EuroWire September 2022

Technology News

Technology for CHQ production Since the invention of the e-phos electro phosphating process in 1998, Staku has experienced worldwide growth for single- and multi-wire applications of preparing the wire surface for cold forming. The company’s modern manufacturing concept offers environmentally friendly processes that avoid the use of acids, with equipment that requires a small footprint and no foundation work for secondary containment.

range produced on the machine: a double sand belt cleaning machine for 5.5 to 16mm diameters; and a four-turbine shot blaster machine for 17 to 38mm diameters. The electro-phosphating process is driven by a DC power source that creates an electrical potential higher than the natural one existing between the elements iron and zinc. The system voltage is low, and does not exceed 8 to 13V, making it safe for the operator. Thezinc-phosphatecrystalsareelectrically deposited by ion migration from the anode to the wire surface, which is polarised as the cathode. For optimisation of the coating quality around the wire surface, the electrodes are built in a round shape. The DC power also suppresses the pickling process that is necessary for traditional phosphating. Because the iron ions from the wire cannot contaminate the phosphate solution, the formation of phosphate sludge cannot occur, saving chemicals and reducing waste cost. Staku-Anlagenbau GmbH www.staku-gmbh.de ment, fixed or portable, such as welders, pumps, compressors, motor generators and power transfer switch cabinets. Features include energised contacts that are deeply recessed inside the terminal block to reduce danger of accidental touching and minimise the possibility of exposed arcs; and positive polarisation, so that only plugs and receptacles of the same style, number of poles and amperage rating can be used together. Style 2 plugs, receptacles and connectors provide ground through shell, plus extra pole so that grounding pole “makes first, breaks last”. The 30 to 150 amperage receptacles include a screw and flip cover for NEMA 3, 3R, 4 and 4X applications at no additional charge. The plugs and connectors include a variety of grommets with many cable diameters, providing application flexibility. Emerson www.emerson.com Appleton Powertite lock collars prevent unauthorised cable disconnection

The company says that, while the product quality and environmental aspects were superior to traditional techniques, in the beginning the throughput of the process was not comparable with coil processing systems. Staku’s newly developed method of wire contacting inside the coating chamber has enabled the company to almost double the line speed and the approximate annual capacity.

Other claimed benefits include high quality in-line production at high speed and quality; homogeneous coating quality around the surface; no voids resulting from contact spots; and a fully automated chemical analysis and metering system connected to a Level 2/3 process data network. All bath temperatures are between 50 and 60°C, with a closed-loop system that provides optimal heat retention, for lower energy costs. There is no formation of waste sludge or rinse water at disposal, and no down time for bath cleaning, due to permanent in-line filtration. The use of electrochemical reaction reduces chemical usage, and there is no harsh chemical odour or equipment contamination in the surrounding area. Staku recommends two different methods of descaling, based on the wire diameter Electrical accidents can occur because of negligence or unmonitored working conditions. For example, a welder working in a compact and cluttered environment may want to move a heavy cable out of the way. Despite knowing the safety code, the welder may not wait for an electrician. Disconnecting an energised cable can expose the welder to arc flash or electrical shock. This can be prevented by using the Powertite lock collar. The lock collars fit both the 60A and 100A versions of Appleton’s Powertite pin and-sleeve plugs and connectors, as well as similar models from Crouse-Hinds®. The thick resin construction withstands extreme environments and handling. The collar works with either the provided keyed padlock or all standard lock-out padlocks, such as American Lock® from MasterLock®. Appleton Powertite plugs, receptacles and connectors have a durable, copper-free aluminium construction with an epoxy powder coat finish, ensuring long-term protection against damaging chemicals, water, dust and debris. They supply power to all types of heavy-duty electrical equip

e-phos off-line device with a four-ton-spooler for the production of phosphate steel wires

Preventing unauthorised access to high-voltage connections

The Occupational Safety and Health Administration (OSHA) estimates 350 employees are killed annually in electro- cution accidents – almost one fatality per day. Both OSHA officials and industry safety consultants recommend eliminating potential hazards on work sites, rather than relying on contractors or employees to follow safety guidelines. Emerson’s Appleton™ Powertite™ lock collar fastens over plug and connector connections and is securedwith a padlock, preventing unauthorised personnel from disconnecting the cable connection once in place. The Powertite lock collar reduces companies’ exposure to risk and liabilities from injury or death, and increases overall safety on-site.

The collars are secured by padlock

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September 2022