one or

36 | WIRE JOURNAL INTERNATIONAL

two non-officer members. As with all WAI Committees, volunteers are welcome. If you are interested in WAI’s various volunteer bodies, you can contact WAI President Dane Armendariz at darmendariz@wirenet.org or Executive Director Steve Fetteroll at sfetteroll@wirenet.org. For more information on the Brian Bouvier, Association’s different committees, go to www.wirenet.org, then click on chairman, WAI Nominating “Membership,” then “Committees.” Committee. Committee Members Brian Bouvier (Chairman), Lloyd & Bouvier John Drummond, Scotia Group David Richards, RichardsApex Scott Higgins, Consultant Paul Pawlikowski, Delphi Committee Liaisons Steve Fetteroll. WAI Executive Committee Liaison, SAMP USA Marc Murray WAI (Staff Liaison)

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Are you? At 80, WAI isn’t old. It’s mature. And as the industry’s cornerstone technical society it is set in its ways of inspiring today’s leaders and cultivating tomorrow’s pioneers. WAI’s products are individually focused. They also happen to have mass appeal. That’s why your association with WAI will put thousands of constituents in our international network within your reach. Sure. The way we communicate has changed over the years. WAI’s high standards have not. Like you, we’ve seen faxes give way to e-mails, instant messaging, and blogs. But they haven’t invented a direction in wire and cable that we’re not interested in learning about and sharing with you. WAI now offers: • a series of live and archived educational webinars—free to members • electronic delivery of the industry-leading Wire Journal International magazine and twice monthly WAI Connection newsletter • instant chat customer support online for Interwire and Wire Expo • PDF files of the more than 5400 technical articles in WAI’s library Members receive the annual WJI Reference Guide, discounts at events, savings on WAI products and more. So if you’re still wondering what happened to the letter—here are three to remember W A I. We may not be ready to pass the torch but we’re pleased to light the way.

Learn membership details and join WAI’s network today at: www.wirenet.org or complete the form on the reverse side. The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

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Joseph P. Domblesky, an associate professor in the mechanical engineering department at Marquette University in Milwaukee, will present a webinar on Mechanics of Wiredrawing from 11 am to noon EDT on Wednesday, October 13. The course will cover basic engineering principles and process calculations that are used in wiredrawing processes for metal rods and wires. Topics that will be covered include stress-strain curves, material heat-up during drawing, and friction. Calculating reductions and draw forces for sizing drawing stands using standard engineering formulas will also be considered. Also the effect of alloy chemistry on drawing performance will be considered, along with an overview of common die materials. Domblesky, who teaches manufacturing processes/engineering and performs research in mass finishing and metal forming, also teaches a workshop in die stress analysis for the cold and hot forming industries. He has been with Marquette since 1996. He previously held positions at General Motors and MSW Inc. as a manufacturing engineering and tool room supervisor. He holds B.S. and M.S. degrees in industrial engineering from Penn

State University and a Ph.D. in metal forming from Ohio State University. He is a licensed Professional Engineer in Wisconsin. The seminars, free to WAI members and $55 each for non-members. For information and to register, visit www.wirenet.org/events/webinars.

Second half of webinar on polymer degradation to be held September 15 Dr. Sitaram Rampalli is scheduled to present the second half of his two-part webinar (Polymer Degradation, Stabilization, and Failure Analysis) on Wednesday, Sept. 15, from 11 am to noon EDT. Part 2: Polymer Stabilization and Failure Analysis, will cover various stabilizers that are needed to combat the degradation process. It will also cover failure analysis and prediction techniques, and includes a discussion of reallife product failures. The seminar, free to WAI members and $55 each for non-members, will discuss the nature of polymer degradation, possible causes and ways to minimize its effects. For information and to register, visit www.wirenet.org/events/webinars. (continued on p. 40)

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ai ina 2010 in Shangh Fuhr at the Wire Ch 64

63/W1E Japan Pavilion W1D

SEPTEMBER 2010 | 39

WAI NEWS

Mechanics of wiredrawing webinar has been scheduled for October 13

WAI NEWS

Monterrey ITC set for Oct. 28-20 The elements are in place for the WAI’s International Technical Conference (ITC) in Monterrey, Mexico, which will be held October 18-20 at the Crowne Plaza Monterrey, which also hosted the WAI’s 2008 ITC. The 2010 ITC, co-sponsored by Mexican wire association Asociación Nacional de Transformadores de Acero A.C. (ANTAAC), will feature technical paper presentations, tabletop exhibits (Suppliers Market), a reception, a plant tour and lots of networking potential. Technical paper sessions will run in the mornings and afternoons of both Monday, October 18, and Tuesday, October 19. The schedule has recently been adjusted to accommodate some late changes to the program. As of press time, the technical program is scheduled to include 22 papers. For the most up-to-date schedule, go to the listing at http://www.wirenet.org/events/itc/papers.htm. As of press time, a total of 51 tabletop exhibits had been allocated for the Suppliers Market, which will be open on Monday, October 18, from 8 am until 9:30 am, then close for the official opening/keynote speaker presentation, and be open during the technical presentations on both days. A reception will be held Monday at the hotel in the tabletop area, making it easy for attendees to talk to each

other and tabletop company representatives. The papers resume on Tuesday at 9 am and conclude at 4:30 pm. The program hours have been planned so attendees will have plenty of opportunities to visit the Suppliers Market displays. The plant tour, on Wednesday, October 20, will be at Ensamble de Cables y Componentes, Guadalupe III, which is part of the Delphi Packard Electrical/Electronic Architecture division. The plant is located at Guadalupe, Nuevo Leon, Mexico, where the company manufactures components and systems for the automotive industry. The Guadalupe III plant, which started operations in 1999, embodies Delphi’s Excellence Philosophy aimed at exceeding customer expectations. The ISO 9000 and ISO 14001 registered plant has been a recipient of the Q1 Ford Award and the Industria Limpia Award, among others. The plant, headed by Plant Manager Quirino Anaya, has around 2,700 employees.

Interwire 2011 exhibits: 90,000 sq ft WAI Sales Director Robert Xeller reports that nearly 90,000 sq ft of floor space has been sold for Interwire 2011, to be held May 2-5 at the Georgia World Congress Center in Atlanta, Georgia, a long-time host for the event. The floor space represents more than 85% of the space inventory. ■

For show information: Messe Düsseldorf North America 150 North Michigan Avenue Suite 2920 Chicago, IL 60601 Tel: (312) 781-5180 Fax: (312) 781-5188 E-mail: info@mdna.com http://www.mdna.com

40 | WIRE JOURNAL INTERNATIONAL

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CHAPTER CORNER

CHAPTER CORNER Weather gods prove to be kind to Ohio Valley Chapter’s golf outing In a summer that will be remembered for extreme heat, the golfing gods moderated the hot stuff and served up a pleasant day for the 33 golfers who got to enjoy the long fairways of one of Ohio’s best public courses. The day proved to be especially pleasant for the winning team of Vincent Griffin (Premier Wire Die), Jerry Richards (Adco), Aaron Nolan (Sumitomo Electric Carbide) and Mike Swift (Premier Wire Die), who shot a 10 under par to grab top honors. “It was a beautiful day,” declared Nolan, who in addition to being on the winning team had served as the event chairman. He said the golf course was in great condition, and that the event was enjoyable from the morning start to The winning team (l-r) of Vincent the dinner that followed the golf. Griffin, Jerry Richards, Aaron Nolan and Mike Swift. Second place went to the team of Rob Fulop and Al Luikart (both of Wire Lab Co.), Eric Marquardt (Enkotec) and Bill Dohrman (Condat), which was seven under par. In the skills events, the winners of the closest-to-thepin challenge, sponsored by Wire Lab Co., were John Socrates (Charter Steel) and Chris Ross (Henkel). The two long-drive contests, sponsored by Charter Steel, were won by David Light (Charter Steel) and Fulop. Corporate Hole Sponsors included Premier Wire Die and Enkotec Company. The proverbial good time was had by all, and as chapter President Rob Fulop noted, the golf tourOhio Valley Chapter President Rob ney provides a Fulop (l) and event Chairman Aaron great forum for Nolan, of Sumitomo Electric Carbide. 42 | WIRE JOURNAL INTERNATIONAL

the local industry to gather as well as providing a break from the summer routine. Details for the 2011 golf outing will be announced before the end of the year.

Mere days away: New England Chapter’s 16th Annual Golf Tourney Bragging rights will once again be fiercely contested when the New England Chapter holds its annual golf tourney, which last year saw 153 golfers swinging away at the Mount Pleasant Country Club in Boylston, Massachusetts. The chapter returns there Thursday, September 16, for its 16th Annual Golf Tournament. “The New England Chapter is looking forward to hosting another great day of golf,” said Mike McKee, Lloyd & Bouvier Inc., who is co-chairing the event along with John Rivers, Delaware Marketing. “This event has sold out the past seven years running, and this year’s outing should be no different, as everyone seems to enjoy September golf in New England.” McKee said that registration officially closes on Thursday, September 9, but if someone has not yet registered and wishes The 2009 winning team (l-r) was Mark to particiMathiasen, Pat Staffiere, Steve Navarette pate, they and Phil Dupuis. can either contact him at tel. 978-365-5700, mikem@lloydbouvier.com or Rivers at tel. 860-896-4761, johnr@dms-inc.com. McKee said that companies seeking some publicity at the event can still get a corporation hole sponsorship by contacting WAI’s Anna Bzowski at tel. 203-453-2777, ext. 126, abzowski@wirenet.org.

... and there are 2 chapter golf tourneys being held in October Two WAI chapter golf tournaments will be held in October in North Carolina and California. Players can sign up now, and there are sponsorship opportunities available for companies that would like to have a profile at these popular networking events. The Southeast Chapter returns Thursday, October 14, to the Rock Barn Golf and Spa in Conover, North Carolina, for the chapter’s 9th Annual Golf Tournament. Contact

Bragging rights for golfers are up for grabs in Massachusetts, North Carolina and California. Steve Vannais, Davis-Standard Corporation, tel. 704-7992258, svannais@davis-standard.com. The Western Chapter will return Monday, October 25, to the Los Verdes Golf Course in Rancho Palos Verdes, California, for its 10th Annual Golf Tournament. Last year’s event was won by the team of Paul McLaughlin of NEPTCO, and F. Camarena Inc.’s father-son duo of Fred Camarena Sr. and Fred Camarena Jr. Contact: Michael Howard, Coast Wire & Plastic Tech., tel. 310-639-9473, michael.howard@coastwire.com.

Five students have been chosen to be recipients of the New England Chapter’s scholarship program. The recipients are: • Elizabeth Ann Forest, Fall Mountain Regional High School, the daughter of Steve Forrest, production engineer, Whitney Blake. She will be attending Elmira College to study elementary education. • Bennett Galperin, East Brunswick High School, son of Robert Galperin, sales engineer, Parkway-Kew Corp. He will be attending Ramapo College to pursue a degree in pre-dentistry. • Thomas Canterino, Goshen Central High School, son of Michael Canterino, vice president of manufacturing, Remee Products. He will be attending Johnson and Wales University to study business. • Hillary Reichert, Champlain Valley Union High School, daughter of William Reichert, vice president of operations, Champlain Cable. She will be attending Clemson University to pursue a degree in business. • Marianna Dolce Jordan, Phillips Academy, daughter of Thomas Jordan, president of T & T Marketing. She won (continued on p. 46)

Visit us at wire China, booth #C58

SEPTEMBER 2010 | 43

CHAPTER CORNER

New England Chapter announces the 5 scholarship program winners

INTERNATIONAL TECHNIC AL CONFERENCE

M O N R E Y

Photos courtesy of the Monterrey Department of Tourism.

T E R Wire and Cable Technical Program Tabletop Exhibits | Networking

18-20 O CTOBER 2010 M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL

Venture to a place where wire and cable best practices and technological answers are much more than theory. And leave with ideas you can put into place immediately. Join WAI and educational sponsor ANTAAC for the 2010 International Technical Conference that will leave you both informed and inspired. Learn more at www.wirenet.org or contact WAI’s educational director, Marc Murray at mmurray@wirenet.org; Tel.: 001-203-453-2777, ext. 121. To register complete and return the form at right. Conference organized by:

The Wire Association International, Inc.

LEARN

AT:

Asociación Nacional de Transformadores de Acero A.C.

W W W. W I R E N E T. O R G

INTERNATIONAL TECHNIC AL CONFERENCE

M O N T E R R E Y Photos courtesy of the Monterrey Department of Tourism.

