The Best of... Extrusion & Bending Equipment and the Virtual Industry 4.0 Event

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The Best of...

EXTRUSION & BENDING EQUIPMENT

VIRTUAL INDUSTRY 4.0 CONFERENCE

O F F I C I A L P U B L I C AT I O N O F T H E W I R E A S S O C I AT I O N I N T E R N AT I O N A L

VIRTUAL INDUSTRY 4.0 CONFERENCE

ORGANIZED BY:

VIRTUAL CONFERENCE

Focus on: INDUSTRY 4.0 The setting may have changed to virtual, but not the mission. Industry 4.0 captures the imagination of wire makers. It introduces change. Automation, robotics, and data analytics affect the way wire is made and how well companies compete on the world stage.

You are invited to explore the possibilities at the Wire Association’s Virtual Industry 4.0 conference, Oct. 26-27, 2021. Hear from the machinery makers and software suppliers who can help you realize your goals. Learn what these changes mean for your plant and personnel. And find out what is imminent and what is already here to stay.

Industry 4.0 Conference

This virtual conference focuses on the Industry 4.0 theme with a series of presentations from key industry companies involved in this innovative technology. The schedule is subject to change, so do visit www.waiindustry40.heysummit.com.

Industry 4.0 Briefings

These 15-minute segments highlight exhibitors involved in some aspect of Industry 4.0.

Keynote Speakers

Each day will see the program start with a keynote speaker: On Tuesday, Oct. 26, it will be filmmaker Robert Culp, and on Wednesday, Oct. 27, it will be Southwire EVP Operations Kathleen Edge.

WAI Annual Meeting

This session is just a half hour, but it includes the annual meeting and the presentation of the Mordica, Donnellan and WAI President’s awards.

Note: this issue may arrive late, but you still have time to register

Due to unprecedented printing/mailing delays indirectly related to Covid, this October issue may not have arrived in time for readers to register prior to the start of the Oct. 26-27 conference. The good news is that everything that is presented in this preview can be accessed for a full month beyond those dates.

The on-line format allows attendees to choose the segments and individual sessions. You can create your own schedule, skip or replay according to whatever schedule works best for you.

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F E AT U R E

The Best of...

EXTRUDERS

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Fine International

A close-up view of an extruder available from Fine International Contact: Bruce Ceres, vice president Tel: 732-933-0040 finesales@gmail.com www.fineinternational.net

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This feature asks OEMs of extruders to explain why what they have to offer for customers is “the best of.” That claim could be for a system that either offers the lowest operating cost or the newest advanced technology, but part of the equation has to be what else a company has to offer customers.

What makes it a good potential partner.

U.S.-based Fine International has supplied extrusion equipment and lines since the company’s inception in 1995. Our core expertise is built around our proprietary physical foam technology used for communication cable ranging from mini-coax to RF applications.

Fine International’s gas injection foam extrusion line is designed with our PreciseFlow foam technology to achieve the most uniform mechanically and electrical coaxial dielectric. Our technology employs a uniquely designed extended L/D screw resulting in stable and homogeneous extrudate with exceptionally fine cell structure. Standard foam extrusion materials include both polyolefin type and fluoropolymers.

Fine International also offers general extrusion lines insulating and jacketing. Lines are custom designed based on the customer’s specific application. Cable conductors can range from fine wire (down to 44 AWG) to larger power cable conductors (500 MCM). The production lines are offered as complete with all necessary components including wire handling equipment (payoffs, dancers, accumulators and takeups), main extruders with material handling, cooling/tempering systems, ancillary elements (preheaters, printing, gauging) and operator control units. Constraints such as customer available floor space and layout and productivity requirements are key points in our custom designed offers.

All of the standard line components are also available for existing line upgrades. Based on our short production cycles and overall high value and low-cost economics, Fine International can offer to our customers a valued extrusion line with short delivery times.

Contact us to learn more about our extrusion capabilities, and our ability to provide you the most appropriate lines for your needs.

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F E AT U R E

The Best of ...

