WCA March 2024

Exhibitors at wire 2024

measurement data for its systems. “This allows our customers to document the wire dimensions of each produced reel,” said Mr Gerth. For the second sector, Fuhr offers the compact IPU320 in-line profiling unit. This machine is designed for the continuous production of a certain wire dimension, and is usually installed directly in front of a wire insulation plant (enamelling or extrusion unit). The compact design allows the IPU to be integrated into existing systems.

when specified tolerance limits are exceeded and can take corrective actions in the production process. evaluation technology is based on a method developed for the inspection of 2D surfaces, which has been used for more than 40 years in the paper and printing industry, among others, as well as in the production and coating of foils. A special feature of the inspection system is that it works with just one camera. This high-speed CCD line scan camera is housed in a camera box along with LED ring lighting and several mirrors. The units for signal processing and defect indication are installed in an associated control cabinet, which can be placed near the camera box. A wire passing through the box is illuminated from all sides by the ring lighting. Light is reflected to the mirrors, and from there to the camera. Fluctuations in light intensity caused by surface defects are imaged and analysed in the downstream signal processing unit. The results are then shown on the defect display unit and can be stored. Owing to their arrangement, the rigidly built-in mirrors do not have to be readjusted in the case of diameter fluctuations. The measuring and

During the upgrade process, it was essential to maintain productivity and meet demand, to avoid significant disruption to the production process. This was done by carrying out the upgrade in phases where only a section of the machines were taken offline at any given time. The upgrade process was planned for off-peak production periods to minimise the impact on production levels. FMS Force Measuring Systems AG www.fms-technology.com Fuhr GmbH & Co KG 09 F26 Growing demand for energy and the ongoing energy transition poses challenges for the wire industry, in particular the production of rectangular magnet wires. The carbon footprint in the copper sector is taking an important role. Due to increasing electrification in the mobility sector, manufacturers are facing previously unknown requirements for product quality and process stability, as well as the documentation of these factors. Fuhr GmbH & Co KG, headquartered in Steinheim, East Westphalia, Germany, sees these challenges as an opportunity. The company analysed the market a few years ago and found that it can be divided into two different sectors. One sector is wires for the construction of large generators, transformers and motors. These wires are usually made to order, so manufacturers need flexible machines that can be quickly converted to accommodate changes in wire dimensions. The other sector serves the production of winding wires for the drive motors in electric cars. These are produced in large quantities over long periods of time, so their manufacture is less concerned about flexibility, and more about process stability and product quality. Fuhr offers optimised machine concepts for both sectors. For the flexible production sector, its portfolio includes five-stand rolling mills in different sizes, designed to be as efficient as possible for the required dimensional range. The modular design of these systems allows only the necessary power to be installed. Volker Gerth, managing director at Fuhr, said, “The quality of the produced wire and the documentation of this quality is also important.” For this reason, Fuhr relies on specially developed measuring devices and software for logging and evaluating the

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Five-stand rolling mill

Winding wires, also known as hairpin wire, must not show any damage. Wire forming and insulation are therefore usually performed in one line. The IPU320 is designed for wires up to 15mm². This dimension is sufficient for the automotive sector. In order to serve the growing market for the TMM (transport and mobile machines) sector, Fuhr developed a larger version – the IPU500 – in 2023. 15 A13 Steel and iron wires usually have to fulfil demanding requirements. In certain cases, a high surface quality is also required. Wire manufacturers need to be able to continuously inspect the surface of their products during the production process. An optoelectronic online inspection system from Japanese inspection equipment manufacturer Futec is suited to this task. The compact plug-and-play inspection device, designed for wire diameters from 0.5 to 60mm, can be integrated into production lines without having to modify them. It captures small surface defects such as scratches, cracks, pores and notches, even if not visible to the human eye, as well as contamination. The system registers their size, shape, position and number, and displays the defects simultaneously on a screen. The production line operator recognises Fuhr GmbH & Co KG www.fuhr-wire.com Futec Europe GmbH

The interior of the camera box, showing the high-speed CCD line scan camera and the mirror section

The surface inspection system is also suitable for wires made of other metals, as well as cables and tubes, and can be combined via a signal transmitter with other systems such as eddy current testing, geometry measuring and marking devices. By appointment, visitors to the Futec stand can have their own wires tested.

Futec Europe GmbH www.futec-global.com

GEO-Reinigungstechnik GmbH 11 A32 Achieving a clean finished wire is a complex process. Forming processes and deflection accumulate metal fines,

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March 2024