CONFERENCE REGISTRATION FORM 18-20 O CTOBER 2010 | M ONTERREY, N.L. M EXICO | C ROWNE P L AZA H OTEL ▲ Last Name

First Name

Middle

Job Title

Guest Name (if attending)

Company Address City

State

Postal Code

Country

Phone (Include Country Code)

Fax (Include Country Code)

E-mail:

[

] Early Registration Fee Before September 27 USD$ Only

First Full Registration Includes: Technical Program, luncheons, reception, and breaks

Additional Full Registration First Full Registration Plus WAI Membership Includes: Technical Program, luncheons, reception, and breaks Plus one-year WAI Membership

Regular Registration Fee After September 27 USD$ Only

❑ $250

❑ $280

❑ $210

❑ $240

❑ $300

❑ $330

REGISTRATION FEE IS PAID BY: ❑ Check enclosed in US dollars payable to The Wire Association International, Inc. ❑ Visa ❑ MasterCard ❑ American Express Fax registrations must use credit cards for payments of ALL meeting fees. Fax No.: (001) 203-453-8384

Name on Card (Please Print)

Card Number

Single Day Registration Includes: Monday OR Tuesday Technical Program, luncheons, reception, and breaks Check one: ❑ Monday ❑ Tuesday

Plant Tour – Delphi Packard Wednesday 20 October Space is limited - preference will be given to full registrants

Tabletop & Full Registration Includes: One full registration (see above), table, table drape, two chairs, and table tent sign

❑ $135

❑ $150 Expiration Date (mm/dd/yy)

❑ $40

N/A

❑ $700

Signature Cancellation Policy: Refund requests must be received in writing by October 6, 2010 to receive a full refund. No refunds after October 6, 2010.

Total USD $

MAIL

FORM TO: The Wire Association International, Inc.

1570 Boston Post Road | P.O. Box 578 Guilford, CT 06437-0578 USA

FAX

FORM TO:

VISIT

THE

WAI

SPONSORSHIPS:

(001) 203-453-8384

SITE:

www.wirenet.org for conference updates as they become available. Contact WAI sales to learn more at: (001) 203-453-2777, ext. 119 or 126.

HOTEL RESERVATIONS: www.tinyurl.com/ITCONFERENCE2010 Conference organized by:

The Wire Association International, Inc.

Asociación Nacional de Transformadores de Acero A.C.

CHAPTER CORNER

Elizabeth Ann Forest

Bennett Galperin

Thomas Canterino

the scholarship last year and chose to defer the award until this year as she was selected to be a Junior Fellow at King’s Academy in Jordan. Ms. Jordan will be attending Duke University to study public policy. “The WAI New England Chapter scholarship program has been an extremely rewarding experience for everyone who has been involved,” said Dave Thibodeau, Quirk Wire, who heads the chapter’s Scholarship Committee. “The committee members are very involved in the process and feel very good about helping the children of chapter members get started in college.” Thibodeau said that the chapter has seen its first class of scholarship recipients complete their undergraduate work.

Hillary Reichert

Marianna Dolce Jordan

He added that the chapter received the following letter from one of those first recipients. I wanted to thank you for the generous scholarship I received, which helped me get through college. I graduated from Norwich University this past May and have recently become a registered nurse! Thanks again. Respectfully, Kathleen Hennessy “It is students and experiences like this that make it very special for everyone involved,” Thibodeau said. ■

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Lightweight and comfortable to hold, our M10 welder enables you to fix non-ferrous wire breaks fast even in the most confined spaces. It produces a strong, permanent weld on fine wire up to 0.50mm (.0196") diameter in seconds, saving you time, money and materials. To find out more, call +44 (0) 1233 820847 or visit www.pwmltd.co.uk PWM. Precision you can depend on. All inquiries within North America for machines, spares and dies, contact: AMARAL AUTOMATION ASSOCIATES PO Box 7816, Cumberland, RI 02864 Tel: 401 405 0755 / 774 991 0504 Fax: 401 405 0757 E-mail: joe@amaralautomation.com www.amaralautomation.com Welders and dies available from PWM or authorised distributors only.

46 | WIRE JOURNAL INTERNATIONAL

WOODBURN IS THE PERFECT MATCH!

part 2

FEATURE

Equipment his feature presents a wide range of capital equipment, much of it displayed at the

wire Düsseldorf show that was held earlier this year. Below are brief write-ups

provided by equipment suppliers.

Comapac Wire Machinery Srl Italy GCR Group Italy Comapac Wire Machinery Srl now offers to customers, together with all the other companies that are part of the GCR Group, complete welding wire solutions (machinery, equipment and technology) for the manufacturing of a complete welding wire product range: SMAW, GTAW, SAW, FCW and MIG. At wire Düsseldorf, the company presented a small sample of its wide product range for the production of copper-coated, solid welding wires of diameters from 0.8 mm up to 1.6 mm of unalloyed and low alloyed steels at a manufacturing speed up to 25m/s. The line is composed of a wet drawing machine (not shown),

a copper coating tank, a dancer arm and a skin pass block. On the stand there was also a semi automatic level layer re-spooling line suitable for all solid and all flux cored wires to be packaged on D300 (15 kg plastic), K300 (15 kg wire basket) and D200 (5 kg plastic) spool types at a speed up to 35m/s. The most requested technology nowadays is for welding Flux Cored Wires (FCW). Comapac has both the technology and a state-of-the-art manufacturing process to produce unalloyed, low-alloyed, high-alloyed (stainless) and hard-facing welding FCW, with an advanced “tube” mill and a very productive rolling concept. The advanced welding wire solutions offered by Comapac follows the GCR Eurodraw strategy of providing turnkey processes. Customers today are looking for knowledgeable partners that bring value added solutions to their existing challenges. Comapac Wire Machinery Srl, l.montaldot@gcrgroup.com.

EJP GmbH Germany Wire Machine Systems U.S.

Comapac Wire Machinery Srl General Manager Lionel Montaldot by the company’s system for producing solid welding wire. 48 | WIRE JOURNAL INTERNATIONAL

At wire Düsseldorf, Germany’s EJP GmbH, represented in North America by Wire Machine Systems Inc. (WMS), displayed an in-line shot blaster along with a Model 160/100 drawing unit with integrated push pointer, a tworoll straightener and a hydraulic impact shear. The system is ideal for processing products such as tubes and bars (round, hex, square and flat profiles) out of steel, steel alloys, titanium, copper, copper alloys and aluminum. It can be set up with automatic feed and collecting systems. EJP GmbH manufactures state-of-the-art combined drawing systems for coil to bar and bar to bar.

Wire Machine System’s Bo Kneuppel by an EJP system at wire Düsseldorf.

The company notes that it is the first and only one in the industry to have built a 60 mm (2.4 in.) capacity drawing unit. EJP’s drawing design facilitates extremely fast changeover times, from small diameters to the largest profile size only taking about 25 minutes. EJP GmbH, info@ejpmachines.com; Wire Machine Systems Inc., sales@wire-machine.com.

FUHR GmbH & Co. KG Germany At wire Düsseldorf, and again later this year at the upcoming wire show in India, FUHR GmbH & Co. KG will have showcased its advanced technology for rolling mills. For wire India, it will team up its regional partner,

GCR Eurodraw SpA Italy At wire Düsseldorf, the GCR Eurodraw SpA booth included the company’s GRM double-belt grinding machine, which is designed to process medium- and high-carbon steel wire rod from 14 mm to 5.5 mm. All the rotating parts are mounted on the sturdy frame. The machine has three elements: the first grinding head, the main motor and the second grinding head. Each rotating head carries a grinding belt that sits on two spindles, one of which is motorized, and provides precise belt speed. The second spindle is mounted on an eccentric shaft and can be moved to ease the replacement and tensioning of the belt. The idle spindle has a small motor that allows perfect alignment with the motorized spindle, moving the head to the right or the left so the sandpaper stays in a central position. The heads rotate at speeds up to 600 rpm and the belt rotation speed is up to 25 m/sec for each belt. Belt tensioning adjustment is pneumatic, with a pressure regulator and manometer. The belts are simple to change

A close up of a FUHR GmbH & Co. KG rolling mill shown at wire 2010 and to be displayed at wire India. the Sojitz Machinery Corporation, for the joint exhibition stand, located in the Japan Pavilion in Hall W1 (stand no. W1D63 & W1E64), where the company will display its latest developments in cold rolling technologies for rectangular and flat copper wires. The production of these high-precision magnet wires, particularly for CTC appli-

GCRs Lorenzo Facchinelli by the company’s new GRM 800-2, double-belt grinding machine.

SEPTEMBER 2010 | 49

FEATURE

cations, is able to keep tolerances as small as +/- 0.003 mm on the downstream side. This wire is being processed through an enameling unit where minimal deviations from nominal width and thickness values would result in poor surface quality of the final product. Further, FUHR has also become an increasingly important supplier to the PV ribbon manufacturing industry where a constantly growing global demand in GWp capacity, along with a yearly price decay of 10-15%, forces the leading manufacturers of PV bus bar and interconnect wire to further increase their production capacity and thus, also improve their scale effects by the deployment of high-efficient rolling mills instead of drawing machines. In this respect, the key advantages of FUHR’s wire rolling mills is that with minimal set-up times, different profiles of flat copper wire can be produced at speeds of up to 800m/min. At these high production rates, customers have a great deal of flexibility for both in- and off-line annealing and tinning processes. FUHR GmbH & Co. KG, www.fuhrwire.com.

FEATURE

Upgrade your knowledge of polymer degradation at WAI’s

SEPTEMBER WEBINAR SERIES.

(30 seconds). Each grinding position is enclosed in a soundproof and dustproof box that must be connected to an optional dust collection system. An air blower is located at the exit of the unit to remove the fine dust from the wire and keep the dust inside the unit. A foundation is not necessary. Lorenzo Facchinelli, GCR Eurodraw SpA, l.facchinelli@gcrgroup.com.

Gimax Srl Italy Gimax Srl notes that it has long been very active in finding specific solutions tailored to a customer’s requirements. That approach can be seen in an offloading system it presented at wire Düsseldorf. The respooling line connected to the offloader was designed specifically for coils or spools of sub-arc wire. These coils that can weigh up to 30 or even 40 kg (66 and 88 lb) and therefore cannot easily be handled by the operator (keeping in mind that legislation in most countries limits the weight that an operator

FEATURING: Part 1: Polymer Degradation Wednesday, September 8, 2010 | 11:00 a.m. - Noon EDT Part 2: Polymer Stabilization & Failure Analysis Wednesday, September 15, 2010 | 11:00 a.m. - Noon EDT Presenter: Dr. Sitaram Rampalli Polyplast Consultants International (PCI) Inc.

FREE TO MEMBERS. Find out more at:

www.wirenet.org/events/webinars/index.htm The Wire Association International, Inc. 1570 Boston Post Road | P.O. Box 578 | Guilford, CT 06437-0578 USA Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org

50 | WIRE JOURNAL INTERNATIONAL

Gimax Srl’s Enrico Romaganolo by the company’s new offloading system. can handle for any period of time. The Gimax respooler was already an operator-friendly machine in the sense that it removes the coil from the machine with little help from the operator, but with the addition of the offloading system, the operator needs not lift anything, just maneuver. The coil is automatically discharged from the machine, and then is rolled into a vertical container. The operator only has to push a button to move the container sideways so the next coiling process can be started. While the coiling proceeds, the operator is free to bag and box the coil held by this container, which then transfers it to a conveyor. From the conveyor, the operator maneuvers an arm that is equipped with an electro magnet, that lifts the coil and transfers it to a palette. The system can be customized to suit the space limitations and specific requirements of a customer. Gimax Srl, www.gimaxgroup.com.

Maillefer SA Switzerland

FEATURE

The Maillefer SA booth at wire Düsseldorf included a section of a fiber optic secondary coating line. It represented the complete offering that Maillefer has for every stage of the fiber optic cable process. Tight buffering, secondary coating, SZ stranding and jacketing lines are available for producing FTTx cable with low fiber counts and short lengths. The equipment included two payoff bays for eight reels, an MXC 60 mm 24 L/D extruder with an ECH crosshead, and a CCA compression caterpillar. Technology like the compression caterpillar with tension feedback serves to keep accurate control of excess fiber length. Characteristics include real-time tension measuring and

Manuel Felder (l) and Antti-Jussi Rissanen standing by a Maillefer SA fiber optic secondary coating line.

control during the tube crystallization to ensure zero shrink-back; technology suited for both jelly-filled and dry loose tubes and geared for higher line speeds; a compact and modular design enabling easy upgrades for existing secondary coating lines; and a capability to produce loose micro tubes for blown fiber applications. Maillefer is a leader for cable manufacturing solutions worldwide and has long track record with a large installed base. Manuel Felder, Mallifer SA, manuel.felder@maillefer.net.