Rosendahl Nextrom

The ROEX extruder fills many needs Contact: Harri Turunen, managing director Tel: 828-464-2543, ext. 304 harri.turunen@rosendahlnextrom.com www.rosendahlnextrom.com

The Best of ...

SAMP

SAMP’s 80-25 extruder Contact: David Graff, project engineer Tel: 301-223-8584 dgraff@sampinc.com www.sampinc.com.

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Austria’s Rosendahl Nextrom is a leading global supplier of production technologies for cables, steel ropes, shock tubes, blasting wires and optical fiber. Its ROEX extruder is, along with the crosshead, the heart of each extrusion line. But why choose the ROEX extruder?

Energy savings and reduced power consumption. Low power consumption is becoming increasingly important. An extruder is the biggest power consumer within an extrusion line. Hence, an improvement in the extruder energy consumption has the highest impact on overall production energy consumption. The main energy demand is influenced by the design of the processing unit of the extruder (feeding section and screw design) as well as by that of the extruder drive.

The CMG (compact motor gearbox) is the latest extruder drive technology. Within its housing, four motors are symmetrically placed around one planetary gear. This layout enables very uniform load transmission, resulting in lower noise emission and a long machine lifetime.

Higher and counter-pressure independent output. ROEX extruders are equipped with a specially designed water-cooled feeding section.

Together with the appropriate screw, this design imparts a conveying extruder characteristic. Compared to conventional extruders, the influence of counter-pressure fluctuations is reduced to a minimum for consistently high-quality final product and significantly higher output.

Higher linearity over the whole operating range. In addition to their higher output and insignificant melt pressure fluctuations, ROEX extruders have the significant advantage of a high linearity of output over the entire range of operation. This results in stable product dimensions over the complete operating range of the extruder.

Founded in 1936, Italy’s SAMP supplies precision machines, spare parts and services to leading wire and cable manufacturers around the globe from locations in Italy, China, Brazil and the U.S. Consistent with its long history of superior engineering and Italian craftsmanship, SAMP designs and manufactures innovative and high-performance machines in the industry.

The SAMP 80-25 extruder embodies the company’s legacy of providing the finest technology as well as a forward mindset that addresses the need for manufacturers to adapt and benefit by evolving solutions. The extruder—designed for thermoplastic and thermosetting compounds for low voltage, datacom, signal and automotive industry—increases productivity while ensuring maximum flexibility and stability in terms of manufacturing process. The high capacity and productivity stem from SAMP’s screw/cylinder profile. Customers benefit from an extremely flexible solution that can produce different compounds (e.g. PVC, PE, PP and XLPE) using the same screw. The compound thermic stability can be monitored and controlled at any time by anticipating the thermic flow during thermoregulation to increase the line productivity.

The SAMP 80-25 features improved SAMP software for the automatic calculation and monitoring of the screw rpm during the start-up, set-up and acceleration/deceleration ramps. The solution includes a plug-and-play version for a fast and easy installation. Several accessories can customize this model for different final applications.

All SAMP machines are developed to the most recent innovations of Industry 4.0, allowing customers to manage all production and maintenance data remotely in an easy and convenient way.

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F E AT U R E

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BENDING

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AIM Inc.

AIM’s newly updated AFES-3DxT model Contact: Constantine Grapsas, president Tel: 813-543-4911 info@aimmachines.com www.aimmachines.com

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This section asks OEMs to explain why what they have to offer for customers is “the best of.” That claim could be for a wire drawing system that either offers the lowest operating cost or the newest advanced technology, but part of the equation has to be what else a company has to offer customers. What makes it a good potential partner. Also, one of the companies presents more technical details in the Products section.

AIM Inc. (Automated Industrial Machinery, Inc.) manufactures two-dimensional and three-dimensional CNC bending machinery. The company is an active machinery exporter via its two manufacturing facilities in North America and Europe.

AIM’s modular construction technique provides unprecedented machine upgrade flexibility and versatility. Its 2D machines can manufacture rectangular frames as large as 72 in. by simply changing frame modules. Both 2D and 3D machines can expand to accommodate accessory machine modules such as chamfering, butt welding, end forming, drilling, marking, threading and press operations. Many modules are offered in-line, allowing turn-key end product manufacturing.