Niehoff GmbH Germany At wire Düsseldorf, Germany’s Niehoff GmbH displayed one of its latest developments for specialty wire drawing: an intermediate wiredrawing/annealing line consisting of an MSM 224 machine with individually driven capstans inline with a newly designed induction annealer RI 250. The electronically driven wiredrawing line is designed for wires made of copper alloys, German silver, nickel and nickel alloys, aluminum and aluminum alloys as well as other nonferrous metals like platinum, rhodium and special materials with inlet diameters of 3.5 mm (7.5

SEPTEMBER 2010 | 51

FEATURE

AWG) to a final diameter range of 0.2 to 1.8 mm (20–13 AWG) with line speeds up to 25 m/s (5,000 fpm). Minimized slip operation, completely submerged drawing, high pressure die lubrication and contactless annealing result in high surface quality wire with excellent processing properties. The line is equipped with Class IE2 energy-saving AC motors and energy optimized components. It meets current safety regula-

tions of the machinery directive RL 2006/42/EG and features a completely new and functionally optimized machine design. The line is the result of Niehoff’s continuous improvement development efforts to maximize energy and material efficiency and the performance of its machines for the sake of the environment and for the benefit of its customers. Niehoff GmbH, www.niehoff.de; Niehoff Endex North America, www.niehoff-usa.com.

Pourtier/Gauder Group France/Belgium

Niehoff GmbH President Heinz Rockenhaeuser by the company’s intermediate wiredrawing/ annealing line.

Manufacturers of both

‘HUSH’ & ‘LOCK ON’ PULLING IN DOGS T: +44 (0)1527 570977 F: 882423 E: sales@locton.co.uk www.locton.co.uk

52 | WIRE JOURNAL INTERNATIONAL

Pourtier, a supplier of rotating equipment and part of the Gauder Group, at wire Düsseldorf highlighted its innovative multiwire concentric stranding line for the production of SWA cable at high speed. The COS 1200 line, shown for the first time at the show, is basically designed to produce high quality round or sectoral compacted strands of 7, 19, 37 or 61: the concentric construction enables speeds up to 500 RPM (compared to 200 RPM with a traditional rigid stranding line) while keeping a short line length thanks to the multiwire process. Moreover, each bobbin is equipped with individually driven tension control for prevention of wire breakage, optimization of the final section and therefore resistance of the cable. The 37-wire line is composed of six independent modules of two reels of three wires each, individually motorized by AC motors. The reels are filled by basket payoffs with individual capstans to pull the wire and to equalize the tension characteristics for the best winding quality. The flexible Pourtier Sales Manager Philippe system, which offers Letout by the company’s new mulhigher speed, tiwire concentric stranding line. requires less space and is very safe to run, also allows reduction of copper remainders. Further, it also has power recovery technology that reduces power consumption by using regenerative power from the large and heavy built-in reels to produce electricity through a bus connection. The reels, in this case, become a power generator, and the results are impressive. For example, to strand 150 sq mm, the complete line uses only 40 KW (36 KW for 120 sq mm), which is much lower use of power than a conventional stranding line. Pourtier, pourtier@gaudergroup.com, www.gaudergroup.com.

The new RBL1 rod breakdown line introduced during wire Düsseldorf is SAMP’s answer to the challenges of ever increasing energy costs. This new line introduces to

The RBL1 line is capable of providing the end user savings up to 30% when compared to existing traditional equipment. Some of the key technical features of this new line include: high-precision production with continuous process control by means of CNC controls; the introduction of a cast polymer frame that ensures great structural stability while reducing the noise normally produced by the machine; and torque motors with direct shaft-to-hub technology. SAMPSISTEMI, www.sampsistemi.com; SAMP USA, www.sampinc.com.

Team Meccanica/Eurolls Group Italy

SAMP USA’s Dominique Perroud by the company’s RBL 1 rod breakdown line. the wire and cable industry established and reliable technologies already adopted in other manufacturing fields.

Team Meccanica, represented in North Anerica by Cortinovis Machinery America, has developed a Direct Synchronous Drive DSD 610/8 wiredrawer that was displayed at wire Düsseldorf. This model is a ground-breaking Plug & Play synchronous drive 610 mm drawing machine with eight blocks, and is equipped with a prewired, mounted electrical cabinet that eliminates field wiring and commissioning. There are eight 45KW synchronous motors directly connected to the capstans which are cooled by a closed loop liquid glycol circuit. There are no gearboxes, no belts, no transmission and no need

SEPTEMBER 2010 | 53

FEATURE

SAMPSISTEMI/SAMP USA Italy/U.S.

FEATURE

for lubrication oil. This machine can either be supplied to be used with dies, or can be equipped with EUROLLS Rolling Cassettes. The construction of the machine is a monolithic structure designed to be installed without special foundation requirements. This particular model is

A Team Meccanica wiredrawing system.

designed to produce a wire range from 6.5 mm to 1.5 mm at 25 m/s SAE 1004-1060. There is practically no need for maintenance. A five-year warranty is offered with option of extending the agreement to seven years. Tony DeRosa, Cortinovis Machinery America, Inc., tdr@cortinovisamerica.com.

Teurema/Eurolls Group Spain/Italy Teurema, represented in North America by Cortinovis Machinery America, has designed a rolling line for the production of smooth and/or ribbed wire. The line is extremely compact and equipped with protections to safeguard the operator while in production. The basic version

A Teurema rolling line for smooth/ribbed wire.

(pictured here) is provided with a vertical or horizontal spooler for the production on to spools or coils. It can also be used for the in-line supply to a wire mesh line. The function is as follows: the wire rod, from a coil is positioned on tilting fingers and will run through the ver54 | WIRE JOURNAL INTERNATIONAL

pillar that has been designed specifically for the manufacture of large submarine cables, with diameters of up to 300 mm. The AGP 300/35 S is maintenance-free, com-

FEATURE

tical payoff, through the mechanical descaler, and the lubrication unit. The wire then goes through the Eurolls cassette until it reaches the capstan, which provides the necessary pulling force for cold rolling deformation. The wire is then collected by the spooler, which is positioned after the bullblock. This unit can handle a coil of 3000 kg and inlet sizes ranging from 5.5 mm to 16 mm. The corresponding outlet sizes range from 4 mm to 14 mm. Tony DeRosa, Cortinovis Machinery America, Inc., tdr@cortinovisamerica.com.

Troester GmbH Germany At wire Düsseldorf, Troester displayed technology that responded to industry demand, especially from the high and ultra-high-voltage sector. Troester’s Dirk Schmidt notes that this is an area which is currently experiencing a boom as investments now need to be made worldwide in the renewal and enlargement of power grids. Troester is well prepared for the increasing development of power generation from renewable energy. The cable line manufacturer not only documented this with its innovative presence at the wire exhibition, but primarily by the product solutions that were presented. By way of example, the company showcased a new AGP 300/35 S belt-type cater-

Troester GmbH highlighted high- and ultra high-voltage technology at wire Düsseldorf.

pact in design and can be used both as a traction and a braking unit. This makes it an economical solution where

Universal screw technology for the ﬂexible cable production

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For more information about our rod breakdown and drawing equipment please contact us at info@sampinc.com www.sampsistemi.com

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weights of up to 100 kg per cable meter need to be transported and held securely at the end of the submarine cable manufacturing process, which passes through several stages. The high effectiveness of individual drives and its wide control range underscore the efficiency of the Troester belt-type caterpillar. Troester GmbH, info@troester.de.

Ultimate Automation Ltd. U.K. The Ultimate Automation booth at wire Düsseldorf included the company’s UMW-50-ASP model for the manufacture of multi-point star forms and welded rings used for the production of filter bag cages by manufacturers of dust collection systems. The line consists of the standard UMW-50 model for forming and welding a round ring that is transferred by a pneumatically actuated transfer arm into the ASP forming press. The ring is then pressed into the required “star” form, typically with 12, 16 or 20 points.

The Ultimat UMW-50-ASP Star forming and welding machine.

The company also displayed its very successful UMW range of wire forming and welding machines, which are used for the manufacture of a wide range of wire products, from POP displays to automotive components. Comprising six standard models for processing wire ranging from 2.00 mm to 16.00 mm, all ULTIMAT UMW models use a closed-die forming and cutting system that produces high-quality bends with square, burr-free cuts. The versatile ULTIMAT design negates the need for special tooling to produce high-quality parts and components. Options include versions for use with flat strip or profiled wire, press and chamfering stations, secondary bend heads for intricate forms with a tilting table to accommodate large components or forming spirals. Ultimation also discussed its new USW/UGW range of machines for the fully automatic forming and welding of

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the “Goalpost” type signs frames/yard stakes used in the political sign industry. Ultimate Automation Ltd., www.ultimat.com, sales@ultimat.com.

Vapormatt Ltd. has developed a range of technologically advanced, compact, in-line wet blasting machines, custom-engineered for the continuous cleaning and surface preparation of wire products. The Vapormatt wet blasting process (often referred to as “Vapormatting”) is particularly effective for cleaning and preparing the surface profile of drawn wire products made from steel, brass, bronze, aluminum and other metals, prior to the application of subsequent functional coatings or insulating coverings. It can also be used for the surface preparation of fiber optic cables and wire manufactured from plastics. Vapormatt wet blasting is a proven solvent- and dust-free simultaneous degreasing and cleaning process, which employs a cleaning solution or “slurry” comprising a specially formulated mix of water, detergent and abrasive media. This is projected at a product or component through special blast nozzles. Wet blasting is highly controllable and can be tailored to suit a wide variety of components and materials. The process does not impinge on

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Vapormatt Ltd. U.K.

Vapormatt Ltd.’s Helen Costema and Allan Parker with a Vapormatt system at wire Düsseldorf.

or damage the surface of a material or substrate, and produces a higher quality, much smoother finish than alterna-

SEPTEMBER 2010 | 57

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tive methods. As no dust is produced there is no detrimental effect on the working environment. Added to this, no solvents or other potentially hazardous “pickling” or other chemicals are used by the process, so it is not subject to strict solvent emission, VOC or dust emission regulations and there is no risk to operators. The use of the wet blast process also eliminates any potential danger from static electricity, often a problem with dry blasting. The latest Vapormatt wet blast machines are fully automated and programmable, and provide degreasing, cleaning, rinsing and drying in a single, in-line enclosed unit. Vapormatt Ltd., sales@vapormatt.com.

of the FSE 15 features one pair of feed rollers; depending on the wire size range (up to 0.6 or 0.8 mm), an additional pair is optionally available upon request. The number of axes varies from four to seven at the final expansion stage. For the first time, the powerful straight cut capability can, upon request, be replaced with or expanded by an additional rotating multiple-cut capability. The “parallel pitch” feature is a further option. This gives the machine operator two pitch possibilities: vertical or parallel for use as needed. Both the multi-cut and pitch variations have been added to the reliable FSE control. Wafios AG, www.wafios.de.

Wafios AG Germany

The vast array of equipment on display at the Wafios booth at wire Düsseldorf included the company’s FSE 15 model, which through all its available options enables customers to set it up to serve different production needs and to operate it cost-effectively under completely different economic conditions. The system is designed for wires ranging from 0.16 to 0.6 mm in diameter, but as noted it can be set up to create a number of different machine variants. It was shown in two versions: the standard version, linked with a spring-end grinding machine, and the maximum, in the form of a standalone solution. Compared to other machines with the same processing capability, the small footprint is a significant and obvious feature. This translates into not only improved machine handling, but also simplifies integration of the machine into existing production lines, e.g., when replacing, exchanging or adding equipment. During development, similar emphasis was placed on providing very good accessibility from all sides. The basic version is characterized by a lean, sophisticated machine concept, yet retains in this minimal variant its functionality as a fully capable, state-ofthe-art compression spring production machine. Depending on the intended use, the capability of FSE 15 can be expanded, be it in terms of handling, ease of use or, for instance, with regard to zerodefect production through incorporation of optical monitoring systems. The FSE 15 does not need The FSE 15 compression spring sys- a blower or airtem from Wafios AG. conditioning unit. The basic version

The Wafios booth at wire Düsseldorf also included the company’s NAILMASTER system, which significantly increases the effectiveness of downstream processing machines through its very high continuous production output. The energy-efficient NAILMASTER produces clean finished nails that do not require additional cleaning before further processing. A newly designed cutter arrangement makes it possible to produce nails at rates of 1,400 per minute without split tips. The high production output enhances the efficiency of the entire process chain (collator, thread roller, etc.). The upright design of essential parts and complete tool area provide exceptional accessibility by the machine operator. Down time is reduced because of short re-tooling times, minimal number of tools, simple exchange of straightening devices and long tool life. Every nail is checked for proper length, point and head, and nail ejection is made through an exit chute at a defined transfer point. In terms of quality, the system’s linear pressing principle assures well-centered nail heads while an improved cutting process enables it to hold the smallest of length tolerances. A new arrangement for the pressure jaws makes for problem-free production of D-head and offset nails. A punch cassette system decreases re-tooling times and allows production of specialty nails. Vacuum extraction of chips The NAILMASTER system from Wafios AG. is not required. A closed oil circuit lowers oil consumption while the system itself is completely encapsulated with a new noise protection

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Windak AB Sweden At wire Düsseldorf, Windak AB presented its new flexible coiler, FC5, and automatic reeler, AR24-S. The FC5 is a fully automatic coiling machine with optional palletizing of wire, cable, tubing and other flexible products. It has been designed by the company to accommodate a wide range of product diameters and coil ODs from 220 mm (8.5 in.) to 480 mm (19 in.). A unique feature with the FC5 coiler is that the coil can be stretchwrapped, shrinkwrapped Windak AB’s new FC5 flexible coiler.

or strapped, making this one of the most flexible and versatile coilers available. The AR24-S is a new dual-head fully automatic reeler developed Windak AB’s new AR24-S automatic for automat- reeler. ic packaging of cable and wire products on spools and reels between 300 mm (12 in.) and 600 mm (24 in.) in overall diameter. It can be run both in-line applications and off-line applications. It loads and unloads the reels automatically and includes stretch wrapping of the spool to contain the cut end. The AR24-S requires minimal floor space, and when combined with the integrated palletizer, it makes a complete automatic spooling line with a short investment payback. Windak AB, info@windak.se, www.windak.se; Windak Inc. (U.S.), info@windakusa.com, www.windakusa.com. ■

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hood. A single-belt transport system allows direct interlinking to downstream operations e.g., thread roller (optional). Wafios AG, www.wafios.de.

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High productivity and reliability of XLPE insulated medium-voltage cables

TECHNICAL PAPERS

TECHNICAL PAPER

Further advances in XLPE insulation technology have resulted in a product that is more resistant to water-tree faults while remaining cost-effective to manufacture. By Paul Laurenson and Jan-Ove Bostrรถm

The development of cable standards has given utilities assurance that Medium-Voltage (MV) cables designed and manufactured to major standards will provide appropriate performance and long life. However, the performance expectations cannot be met if critical quality criteria are neglected and there are different operation standards and quality philosophies applied in different parts of the global market. If these aspects are not up to requirements, the result for utilities might be short cable life and unforeseen failures. Power outages are not acceptable in modern society, and authorities in various countries are implementing legislation that forces utilities to pay financial compensation to subscribers in case of outages. Consequently, a high standard with regard to cable design, manufacturing, material selection and testing will be to the

benefit of the utilities and end customers. The MV cable segment is highly competitive and cable makers continue to search for ways to reduce their costs. One such solution is to improve productivity and reduce scrap. By implementing a high-quality standard and using state-of-the-art insulation and semiconductive compounds, both reliable, long-life cables and high productivity with minimum scrap can be achieved.

Fig. 1. Water trees growing from the insulation shield.

Fig. 2. Container for bulk handling of insulation compounds.

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Technology evolution Modern MV cables are based on XLPE insulation systems that has seen stepwise development since the 1970s in the processing technique and material technologies. The main development steps are: use of cleaner materials; triple extrusion,

Material aspects The use of clean insulation and semiconductive compounds is paramount for high reliability of cables in service. Contaminants with a high-dielectric constant, e.g. iron or steel with sharp geometry, result in high electrical stress in sites where the result can be fast degradation of the insulation material. Fibrous contaminants, such as cotton or particles with low affinity to the polymer matrix, form sites for partial discharges and can accelerate degradation of the material. Even very small contaminants that are not visible to the naked eye can initiate the creation of harmful water trees. Consequently, insulation compound has to be received in a very clean state from the compound supplier and the materials handling at the cable maker has to be done so as to avoid introducing any foreign materials. One approach is to minimize the handling steps by using insulation compounds in large containers (>20MT) equipped with a plastic inner liner to separate the material from the inside of the container. Using bulk supply can reduce by a factor of 20 the number of connect/disconnect operations, which considerably reduces the introduction of extraneous contaminants. See Fig. 2. For semiconductive shields that are filled with conductive carbon black that is co-extruded with XLPE insulation compounds need to have smooth interfaces to the insulation, combined with low level of ions. Although high levels of soluble ions generally do not create water trees, they do fuel and accelerate their growth. Cable reliability is improved by a

Fig. 3. Electrical breakdown initiated by a vented water tree growing from the semiconductive conductor shield.

combination of semiconductive compound layer cleanliness and smoothness.

Cable performance in the network Enhanced performance of water-tree compounds has been reported in several publications1,2. A study by the FGH Institute in Germany found that the improved performance of modern cables can be seen by looking at the time to failure rate. Second-generation power cable insulated with copolymer modified XLPE compounds has a significantly lower failure rate over time than does the earlier cable generation. See Fig. 4.

Long life cables and recent development As noted above, two major types of insulation compounds exist on the market. Within the family of water-tree retardant compounds, the copolymer-modified XLPE was introduced to the market in the 80s and contributed considerably to the reliability of the MV grid. See Fig. 4. Fig. 5 shows the improvement achieved with copolymer modified XLPE over standard (classic) XLPE when tested according to the Cenelec HD620/6054 two-year test. Recent developments have resulted in further improvements in the performance of copolymer-modified XLPE. Cables have been made using the new compound acting together with semi-conductive materials. After the two-year test (to Cenelec HD620/605), these cables outperform even the highest requirements in the market, giving customers a safe margin in producing reliable medium-voltage cables. See Figs. 6-7. Fig. 6 compares the results of this new material system with the most common Cenelec requirement as well as high-performance requirements, like those in Germany. Fig. 7 positions the average results in the two-year wet aging Cenelec test. It shows the superiority of the new copolymer XLPE, and the improvement compared to standard XLPE and standard copolymer XLPE.

Fig. 4. Estimate failures rate of different generation of XLPE cables3. SEPTEMBER 2010 | 61

TECHNICAL PAPERS

dry curing; cleaner handling of materials; use of water-tree retardant compounds; and change from PVC jacketing to polyethylene. This evolution has been driven by observations in the 1970s where unexpectedly early cable failures were experienced in Germany, Japan and the U.S. The cause was a degradation phenomenon, today well known as â&#x20AC;&#x153;water treeing.â&#x20AC;? See Fig. 1. Due to the implementation of the above-listed steps, the life of modern cables manufactured to high-quality standards is estimated to be at least 40 years.

TECHNICAL PAPERS Fig. 5. Relative difference in breakdown strength after two years wet aging between classic and polymer WTR insulation.

Productivity High-performance MV cable has to be manufactured in a cost-effective way. The new copolymer-modified XLPE contributes to this goal due to its high throughput and much longer operating time before the extruder needs to be cleaned, compared to standard XLPE compounds. Extruder output and length of extrusion run (scorch) are a key part of the throughput equation as they can make significant contributions to the total amount of cable that can be extruded in a year. Fig. 8 shows that the copolymermodified XLPE offers large productivity advantages compared to the standard polymer. Fig. 9 shows that the new copolymer XLPE has processing behavior that is similar to the previous standard copolymer XLPE.

Fig. 7. Cenelec HD 605 two years aging of 20KV/150mmÂ˛ cables. 62 | WIRE JOURNAL INTERNATIONAL

Fig. 6. Results of a new copolymer modified XLPE medium-voltage compound compared to the requirement in Europe.

Extrusion performance is equally important for semiconductive compounds as they need to be processed at the same speed as the insulation. A more scorch-resistant semiconductive compound was developed to follow extrusion of new copolymer XLPE. The adoption of scorch-resistant semiconductive compounds will minimize the risk of defects at high line speeds when melt temperatures increase at higher extrusion speeds. Fig. 10 shows typical results in a laboratory scorch test (volume of scorch formed in a specially designed die at different temperatures) that demonstrates a large increase in scorch resistance. This allows for increased melt temperatures compared to a standard semiconductive compound.

Fig. 8. Output and run length of standard polymer and copolymer XLPE.

TECHNICAL PAPERS Fig. 9. Similarity in extrusion for previous and new copolymer XLPE.

Fig. 10. Effect of temperature for two selected semiconductive compounds.

Conclusion

References

Utilities are confronted with requirements to provide medium-voltage cables that are highly reliable in their ability to supply electricity to their subscribers. The market competition for these cables drives solutions for reduced costs. However, these solutions should not compromise cable quality as that might jeopardize the long-term reliability of power networks. Development of a new copolymer-modified XLPE compound has successfully demonstrated that excellent wet aging performance and high productivity can be combined without sacrificing cable quality and, consequently, longterm reliability.

1. A. Campus and M. Ulrich, “20 years of experience with XLPE copolymer power cable insulation,” JiCable, 2003, pp. 350. 2. D. Wald and A.Smedberg, “Performance of modern cables in central Europe,” Jicable, 2007. 3. Technischer Bericht 299, “Asset-Management von Verteilungsnetzen,“ FGH Cenelec HD620/605. ■

Paul Laurenson is senior technical service manager, wire and cable, at Borealis Polymers NV, Belgium. He has spent more than 13 years working on the development and technical service of wire and cable products. He holds a doctorate from the University of Clermont-Ferrand, France. JanOve Boström is senior application development engineer at Borealis AB, Stenungsund, Sweden. His background is in product development, product management, production, marketing, and technical support of compounds for wire and cable applications. This paper, which was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009, won the Urbain J.H. Malo Memorial Award for best electrical paper.

Laurenson

Boström

SEPTEMBER 2010 | 63

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Improvement of straightness in rotational blade straightener for superfine wire

TECHNICAL PAPERS

TECHNICAL PAPER

This study found that a higher rotational blade speed, lower feeding velocity and gradual decrease in curvature ratio during straightening can produce excellent straightness. By Masahiro Yoshida, Motoo Asakawa, Satoshi Kajino, Motohiko Urabe and H. Kanaeda

Superfine wires need to have exceptional straightness to be able to be used in the manufacture of high-precision electronic and mechanical devices. A rotational blade straightener, a type of mechanical straightener, is commonly used to straighten superfine wire. This device bends and counterbends wire by two blades1. The blades are rotated such that the wire is bent in the longitudinal as well as circumferential directions2. This device requires a skilled operator. The role of rotational blade straightening warrants more research. This study investigates the effects of feeding velocity, the rotational speed of blades and dowel intermesh on the straightness of superfine wires.

Experimental methods For this experiment, 0.07 mm superfine tungsten wire was used. Table 1 shows the chemical composition of the wires and Fig. 1 shows the experimental rotational blade

Fig. 1. Schematic of rotational blade straightener. 64 | WIRE JOURNAL INTERNATIONAL

straightener. The superfine wire was fed by a feeding belt, while back tension was loaded using a pulley. The straightener had two blades that rotated in directions opposite to each other. Fig. 2 shows the rotational blades in greater detail. Each blade had seven dowels, and the intermesh h of the even-numbered dowels could be changed. Fig. 3 illustrates the definition of straightness, which for teh tungsen wire was defined as the two-dimensional deflection ψ per 30 mm in length. The initial straightness of the superfine tungsten wire was almost 1 mm/30 mm.

Experimental results and discussion Feeding velocity and rotational speed of blades. First, the authors investigated the effects of the feeding velocity v and the rotational speed of blades f on the straightness ψ. As shown in Fig. 4, h was 6 mm. Fig. 5 shows the relationship between v and ψ. For the tests, f values of 500, 2000,

TECHNICAL PAPERS Fig. 2. Arrangement of rotational blades and cut section model of dowel.

3000 and 4000 rpm were used. It was observed that ψ improved as v decreased and f increased. In this experiment, the relationship between f and v was defined as the bending pitch p (unit: mm/r), as given by Eq.(1)3. r meant a rotation number of blades. The bending pitch represents the feeding distance of a wire per rotation of the blade.

Table 1. Chemical composition of superfine tungsten wire/mass percent.

Eq. (1) Fig. 6 shows the relationship between p and ψ. It was observed that as p decreases, ψ improves because the Fig. 3. Definition of straightness.