AIM’s new AFES-3DxT, an updated five servo-axis turret toolchanger machine with an ultra-fast servo cutter, is available at a very attractive price. It has been AIM’s most robust and proven model for 20 years. The model’s turret head indexing tool changer provides even more wire forming flexibility while its servo-cut function assures fast and quiet production. Standard features include DXF, LRA and XYZ import, animated bending simulation with collision detection, Auto Pilot speed/load monitoring, touch screen monitors, Microsoft Windows®, 5 HP wire payoff, “Dial-A-Service” for remote support via the Internet, and a maintenance module.

Options include automatic bend setup with our AccuCal, easy production statistics with AccuTrack, 24/7 online AIM Academy training, FARO, ROMER and AICON CMM’s communications for automatic programmer corrections, integration with robots, and STEP and IGES files import.

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F E AT U R E

The Best of ...

OMCG Italia Srl

OMCG’s C31E bending system Contact: David Galas, president Tel: 630-860-1016 / Mobile: 630-337-9200 d.galas@omcg.com www.omcg.com

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Ultimation

An ULTIMAT bending system Contact: Scott Liebenberg Tel: 815-315-4260 scott@awtmach.com www.awtmach.com

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Italy’s OMCG Italia Srl., represented in North America by OMCG Inc., is a world leader in the design and manufacture of CNC bending machines for wire, tube and strip materials.

Founded in 1963 by Luigi Maggi, OMCG introduced a completely innovative multi-slide technology concept that was used in the first CNC wire bending and forming machines to have six axes. He further improved the technology and the bending capacity of the machines, by developing Easy Programming: OMCG patented programming software with 3D human-interface simulation and anti-collision check.

Today, OMCG has continued to grow, and is able to serve different industries by offering a complete range of CNC bending machines for wire diameters from 2 to 18 mm, strip up to 12 mm x 4 mm and tube up to 16 mm x 3 mm. Two examples of OMCG’s capabilities are its C31E model (pictured) and its Minimalist 6 bending system. See p. 78 for more details on these models.

Besides standard machines, the company designs customized work cells for specific products to meet the most demanding customers.

OMCG has also developed ancillary equipment for the execution of secondary operations (end forming, chamfering, threading, punching, marking, notching, welding, 3D controls, transfer) to provide complete turnkey solutions.

Reliable and long-lasting mechanics, a user-friendly machine interface, high-quality components, production flexibility and timely after-sales service have made OMCG one of the best-known and worldwide-renown bending machine manufacturers. It is also backed by its U.S. office, which provides support, advice and spare parts.

Ultimation has been manufacturing wire forming and welding machines since 1993, and is well respected by its worldwide customer base for offering a wide range of groundbreaking models.

Launched in 2002, under the “ULTIMAT” brand name, the UMW series of 2D wire forming and welding machines have a robust, modern, modular design, paired with user-friendly Windows10 based software. The UMW series has five standard models for processing wire from 2.00 mm up to 13.00 mm, with maximum frame sizes up to 1200 mm and beyond. They manufacture a wide range of wire products, from POP displays to appliance shelving to automotive components.

The versatile ULTIMAT design negates the need for special tooling to produce high-quality parts and components. Versions are available for use with flat strip or profiled wire. Other options include press and chamfering stations, secondary bend heads for intricate forms with a tilting table to accommodate large components or for forming spirals.

Ultimation also offers automatic ring forming and welding machines, with resistance and TIG/heli-arc welding, cross/brace wire welding machines for oven/refrigerator racks and HVAC filter frames, and sign wire frame welding machines for yard stakes/political signs. They also design special purpose models to suit customer requirements.

ULTIMAT wire forming and welding machines provide reliability that meets and exceeds customers’ expectations. They are affordable, progressive and innovative to make you more efficient, more competitive, and more profitable. North American companies can contact AWT Machinery, Inc., or Sales Director Martin Smith at Ultimation, tel. 44-1403-710043, martin@ultimat.com,www.ultimat.com. 

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