Fig. 4. Setting of dowel intermeshes. SEPTEMBER 2010 | 65

TECHNICAL PAPERS Fig. 5. Relationship between straightness ψ and feeding velocity v and rotational speed f.

Fig. 6. Relationship between bending pitch p and straightness ψ.

Fig. 7. All dowels intermeshes were h mm.

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bending frequencies increase. The best condition was found to be p = 0.13 mm/r in this experiment. Therefore, the values of f and v were set as 4000 rpm and 520 mm/min, respectively. Effect of dowel intermesh. The effects of the bending times on the straightness were then investigated. All even-numbered dowel intermeshes were set to the same value h. The dowels of the first and second blades were set as shown in Fig. 7. h was changed from 0 mm to 0.8 mm. Fig. 8 shows the relationship between h and ψ. h = 0.6 mm was found to be the optimum condition for straightness. Next, the dowel intermeshes were set by decreasing them gradually. At dowel two of the first blade, h was 1.4 mm. It was gradually decreased to 0.4 mm at dowel six of the second blade. Fig. 9 shows the straightening condition. Fig. 10 shows the relationship between the straightening condition (constant intermesh and gradual decrease of curvature) and ψ. The gradual decrease of h was found to be slightly better than the use of a constant intermesh. Straightening mechanism. The straightening mechanism can be explained by using the relationship between the curvature ratio κ and the bending moment M. The initial curvature ratio of wires has dispersion κα0 along the longitudinal direction, as shown in Fig. 11 (a). Considering the bending at a large curvature ratio κA and the spring back recovery, the curvature ratio becomes κB. The dispersion of the initial curvature may decrease from κα0 to κα1; however, a large residual curvature ratio κB remains. On the other hand, as shown in Fig. 11 (b), considering the bending at a small curvature ratio κC and the spring back recovery, the curvature ratio becomes κD, which is less than κB. However, the dispersion of the curvature ratio κα2 is greater larger than κα1. Therefore, it is necessary to consider another condition, as shown in Fig. 11 (c). First, a large curvature ratio κE was considered and attempts were made to reduce it. Large bending at the curvature ratio κE may lead to a decrease in the dispersion of the initial curvature ratio from κα0 to κα3. Finally, as shown in Fig. 11 (d), the wire was bent at a small curvature ratio κG and after spring back, the final curvature ratio κfinal was around 0 mm–1. To achieve this

TECHNICAL PAPERS

condition, the dispersion of the initial curvature ratio κα0 can be decreased, with a small residual curvature ratio (κα4). A gradual decrease in the curvature ratio is effective for achieving straightness. Curvature ratio κ during straightening. A case has been shown in which the intermesh is decreased gradually. However, in a rotational blade straightener, the wire is bent, twisted, and tensioned4. Therefore, its deformation is too complicated to calculate the curvature ratio κ, and the gradual decrease in the intermesh should not lead to a gradual decrease in the curvature ratio κ. To use the straightening theory, the curvature ratio κ of the wire during straightening has to be known. To do this, the wire was photographed at the top of the dowel, as shown in Fig. 12. Fig. 13 shows a photograph of dowel 2 having an intermesh of 1 mm. In this experiment, the blades did not rotate, and the intermesh of the other dowel was 0 mm. For example, when the photo of the top of dowel 2 was taken, the intermeshes of dowels 4 and 6 were 0 mm. Fig. 14 shows the relationship between dowel intermeshes h2~h6 and curvature ratio κ of the straightening wire. The curvature ratio at dowel 4 was larger than those at dowels 2 and 6 for the same intermesh h. This phenomenon was attributable to the restraint at the back and front of the dowel. Dowel 4 had a dowel behind and ahead of itself; therefore, the amounts of restraint were large. However, dowel 2 had only dowel 1 at the back and dowel 6 had only dowel 7 at the front. Therefore, the amounts of restraint were small. The experiment used a constant dowel intermesh h; however, dowel 4 had a larger curvature ratio than dowel 6 for the same intermesh. In this condition, the curvature ratio gradually decreased from dowel 4 to dowel 6; therefore, there was a difference between the straightness in the case of a gradual decrease in the intermesh and that in the case of a constant intermesh, as shown in Fig. 9. Gradual decrease in curvature ratio κ. The dowel intermesh h was set to

Fig. 8. Relationship between dowel intermesh h and straightness ψ in constant dowel intermesh.

Fig. 9. Gradual decrease of intermesh.

Fig. 10. Comparison of straightness ψ between constant intermesh and gradual decrease of intermesh. SEPTEMBER 2010 | 67

TECHNICAL PAPERS Fig. 11. Straightening mechanism by moment M-curvature ratio κ.

Figs. 12/13. Photograph position and photograph of wire during straightening. 68 | WIRE JOURNAL INTERNATIONAL

decrease the curvature ratio gradually. The curvature ratio at dowel 2 of the first blade was set at the maximum curvature ratio, as shown in Fig. 14. Fig. 15 shows the relationship between the dowel, dowel intermesh h, and curvature ratio κ of the straightening condition. The dowel intermesh h was set to decrease its curvature ratio gradually from 0.30 mm–1 to 0.05 mm–1. The curvature ratio was calculated between the measured results by linear approximation. Fig. 16 shows the relationship between the straightening condition and the straightness ψ. The condition of gradual decrease in the curvature ratio was found to be much better than that of gradual decrease in the intermesh. The highest straightness of 0.028 mm/30 mm (κ = 2.48 × 10–4 mm–1) was achieved. Plastic ratio ξ in longitudinal cross section. The amount of plastic deformation was defined as the plastic ratio in order to generalize the straightening. The wire was regarded in two dimensions at a longitudinal cross section, as shown in Fig. 17. When a straight wire with diameter d was bent with a radius of curvature ρ, the surface strain ε was calculated by Eq. (2). The plastic ratio ξ was defined as the ratio of the length deformed plastically on the wire diameter d, as given by Eqs. (3) and (4). The wire deformed plastically if the strain became greater than the total strain of the elastic limit εe measured from the stress–strain diagram, as shown in Fig. 18. From the result, εe was approximately 0.6%. In the experiment in which the curvature ratio was decreased gradually, as shown in Fig. 15,

Fig. 14. Relationship between curvature ratio κ and dowel intermesh h of dowels 2, 4, and 6 during straightening.

TECHNICAL PAPERS Fig. 15. Gradual decrease of curvature ratio.

Fig. 16. Comparison of straightness ψ between gradual decrease of intermesh and gradual decrease of curvature.

the curvature ratio κ was 0.3 mm–1 at the dowel 2 of the first blade. Therefore, the maximum plastic ratio was around 43%. In other words, it is estimated that the plastic deformation area occupied almost half the diameter of the wires in this condition.

Eq. (2) Fig. 17. Definition of plastic ratio ξ.

Eq. (3)

Eq. (4)

Conclusions This study investigated the effects of the feeding velocity v, rotational speed of blades f, and dowel intermesh h of a rotational blade straightener on the straightness of a superfine tungsten wire. The following results were obtained. 1. A higher blade rotation speed and slower feeding velocity were effective for achieving better straightness. 2. In the case of blades with seven dowels,

Fig. 18. Stress-strain diagram of specimen.

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TECHNICAL PAPERS

the curvature ratio of a wire at the center dowel in a blade is larger than those at the dowels close to the end of the blade, even when all dowels have the same intermesh. 3. The gradual decrease in curvature ratio κ was found to be more effective for achieving straightness than the gradual decrease in intermesh h. The highest straightness of 0.028 mm/30 mm (κ = 2.48 × 10–4 mm–1) was achieved when the curvature ratio ranged from 0.30 mm–1 to 0.05 mm–1 and the maximum plastic ratio at the dowel 2 of the first blade was 43%.

References 1.S. Yonetani, M. Kaneko, S. Kohayakawa and M. Yairi, Japan Plasticity and Processing, 5-41, 1964, pp. 403-416. 2.M. Asakawa: Plasticity and Processing, 39-447, 1998, pp. 338-341. 3.D. Kashiyama, M. Asakawa, H. Sekiya, A. Maeda and A. Okino, Japan Society for Technology of Plasticity, 2003, pp. 461-462. 4.The Japan Society of Technology for Plasticity, Straightening processing, 1992, pp. 90-113, Corona Publishing Co., Ltd. ■

Yoshida Masahiro Yoshida is a student in the School of Fundamental Science and Engineering of Waseda University, Tokyo, Japan. Dr. Motoo Asakawa is a professor in the mechanical engineering department at the School of Fundamental Science and Engineering of Waseda. He came to the university 10 years ago from Sumitomo Metals Co. He has studied both the process engineering and materials engineering of the mechanical parts of cars, trains, aircraft, and construction and electric devices. He

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Asakawa

Kajino

earned a doctoral degree in bar and rod rolling from Waseda in 1980. He is a recipient of Japan’s Okochi Memorial Prize, the Society for Technology of Plasticity Prize, the Institute of Metals Prize, and Iron & Steel Institute Prize. Satoshi Kajino works at the National Institute of Advanced Industrial Science and Technology (AIST), Ibaraki, Japan. He earned a doctoral degree in engineering from Waseda. He is a recipient of the WAI Silver Certificate Award in the ferrous division for 2005. Motohiko

Urabe Urabe is a graduate student at Waseda’s School of Fundamental Science and Engineering. H. Kanaeda works for Honda Motor Co., Ltd., Japan. He previously was a student in the school of science and engineering at Waseda. This paper, which was presented at WAI’s 79th Annual Convention, Cleveland, Ohio, USA, April 2009, won the Horace Pops Award for the best paper in the General Division.

Integrated, one-step, high-speed line for the production of low-relaxation, prestressed concrete wire This paper outlines the elements and advantages of an innovative integrated PC wire line. By Lorenzo Facchinelli

This presentation introduces a modern integrated PC wire line from GCR Eurodraw SpA, highlighting the advantages of placing the wiredrawing machine directly in line with the stress-relieving equipment instead of having the two as separate operations. First, one should consider the product that a line is intended to produce, in this case low-relaxation, prestressed concrete (PC) wire. This product, a high-carbon drawn wire that is indented, stretched and heat-treated to obtain relaxation values within certain parameters. It is used in the construction industry as a reinforcement product for stay poles, train sleepers, pre-cast architectural panels, concrete sewage pipes, large water tanks, nuclear power plants and other similar structures. Of those end uses, a growing market is for its use in reinforcement of train sleepers, which replace traditional wood rails. PC wire is normally used in diameters between 4.00 mm to 14.00 mm, with 7 mm and 9 mm being the most common sizes. It is supplied in three different types of packages, the choice depending on the final usage and cus-

tomer. A typical package is a coil (1.6-1.8 meter diameter) that weighs 1.50 to 2 metric tons. Other typical packages are 1.5 meter-diameter coils wound on either collapsible spools or in bundles of cut bars. One of the main characteristics of PC wire is its straightness. By submitting the wire to a stretching and heating process, the wire becomes straight and remains in that form even after being wound on a spool. In the past, the production of PC wire was split into two different steps because the speed of one step was significantly different from the other. The wire was drawn on a wiredrawing line, then collected on large capacity spools. These spools then had to be placed into a spool payoff and unwound into the stretching and heat-treating line. Modern PC wire lines are designed so that the wire drawing process is in line with the stretching and heat treatment line and can be operated at speeds that do not handicap any of the two steps of the process. The line presented in this paper includes the following elements: wire rod payoff; continuous flyer type wire rod

Fig. 1. Wire rod payoff.

Fig. 2. Latest-generation wiredrawing machine. SEPTEMBER 2010 | 71

TECHNICAL PAPERS

TECHNICAL PAPER

TECHNICAL PAPERS

payoff; wiredrawing machine with 1200 mm capstans and 7 dies; synchronization arm after the wiredrawing machine; wire indenting unit; wire straightening unit; wire washing unit; first double-pulling capstan group; movable induction furnace; cooling tray; second double-pulling capstan group; pinch wheel; rotary cutting shear or hydraulic cutting shear; and basket coilers, spooler or barcutting unit. The combination of a wiredrawing line with the thermal treatment line is not just the conjunction of the two lines but involves an extensive re-engineering of the operative mode of each line section.

Description of line components Wire rod payoff. The wire rod payoff as well as the takeups are important items of the line as only through consistent and smooth operation of these units is it possible to operate the line on a continuous basis. In order to avoid tangles, the distance of the rod from the unwinding flyer is kept constant with the wire rod pusher. By controlling the distance of the coil from the flyer with a sensor, the pusher is activated as needed ensuring stable operative conditions. See Fig. 1. Wiredrawing machine. This latest generation wiredrawing machines for PC products such as wire and strand has a capstan size of at least 1200 mm. The large size of the capstan ensures that the wire is cooled in a efficient way at speeds that where unthinkable just a few years ago. The latest machines are designed so that there is no need for any foundation work for the installation and to minimize and ease the maintenance needs and accessibility as much as possible. An ergonomic design is of primary importance because of the large size of the wire to be processed and the machine itself. Key factors to an efficient line include: low wire lines; easily accessible, removable and adjustable

Fig. 3. Rolling cassette.

72 | WIRE JOURNAL INTERNATIONAL

soap boxes and dieboxes; two-stage press rollers on the capstans; correctly placed operator control panels; internal lights; and accessible locations for the fixing of the pulling dog. While drawing machines for producing PC strand are generally equipped with nine or 10 drafts, when the drawing machine is part of a PC wire line, the number of drafts normally never exceeds seven, with the option of having a 8th reduction on the heat treatment line section. Modern wiredrawing machines are motorized with efficient AC motors driven by digital vectorial drives that greatly reduce the power consumption and the disturbances fed into the power supply line. A sensor arm follows the wiredrawing machine and synchronizes the speed of the following part of the line. See Fig. 2. Wire indenting unit. PC wire can be produced to different standards (e.g., British, Japanese, American, European, Russian). The main difference between standards is the type of indentation. There are wires with a three-side indentation, a spiral-shaped indentation, a two-side indentation and a multitude of different indentation patterns. All these standards can be made with specific rolling cassettes and specific rolls that are made of high-strength materials to sustain heavy loads and wear. The rolling cassettes are normally equipped with water-cooled roller shafts, watercooled bearings and fitted with centralized, automatic bearing greasing systems. The rolling cassette may be inserted into a ventilated noise abatement cabinet to reduce the noise level generated while producing certain types of shapes. See Fig. 3. Wire straightening unit. Straightness is one of the most important parameters of PC wire. Generally, the standards allow only a very small deviation from straight over a length of six meters of wire. The straightening unit, therefore, is a key line component that must be easily adjustable and easy to open and close while returning to the exact

Fig. 4. Wire-straightening unit.

TECHNICAL PAPERS Fig. 6. Wire-washing unit. Fig. 5. Capstan with high-torque, planetary gearbox.

same closed position to avoid re-adjustment of the rolls. Most important, the rollsâ&#x20AC;&#x2122;s shape and diameter need to be correctly sized to ensure absolute straightness within the complete wire diameter range for which the line has been designed. See Fig. 4. First double-pulling capstan. The double-pulling capstan features, model KK, two large-diameter wheels (3000 mm or 4000 mm). The large size is needed because the finished wire has very stringent straightness requirements, and the wire-bending effort must remain well below the elastic limits of the material. The motorized capstan is V-grooved to ensure maximum grip with the wire; the other idle capstan is U-grooved. The line is equipped with two pairs of such pulling capstans. The two are synchronized by a load cell that reads the pull applied to the wire and adjusts the capstan pull as per technological requirement of the wire. The motorized capstan is equipped with a high torque planetary gearbox driven by a powerful AC motor. See Fig. 5.

Wire-washing unit. Prior to the induction furnace, the wire should be clean and not have any residual lubricant, which ensures that only a very minimal amount of wiredrawing lubricant will enter the furnace. The clean wire should translate into virtually no smoke being generated in the furnace as well as no clogging of the inductor with burnt lubricant accumulation. Thus, a wire cleaning unit should be located before the furnace. The unit is composed of a lower three-stage cascading storage tank equipped with a pump and a heater, and a upper process tray where the cleaning takes place. See Fig. 6. Movable induction furnace. The induction furnace of a PC wire line can be sized to the wire size range and speed that the line is capable of processing. Typical furnace sizes are 450 or 600 kW. The induction furnace can be either a fixed or movable. Fixed-type furnaces require less space but are not suitable for one-step integrated lines as it would not be possible to heat-treat the wire in the start and stop transient periods.

Fig. 7. Movable induction furnace.

Fig. 8. Cooling tray. SEPTEMBER 2010 | 73

TECHNICAL PAPERS Fig. 9. Pinch wheel unit.

Fig. 10. Cutting shears.

The movable induction furnace is mounted on a transfer trolley that allows movement of the furnace in order to follow the wire in the start and stop transient times and process it thoroughly process all the material. The control of the furnace is performed through a optical pyrometer that constantly reads the temperature of the wire. This provides a feedback signal to adjust the power to keep it at the correct temperature values, which for wire is between 360째C and 420째C. See Fig. 7. Cooling tray. The cooling tray is located after the induction furnace to rapidly cool the wire in order to freeze the mechanical properties obtained after the heat treatment. It is composed of a working tray and a lower water storage tank. The water is recycled by a pump that takes the water from the storage tank to the cooling tray. The water temperature is controlled by a temperature probe that opens a fresh-water valve that adds cold water as needed to maintain the water temperature at the pre-set level. See Fig. 8. Second double-pulling capstan. Same as first. See Fig. 5.

Pinch wheel unit. A pinch-wheel unit equipped with three pairs of motorized rubber wheels is used to pull the wire away from the second pair of pulling capstans and direct it into the take-ups. The unit clamps the wire between the wheels and pushes it towards the cutting shears. The synchronization of the unit is by torque control. See Fig. 9. Cutting shears. The PC wire line can be equipped with two different types of cutting shears. A hydraulic shear is suitable to cut wire when the line is equipped with either basket coilers or with spooler as take-ups. The cut is precise, although line speed must be reduced when the cut takes place. A rotary shear is used when the line is combined with a straightening and cutting machine and there are many cuts. A special length measurement system ensures that the cut length is precise and consistent. A rotary shear allows also to cut in small length wire that does not comply with the specifications, especially of the line is equipped with a non movable furnace. See Fig. 10. Basket coilers/spoolers/bar cutting. Generally, a PC wire

Fig. 11. Basket coilers/spoolers/bar cutting.

Fig. 12. Control unit.

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Fig. 13. Wire threading unit.

line is equipped with two basket coilers that wind the wire into large diameter coils of about two meters in diameter. The design allows switching from one basket coiler to the other on the fly without having to stop the line. As an alternative, the wire can be wound on a spooler equipped with collapsible spools or it can be directly cut into bars with a straightening and cutting machine connected in line with the rest of the line. See Fig. 11. Control unit. The PC wire line control panel includes a complete supervision system of the line, starting from the wire rod payoff up to the finished wire take-up. The control panel allows setting of all production parameters, such as speed, furnace temperatures, pull, cooling water temperature, speed of the furnace movement. See Fig. 12. Wire-threading unit. A PC wire line is a very long line composed of various unit that have significant dimensions. As some of the units are quite large, it is not easy for the operators to thread the wire alone. The newest lines can now be operated by one single operator as most are equipped with wire-pulling units that will keep the wire tensioned all the time and will, without effort, feed the wire through all the various components of the line. A specific wire-threading unit has been designed to take the wire all around the pulling capstans without the need of operator assistance. This unit dramatically increases the efficiency of the line as the time required for the threading operations is now only about 25% of the time that was required without this unit. See Fig. 13.

Advantages of an integrated PC wire line The equipment from GCR Eurodraw SpA described in this paper offers both technological and cost-savings advantages, which are listed as follows. Technological advantages • One step operation from wire rod to finished product. • The wire is always processed in the same direction. • The line never needs to stop as the wire rod coils are

Cost-saving advantages • No intermediate stock of work in progress. • No need of spools to store the wire. • No need to stop the line to weld the wire as the rod is welded and feeds continuously the line. Such welding creates down time waiting for the wire to cool down. • One operator can operate/control the complete line. • Lower overall power consumption due to the double capstan configuration that regenerates the power of one of the two capstans, eliminates spooler and spool payoff. • Integrated supervision system for wiredrawing and heat-treatment line allows continuous monitoring of the process and identification of possible problems, avoiding the production of non compliant material. ■

Lorenzo Facchinelli is the managing director of GCR Eurodraw SpA, Italy, and has working for the company for over 18 years. He holds a mechanical engineering degree from Loughborough University of Technology, U.K. This paper was presented at WAI’s International Technical Conference, Istanbul, Turkey, November 2009.

Facchinelli

SEPTEMBER 2010 | 75

TECHNICAL PAPERS

welded together and continuously fed in the line. The weld is automatically detected by a weld detector and automatically removed by the cutting shear at the end of the line. The tension between the capstan is automatically reduced when the presence of a weld is detected between the capstans. • No need for back tensioning die as two double-capstans regulate the tension of the wire to the same value. • In-line continuous control of the wire diameter. • Reduced smoke generation at the furnace with the in-line wire cleaning unit. • Hi-speed bar cutting line allows the production of precision cut bars directly from wire rod. • Hi-speed rotating shear allows the removal of non compliant material without having to wind it on the basket coilers. • Motorized wire pinch rollers placed all along the line ease and speed up the threading operation. • Capstan automatic wire threading unit reduces time required to thread capstans by 80%, increasing line efficiency by over 30% compared to conventional lines. • Better consistency of the finished product.

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PROD DUCTS TPEs said to be ideal for consumer electronics, power cords/cables U.S.-based Alliance Polymers and Services, LLC (APS), a distributor of and technical support resource for elastomers, has introduced a new line of halogen-free, flame-retardant (HFFR) TPE-S (styrenic block copolymer thermoplastic elastomer) for consumer and industrial electronic power cords and auxiliary cables. A press release said that specific applications for the new Maxelast® FH7800 series of TPE-S include power plugs, charger cables, electronic power cords, auxiliary cables and ribbon wire. They are offered as halogen-free and phthalate-free alternatives to flexible PVC (vinyl), are easy to process and have good surface quality, it said. The new grades are offered in a variety of hardnesses, from Shore A 60 to Shore A 96 and comply with RoHS, PAHs and NP (neophenol) standards and conform to UL ratings of 1581 (charger cables) and 94 (power plugs) depending on the grade, it said. APS notes that it is North America’s only all-inclusive TPE supplier, offering consulting services and product solutions with TPEs. Contact: Marketing Department, Alliance Polymers and Services, LLC, tel. 734-710-6700, info@alliance-tpu.com, www.alliance-tpu.com.

to return liquid back to the process without an enclosure if desired, it said. The air wipe has the company’s patented nozzle jets, both in the front and rear, to minimize blow back, increasing performance and keeping product much drier than standard air wipers, said the release. It added that it has much better performance at high speeds over the standard designs and still offer greatly reduced air consumption. Optional metering air valves can be added, allowing customers to fine tune and balance the air flow between the front and rear jets, it said. The units are offered from 1/16 in. (1.6 mm) up to 1 in. (25.4 mm). Contact: Howard Fancher, Huestis Industrial, tel. 401253-5500, sales@huestis.com.

System Solutions Drives NADV Straighteners Rolls Guides Preformers

Air wipe ends ‘blow back’ woes, more U.S.-based Huestis Industrial reports that its “Down Drafter” air wipe resolves a variety of issues within the manufacturing realm, most notably “blow back.” A press release said that the air wipe addresses a problem in the medical tubing extrusion business, where avoiding blow back or disturbances of the water field or trough is crucial for the clean room environment and must be minimized. The air wipe has a rear-exiting 45 degree angle down drain with a threaded reversible .375” opening. “Because most air wipers blow liquid to the rear from a 90 degree opening or drain/exhaust, they blow water back onto moving product as it exits from the previous air wipers in line, diminishing the drying effect,” it said. In response, the all-new “Down Drafter” air wiper has a .750 in. bottom center drain that is threaded, allowing the customer to use a fitting and attach a hose or pipe

Advanced feeding units for material sizes up to 40 mm. Are your feeding units powerful enough to transport large process material sizes safely? The design of NADV feeding units allows a constant or an intermittent process material transport in close tolerances with forces up to 5 kN!

WITELS-ALBERT USA Ltd. Phone: 410 228 8383, FAX: 410 228 1813 info@witels-albert-usa.com, www.witels-albert-usa.com

SEPTEMBER 2010 | 79

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Underground cable can provide dual water-blocking protection U.S.-based Hendrix Wire & Cable reports that its DUAL BLOCK™ product provides a dual waterblocking capability to the company’s primary, underground cable. The technology is available as an option for stranded conductor Hendrix cables. A press release stressed that water has long been “one of the enemies of long life in primary cable, as water entering the cable core can lead to premature failure.” Hendrix’s DUAL BLOCK technology, it said, can help prevent this from occurring. A fill compound is continuously applied into the conductor interstices, which prevents longitudinal water migration, then a water-swellable powder is applied under the polyethylene jacket, it said. This prevents water from migrating along the neutral wires, under the jacket, it said, adding that the two applications provide a reliable barrier that prevents water from entering the cable core. Hendrix/Kerite - MV Underground Cable is one of the operating divisions of Marmon Utility LLC. Contact: Hendrix Wire & Cable, www.hendrix-wc.com.

Circuit wire meets requirements that stem from 2008 NEC code update U.S.-based Cerro Wire LLC, a manufacturer of copper electrical building wire and cable, reports that it is now providing THHN striped circuit wire that will help electrical contractors meet the needs of facility owners driven by changes in the 2008 National Electrical Code (NEC®). A press release noted that Section 210.4 (B) of the

80 | WIRE JOURNAL INTERNATIONAL

NEC) requires that “multiwire branch circuits” must be provided with a means of simultaneously disconnecting all ungrounded or phase conductors where the branch circuit originates. To avoid being considered a “multiwire branch circuit,” one may provide separate neutrals for each individual branch circuit, which allows the use of single pole breakers for each circuit so that multiple circuits are not shut down when working on one circuit, it said, adding that, to keep track of which neutral goes with which circuit, a stripe on the neutral matching the color of the phase conductor is needed. The wire comes in 500-ft spools and 2,500-ft reels, and is available in white with various colored stripes and in green with yellow stripes. It will be offered initially in 14, 12, 10 and 8 AWG sizes. The release said that the wire makes it easy for contractors to know which neutral wire goes with which phase or hot conductor when installing multiple branch circuits in one conduit run. Contact: Dale Crawford, Cerro Wire LLC, tel. 256773-2522, crawford@cerrowire.com.

Assessment tool designed to provide solutions that can cure extruder woes U.S.-based B&H Tool Company, a solutions provider for manufacturers of insulated cable, wire, tubing, hose, pipe and profiles, has introduced a new assessment tool that it said can help resolve serious extruder problems, such as those related to process (wall thickness, OD and ID control, etc.) quality (leaking, burning and knit lines) and equipment issues. The new tool, a press release explained, “is a compre-

Wet blaster can clean in-process wire U.K.-based Vapormatt reports that it has developed a range of technologically advanced, compact, in-line wet blasting machines that are custom-engineered for the continuous cleaning and surface preparation of wire products. The “Vapormatting” wet blasting process “is a proven solvent- and dust-free simultaneous degreasing and cleaning process” that uses a cleaning solution (slurry) that is a special mix of water, detergent and abrasive media, a press release said. The slurry is blasted at a product or component through special blast nozzles that are highly controllable and can be used for a wide variety of components and materials, “being particularly effective for the surface profile of drawn wire products made from steel, brass, bronze, aluminum and other metals prior to the application of subsequent functional coatings or insulating coverings,”

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KEIR Manufacturing, Inc. Tel: +1 828.885.8444 U.S.: 800.992.2402 Fax: +1 828.884.7494 USA Email: Sales@KEIRmfg.com

www.KEIRmfg.com Your Specs! Fast, Personal Service and Great Value!

SEPTEMBER 2010 | 81

PRODUCTS & MEDIA

hensive 15-minute technical assessment, which is offered at no cost to qualified extruders, in both OEM and job shop environments.” Through the service, a B&H Tool Company solution specialist “can help identify the true root causes of problems, and determine whether there are instrumentation, tooling or service solutions that can make their process more stable, consistent and productive,” it said. In months of beta tests with some of North America’s most prominent extruders, the B&H assessment “has proven to be a valuable means for clarifying issues that are critical to extrusion performance, and the development of workable, cost-effective solutions,” it said. The assessment, the release said, can also help extruders who want to increase production without major capital investment, or who want to pursue a quality certification. Contact: Peter Neville, B&H Tool Company, tel. 760471-8949, www.bhtool.com.

PRODUCTS & MEDIA

it said. The automated and programmable process, it added, can also be used for the surface preparation of fiber optic cables and wire manufactured from plastics. The Vapormatting process does not cause surface damage and produces a higher quality, much smoother finish than alternative methods, the release said. As no dust is produced there is no detrimental effect on the working environment and there are no solvents or other potentially hazardous “pickling” or other, it said. The wet blast process, which provides degreasing, cleaning, rinsing and drying in a single, in-line enclosed unit, eliminates any potential danger from static electricity that can often be a problem with dry blasting, it said. Contact: Vapormatt, tel. 44-1823-257976; sales@vapormatt.com. In the U.S., tel. 610-624-3583 or 805-426-9527.

MEDIAA White Paper provides specific approach to help the cable selection process Selecting the Right Cable System for Your Environment,” a new White Paper from U.S.-based W.L. Gore & Associates,

Sjogren Wedge Grips and Replacement Parts

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Whether you require a standard wedge grip assembly or a customized unit, Sjogren Industries has the flexibility to manufacture an assembly to your requirements. Sjogren Industries, Inc. Tel: 1-508-987-3206 Fax: 1-508-987-1965 Email: sales@sjogren.com www.sjogren.com

82 | WIRE JOURNAL INTERNATIONAL

Inc. (Gore), presents a systematic approach that design engineers can follow to ensure that a cable system will provide reliable performance in demanding environments and mission-critical applications. A press release cited author Paul Warren, Gore’s lead design engineer, as saying that cable reliability is based on both durability and signal integrity, and a cable system needs to withstand any environment in which it will be used, regardless of how challenging it may be. Some industries have defined safety, environmental and performance-related standards, but many applications in harsh environments require cable systems that go beyond those standards, such as aerospace, cleanroom and geophysical environments, it said. The paper discusses the electrical, mechanical, environmental, and application-specific constraints that will affect cable performance, including the advantages and disadvantages of typical materials used in cable construction, the release said. The information includes an explanation of the testing and data analysis a manufacturer should do to verify that its cable will perform in a specific application as well as cost considerations and the ramifications of cable failure. To read/download a copy, go to gore.com/cableselection. Contact: W.L. Gore & Associates, Inc., gore.com/electronics. ■

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POSITION WANTED POSITION WANTED. Exec Sales Manager/GM with 20+ years of success in the areas of industrial sales, sales/business management, strategic planning and business development. Global orientation with balance of sales, organizational, managerial and interpersonal skills; relentless, results-driven leader with strong record of building highly effective teams, business start up with minimal resources, and turnaround situations in low growth markets. Specialties include sales management and training, business development, building/managing distribution network, strategic planning, supply chain, business management. Respond to Box 901.

PERSONNEL SERVICES “LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry manufacturers to secure the services of thousands of key individual contributors, managers and executives. For corporations we provide recruitment, outplacement, and salary assessment functions. For the professional exploring a new opportunity, we provide career evaluation and guidance. Our services are performed in absolute confidence. Contact: E-mail Peter Carino at pcarino@wireresources.com or Jack Cutler

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FOR SALE

1 - HALL 500’ Vertical Accumulator, 1997 3 - NEB 48-Carrier CB-1 Cable Braiders 7 - WARDWELL 12-Carrier Braiders 10 - NEB #2 Braiders, 12-C, 16-C, 44-C, 96-C 1 - FRIGECO 800mm D.T. Buncher 13 - LESMO 630mm D.T. Bunchers 1 - WATSON 36” Rotating Cabler Line 1 - EDMANDS 37-Wire 16” Planetary Cabler Line 2 - NEB Model C62-2 12-Wire 8” Vertical Planetary Cablers, 1987 1 - CEECO 6-Bobbin 60” Closer w/ 96” Caterpuller, 120” Take-up 1 - DAVIS ELECTRIC Model CAT-TRAK 22 Caterpuller Capstan 1 - VITECK 24” Horizontal Belt Wrap Capstan 2 - NEIHOFF Model MMH121 MultiWire Drawers, 14 and 16-Wire 3 - DAVIS STANDARD 3.5”, 2.5” 24:1 L/D Extruders 2 - D/S 2.5” 24:1 L/D, 2” 30:1 L/D Hi-Temp Extrusion Lines 1 - D/S / KILLION 1” 24:1 Extruder L/D, 2001 2 - TULSA 24” Motorized Shaftless Payoffs, Model HSPO-1, 12/02 1 - EJR 18”, Model 260FWPPO, Motorized 1 - EUBANKS 6415 Prefeeder, Model 6415-03

1 - NEB 54-Wire, 12+18+24, 22” Rigid Strander Line 2 - MGS 18-Bay 10” Tubular Stranders, outside string-up 5 - DAVIS STANDARD Dual Reel Take-ups, 36” (1), 30” (4) 1 - DAVIS ELECTRIC Model TAP30 Parallel Axis Dual Take-up 5 - NOKIA Model EKP50 Parallel Axis Dual Reel Take-ups 1 - CLIPPER Model SP16 Dual Spooler 1 - DAVIS ELECTRIC Model CRS30 Respooler 2 - WATSON/AFA 84” Rewind Lines, 6,600lb cap. 2 - TEC Model 24STC Hi-Speed Twisters, rated 1300rpm w/2-Wire Payoffs 1 - EUBANKS Model 4000-04 Cutter & Stripper w/HUESTIS 36” Payoff 1 - SCHLEUNIGER PS9500RS Rotary Stripper, 2005 1 - SCHLEUNIGER PF2200 PreFeed, 2005 1 - SCHLEUNIGER MP8015 Coax Stripper, 2005 1 - ZOLLER & FROLICH AI-01 Stripper, 2005 1 - IMAJE Inkjet Printer, Model Jaime 1000 S4, ‘98 29 - 48” x 32-1/4” ID x 25” Barrel x 3” Arbor Toroidal Reels

Contact: Martin Kenner

COMMISSION BROKERS, INC. P.O. Box 8456 • Cranston, RI 02920-0456 • Tel. (401) 943-3777 • Fax: (401) 943-3670 WEB: www.commissionbrokers.com • E-MAIL: marty137@aol.com

SEPTEMBER 2010 | 83

CLASSIFIEDS

WIRE JOURNAL INTERNATIONAL CLASSIFIED AD INFORMATION NAME _________________________________________________________________________TITLE _________________________________________________ COMPANY ____________________________________________________________________________________________________________________________ ADDRESS ___________________________________________________________________________________________________________________________ CITY ________________________________________STATE _______________POSTAL CODE _____________________COUNTRY _______________________ PHONE ______________________________FAX________________________________EMAIL _______________________________________________________ AD CATEGORY____________ ISSUE YOUR AD BEGINS___________E-mail NUMBER OF ISSUES RUN _______LAST ISSUE ________________RUN TILL FURTHER NOTICE? YES____ NO ____ FULL RUN (WJI & ON-LINE) YES____ NO ____

BLIND BOX? YES____ NO ____

WAI MEMBER? YES____ NO ____ WAI MEMBERSHIP # ______________________ (Applies only to “Position Wanted”)

more. Call TERRI TERRY at 828.238.1959, or tterry@charter.net.

DIES DIAMOND & CARBIDE DIES. Take advantage of discounted pricing on new, used and recut diamond and carbide dies in standard case sizes: 2, 5

and 6. For quality dies with competitive pricing, contact Ida Pardo by e-mail at info@knottco.com or by phone at 617519-3303. APOLLO DIA-CARB COMPANY. Buy & sell new/used Natural and PCD DIAMOND DIES. Fair prices and excellent lead times. Contact Paulette,

On the Instructions of the Receiver & Manager Mr Alan Flanagan, Deloitte & Touche Re B3 Cable Solutions (Ireland) Limited (In Receivership) Aghafad, Longford, Ireland

Please e-mail the requested information to: WAI’s Cindy Kirmss at ckirmss@wirenet.org. For more details, you can call her at 203-453-2777, ext. 116.

Owner-Sales, by telephone at 1-508226-1508 or by e-mail at apollodie@ wmconnect.com. WE WANT YOUR DIES! Precision Die Technologies. Do you have a surplus of unwanted or unneeded dies? If you do we can take them off your hands. We are looking to buy any

TENDER SALE OF CABLE MANUFACTURING PLANT Tender Sale

Sale Closing: 12pm GMT Friday 1st October 2010 Inspection: By Prior Appointment Assets include: • Samp TRB1 8mm Twin Copper Rod Drawing Line ~1999 • Heinrich E1-01-GL-3 Wire Drawing Line ~1997 • Samp MT 7+7 Intermediate Wire Drawing Line ~1991 • Setic TA 630 Ki & TA 1250L-3M Wire Stranding Lines ~ 05/96 • Northampton Wire Stranding Line • Rosendahl RE1.80-24/1.30-24 Core Wire Extrusion Line ~1993 • Nokia Maillefer NMA 120-24D/60-24D Wire Extrusion Line • Maillefer BM 150-18D Sheathing Extrusion Line • Skaltek/BiWater/P. Steffano Cut To Length & Rewind Lines • Cortinovus Drum Twisting/Cabling/Screening Line • Cortinovus Copper Screening Line • Pourtier Copper Wire Armouring Line ~1999 For further information, contact: McKay, 4 Blackbourne Square, Rathfarnham Gate, Dublin 14, Ireland Tel: 003531 490 3130; Email: info@mckay.ie

84 | WIRE JOURNAL INTERNATIONAL

• Caballe SingleTwist Steel Wire Armouring Line • SZ Stranding / Bedding & Sheathing Line • 4 x Mailleffer Telecom Core Production Lines • Kabmatic 15/13 & Nokia 13 Pair Group Twinning Lines • Cortinovus Drum Twist / Telecom Cable Laying Up Line • Skaltek Sheathing Line •Telecom Cable Insulating Line • Kompakbandﬁlter & Resy Coolant Filter Plants • Compressors, Chillers, Silos, Laboratory & Workshop • Air Compressors, Gantry Crane & Workshop •Transport Trucks • And lots more! In conjunction with:

MOLONEY DIE COMPANY. Low prices on all sizes of new, used and recut carbide dies. We also recut tapered nibs. Fast turn-around. Quality service since 1985. Tel. 904388-3654. AJEX & TURNER WIRE DIES CO. offers a wide range of PCD/ND/ Carbide Dies, Extrusion Tools, Die Polishing Machines, Ceramic & Diamond Tools. www.ajexturner.com. Send inquiries to ajexturner@ gmail.com/sales@ajexturner.com A-53, G.T. Karnal Road, Delhi-33 India. Ph: 0091-9811078882 (Ravi Bansal). SANCLIFF SHAPED WIRE DIES. All sizes and shapes R2 to R12. Highest

By order of the principles of Norﬁl, Inc.

Quality, Shortest Lead Times, Lowest Cost and Superior Customer Service. 60+ years of quality products and service to the wire industry. Contact Bill Drumm at 1-800-332-0747, or E-Mail at sales@sancliff.com.

MACHINERY WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & Non-ferrous; Marldon Rolling Ring Traverses) and Used Wire & Cable Equipment. Available (Cleaned, painted & checked operational) Buttwelders: Micro Models E1S, J4S, J5S, J6S, THD, J45C, GP-0 and AD-5. Coldwelders: Koldweld Models KBM-5 & KBM-9. Babcock Models CBW-2, CBW-10 & CBW-20. Printers: Gillies Models GS500 & GS100HD. Roll Pointers: Morgan Models #250 and Hand Operated. Inquire on other used equipment. Please contact by telephone at

#727-863-4700 or by e-mail at urbassoc@verizon.net.

MEDIA ELECTRICAL WIRE HANDBOOK. Focusing on the special needs of the insulated wire and cable industry, this three softcover book set examines materials, equipment, and products. The original version remains available while the revised Electrical Wire Handbook is divided into three separate handbooks: Part 1 - Wire and Cable Production Materials, Part 2 - Wire and Cable Production Processes, and Part 3 - Types of Cables. Parts 1 and 2 are now available, but the original handbook will still be available until Part 3 is published separately. List Price: $99, WAI Member Price: $59. To purchase, go to wirenet.org and click on The WAI Bookstore . ■

Wire Drawing Plant Live & Webcast Auction

Sale Date: Thursday, Sept. 23rd, 2010 at 10:00 AM EDT Inspection: Wednesday, Sept. 22nd, 2010 from 10:00 AM to 4:00 PM EDT or by appointment Location: 2550 Industrial Boulevard, Chambly (Montreal), Quebec, Canada J3L 4V2 Assets Include: • Wire Drawing Lines: (7) Vaughn, Morgan & Morgan Mordraw • Stem Coilers: (11) Cattaneo Luigi and Robinson • Butt Welders: (13) Micro • Wire Straightening/Cutoff Machines: (7) Lewis, Waﬁos & Shuster For more information and terms of sale, please visit

www.Go-Dove.com

• Wire Mesh Welding/Cutoff Line: Schlatter 96” • (2) Wire Descalers; Wire Collator; Air Compressors; Shop Presses & Custom Packaging Equipment The auction will be conducted in U.S. funds

For further information, please contact: BRYAN GOODMAN Tel: +1 410 654 7500 Ext. 235 Email: bryan.goodman@go-dove.com

SEPTEMBER 2010 | 85

CLASSIFIEDS

Natural Diamond dies and/or PCD’s. Contact our Sales Department at sales@pdtinc.com or call any of our sales reps at (260 )482-5001.

ADVERTISERS’ INDEX

ADVERTISERS’ INDEX ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISER . . . . . . . . . . . . . .PAGE

AIM Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .Cover 2

Flymca & Flyro . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Anbao Wire & Mesh Co Ltd . . . . . . . . . . . . . . . . . . . . . . . .82

Fuhr GmbH & Co Kg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Beta LaserMike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

T Fukase & Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Bongard Trading GmbH & Co KG . . . . . . . . . . . . . . . . . . .81

Fushi Copperweld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Caballe SA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

GoIndustry DoveBid . . . . . . . . . . . . . . . . . . . . . . . . . . .84, 85

Carris Reels Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Howar Equipment Inc/Metavan . . . . . . . . . . . . . . . . . . . . .57

Chicago Association of Spring Manufacturers Inc . . . . . .9

Huestis Industrial . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14, 22

Commission Brokers Inc . . . . . . . . . . . . . . . . . . . . . . . . . .83

Ideal-Werk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Domeks Makine Ltd Sti . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Jinyoungtech Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . .Cover 3

Eurolls SpA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Keir Manufacturing Inc . . . . . . . . . . . . . . . . . . . . . . . . .16, 81

George Evans Corp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Kiswire Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

MIND THE GENERATION GAP

Great minds are developing. Engineers. Metallurgists. Innovators. The future of the industry depends on them. Find them online. Connect with them. Influence them. And meet them halfway through WAI.

86 | WIRE JOURNAL INTERNATIONAL

ADVERTISER . . . . . . . . . . . . . .PAGE

Lamnea Bruk AB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Power Sonics LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Lesmo Machinery America Inc . . . . . . . . . . . . . . . . . . . . .18

Pressure Welding Machines Ltd . . . . . . . . . . . . . . . . . . . .46

Locton Limited . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Properzi International Inc . . . . . . . . . . . . . . . . . . . . . . . . . .13

Messe Düsseldorf Asia (wire China) . . . . . . . . . . . . . . . . .54

Queins & Co GmbH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Messe Düsseldorf GmbH (wire India) . . . . . . . . . . . . . . . .40

SAMP USA Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34, 55

Metavan/Howar Equipment . . . . . . . . . . . . . . . . . . . . . . . .57

Sealeze A Unit of Jason Inc . . . . . . . . . . . . . . . . . . . . . . . .15

Niehoff GmbH & Co KG . . . . . . . . . . . . . . . . . . . . . . . . . . .27

SIKORA AG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

NIMSCO LLC/SB2C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Sjogren Industries Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . .82

O'Hare Spring Company Inc . . . . . . . . . . . . . . . . . . . . . . .17

Talladega Machinery & Supply Co . . . . . . . . . . . . . . . . . . .4

Paramount Die Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Tubular Products Co . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Pittsfield Plastics Eng Inc . . . . . . . . . . . . . . . . . . . . . . . . .20

Ultimate Automation Ltd . . . . . . . . . . . . . . . . . . . . . . . . . .53

WAREHOUSE SPACE AVAILABLE: PAWTUCKET, RI - ATTLEBORO, MA - MONROE & MORVEN, NC - BONHAM TX

RECENT PURCHASES — INVENTORY HIGHLIGHTS EXPL355 2 ½” D.STD. 24:1 Therm III Line w/36” Hall driven payoff, 16” VITECK multipass capstan, 24” CLIPPER PA-24 dual take up EXPL356 3 ½” D.STD. 24:1 Line w/(2) 36” S/L payoffs, VITECK 14” multipass capstan, D.STD. DR-36 dual take up. EXPL353 2 ½” D.STD. Therm III Line w/36” S/L driven payoff, WST300 Preheater, VITECK 13” multipass capstan, NEWMCO 24” dual parallel shaft take up. CBR1055/CBR1056 (2) 30” COOK BH-30 S.T. Cablers. CBR1059 Cook BH-36 S.T. Cabler w/(3) 24” Payoff Neutralizers. CBR1058 24” NEB 6+12 Planetary Cabler w/Cone taper, 84” Hall S/L take up OPTICAL FIBER: TIGHT BUFFER LINES / S-Z STRANDING/RIBBON STRANDING/LOOSE TUBE/REWIND LINES BARTELL TUBULAR STRANDERS 6, 12, 18 wire 6.5”/10” (50+) SKALTEK 1.2, 1.6, 2, 2.2, 2.6, 3 Meter Portal Traversing Payoff’s/Take ups EDMANDS(3); 60” POURTIER, CEECO; 48” POURTIER, EDMANDS (3).

BRAIDERS: WARDWELL 16C/24C Wire/Textile Braiders (500+) New Speedmaster 150 Heads (30). BRAIDERS: SPIRKA 16C/24C OMA Hi Tech 16C/24C, NEB, TMW Braiders. EXTRUDERS: DAVIS STD. 1 ¼”, 1 ½”, 2”, 2 ½”, 3 ½”, 4 ½”, 6”, Plastic & Rubber. DUAL TAKE UPS: CLIPPER PA-16, PA-24, PA-30, PS-24, PS-36, PS-50 Dual Parallel Axis. CBR984 WATSON 19 wire 22” Planetary cabling line (still installed). WRD831/WRD678 SAMP 8 wire MT8.2.4.21 drawing machine/SAMP 14 wire MLS/5.T.14. COOK CABLERS 48” BH-48 S.T., Cook BH-36, BH-30, BH-24, BH22, BH-16. NEXTROM TAKE UPS EKP-63 Yr. 2000 Never used.(4) EKP 50, Yr. 1998, EKP-5, Yr. 2001. MGS/BARTELL PAYOFFS: 60", 72", 84", 96". Take ups 60", 72”, 84" 96" (some rebuilt).

ALWAYS LOOKING TO BUY/TRADE GOOD SURPLUS MACHINERY PREOWNED HIGH QUALITY WIRE, CABLE & OPTICAL CABLE MANUFACTURING MACHINERY AVAILABLE EX-STOCK FROM EIGHT US WAREHOUSE LOCATIONS.

SEPTEMBER 2010 | 87

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE

ADVERTISERS’ INDEX

ADVERTISER . . . . . . . . . . . . . .PAGE Vandor Corporation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2 Wire & Plastic Machinery Corp . . . . . . . . . . . . . . . . . . . . .87 Witels Albert USA Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

November 2010 WJI • Used equipment & how to make it work • wire China wrapup

Woodburn Diamond Die Inc . . . . . . . . . . . . . . . . . . . . . . . .46 Wyrepak Industries Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . .57

ADVERTISING DEADLINE: Oct. 1, 2010

Yuen Neng Co Ltd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80 Zumbach Electronics Corp . . . . . . . . . . . . . . . . . . . .Cover 4

WIRE ASSOCIATION INTERNATIONAL ADS Global Continuous Casting Forum . . . . . . . . . . . . . . . . . .23 Interwire 2011 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24-25 WAI Membership . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37-38 WAI Monterrey ITC . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44-45 WAI Webinar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50 WAI Reference Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56 Interwire 2011: Call for Papers . . . . . . . . . . . . . . . . . . .77-78

WIRE JOURNAL I N T E R N A T I O N A L

NORTH AMERICA

EUROPE

Robert J. Xeller Anna Bzowski Wire Journal International 1570 Boston Post Road P.O. Box 578 Guilford, CT 06437-0578 USA Tel: 203-453-2777 Fax: 203-453-8384 sales@wirenet.org

U.K., France, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. 63 St. Andrew’s Road Cambridge CB4 1DH, England Tel/fax: 44-1223-360472 franksco@btopenworld.com

88 | WIRE JOURNAL INTERNATIONAL

SALES OFFICES ASIA/WAI INDIA OFFICE Germany, Austria, & Switzerland Dagmar Melcher Media Service International P.O. Box 103 D-82402 Seeshaupt Germany Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de

India Wire & Cable Services Pvt. Ltd. (WCS) 501, Rainbow Plaza, S. No. 7 Pimple-Saudeagar Vil. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org

ZUMB.707.0103.U_WJ JULY.10

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