WCN Autumn 2010

OFFICIAL NEWSLETTER OF THE INTERNATIONAL WIRE & MACHINERY ASSOCIATION WIRE & CABLE NEWS Autumn 2010 ISSUE N° 43

Greater efficiency with Ceeco Bartell’s roll form strander ▲ ▲

High-speed, continuous roll form stranding The roll form stranding process combines the advantages of two highly productive processes, namely: roll forming of shaped wire and double twist stranding of conductors. These two systems are forged together to create one high-speed continuous manufacturing cell, which is capable of producing up to 300mm 2 compact conductors at speeds of over 200m/min. This system not only produces compact strand at high speeds, but also allows significant savings to be made throughout the stranding process, from wire drawing all the way through to the extrusion process. The aim is to present a technological solution in the manufacture of compact conductors, which brings cost savings from the wire drawing process through the cabling and into the extrusion process. This is the use of the roll form strander, which allows the use of a single input diameter wire to be utilised throughout the stranding process, giving significant process savings and advantages, including:

Higher productivity at stranding machine (typically • 40 tonne/day compact Al) Higher productivity in wire drawing • Lower drawn wire scrap • Lower insulating costs • Lower capital investment • Improved return on investment • Quicker set-up • Reduced work in process • Shorter cycle times • Smaller input wire storage area • 75% more energy efficient than a typical rigid strander • The high performance of roll form stranders, coupled with the Ceeco Bartell patented roll forming process, will allow the cable manufacturer to reduce costs without compromising the finished conductor performance. An awareness of this and other new technologies, combined with enlightened specifications, will further enhance the development of strand design and the potential to optimise further the manufacture of stranded conductors.

Ceeco Bartell Products – USA Fax : +1 905 669 2218 Website : www.ceecomfg.com

1

WCN Issue N° 43 www.iwma.org

CONTENTS

Wire & Cable News Machinery................................. 5 Troester GmbH........................... 19 Joachim Uhing KG GmbH......... 10 WGH Wire.................................... 4 Zumbach Electronic..................... 2 Wire & Cable News is published twice a year by the IWMA. All the text and illustrations in this publication are copyright protected. Copying of the contents by photographic or electronic means is forbidden without the publisher’s written consent. The publisher, agents, printers and contributors cannot be held responsible for the accuracy of claims printed or inferred in the editorial or advertisements published in this, previous or subsequent editions. The publication in this newsletter of Brand Names, Trade Names and Trade Marks and similar does not imply that these may be used elsewhere. IWMA 46 Holly Walk, Leamington Spa, Warwickshire CV32 4HY, UK AIM............................................... 6 Ajex & Turner Wire Dies. ............ 14 ASMAG...................................... 24 Beta LaserMike.......................... 11 Ceeco Bartell............................... 1 Condat....................................... 22 Daloo Machines......................... 17 Eder Engineering........................ 18 ESM........................................... 17 Euroalpha................................... 18 FMS. .......................................... 21 Fox Wire Ltd................................. 4 Foxton Dies................................ 23 Gauder Group............................ 19 GER SA........................................ 5 H&R ChemPharm....................... 20 August Hildebrandt...................... 9 Huestis Industrial....................... 16 IBA Industrial................................ 9 InnoVites BV................................. 7 Jiangyin Huafang Electro- mechanical Technology.......... 15 Madem SA................................... 3 Marldon...................................... 24 Microdia SA. .............................. 22 Maschinenfabrik Niehoff............ 10 Pave Automation. ...................... 16 Precision Rolling........................ 24 Pressure Welding Machines....... 10 Proton Products International.... 14 PS Costruzioni........................... 17 Reber Systematic. ..................... 24 Roblon A/S................................. 15 Rosendahl Maschinen............... 16 Shanghai Yessjet Precise Machinery. ................... 4 Sikora AG................................... 21 Techna International..................... 4 Tianjin Hengjiu Tongda

For continuous quality control, lump and neckdown detectors are as important as diameter gauges and spark testers. The new line of KW 13Trio detectors from Zumbach capture even the smallest lumps and neckdowns in wires, conductors, optical fibres and cables both quickly and accurately. The compact design of the KW 13Trio makes it easily integrated in any extrusion line or rewinding process. The measuring field is dimensioned in such a way that during start-up, even extremely big lumps pass smoothly through. Its open design enables quick and easy threading of the product without stopping production. A powerful microprocessor and full digital signal processing make this lump and neckdown detector an important tool for quality control. The detector is available as a standalone device. Using a local operating and display unit, the KW 13Trio can be fully operated and configured at the device. Its features include a minimum detectable fault height of 0.01mm (0.0004") and minimum fault length of 0.2mm (0.008") and full digital signal processing DSP. The versatile KW 13Trio has multiple interfaces, including serial RS, Profibus DP and Ethernet EN. Via the RS interface port, connection can be made Versatile quality control

Versatile KW 13Trio from Zumbach ▲ ▲

to a USYS data acquisition, processing and display system. The Profibus DP and Ethernet EN versions allow the connection to a higher-level host, such as a PLC or data acquisition system. The measuring principle and complex optics solution ensure immunity to stray and intense light whilst providing the highest detection accuracy and identification of lumps and neckdowns in the micrometre range. The KW 13Trio models feature an internal fault database to store the last 100 detected faults, including fault characteristics such as fault number, type, height, position and length of fault. This database can either be accessed via the local operating and display unit or via the optional remote interfaces.

Zumbach Electronic AG – Switzerland Fax : +41 32 356 0430 Email : sales@zumbach.ch Website : www.zumbach.com

IWMA to organise 2011 technical conference in Düsseldorf

The IWMA is planning a two-day technical conference to be held at the Messe Düsseldorf Congress Centre from 7 th –8 th November 2011. This will be the association’s first conference in Germany since the highly successful “Fire performance of cables,” which was also held in Düsseldorf in 2002. It seems logical that the 2011 event should be held in what is now undoubtedly the spiritual home of wire. Other wire industry associations will cooperate in the organising of the conference. Some of the themes the conference will cover are likely to include advancements in data cables and fire prevention improvements – for non-ferrous sessions – and, for ferrous sessions, environmental aspects for rod and wire production and quality requirements for the spring and wire component producing industries. Other topics will be confirmed in due course. Full details will be posted and regularly updated on the IWMA website www.iwma.org, and on the dedicated technical conference website www.cabwire-duesseldorf.com

Tel : +44 1926 834680 Fax : +44 1926 314755 Email : info@iwma.org Website : www.iwma.org Autumn 2010 www.iwma.org

2

WCN Issue N° 43 www.iwma.org

Events for Business, Technology and Education

News from Madem Euromadem, located in Calaf, Barcelona, Spain was officially recommended by Det Norske Veritas (DNV) to receive the ISO 9001 designation for the manufacture of wooden and plywood reels. Euromadem launched operations in 2006 and today is one of the largest reels suppliers in Spain and Portugal, providing logistics, just-in-time, and recycling services. Leandro Mazzoccato, corporate sales and marketing director, said: “The ISO 9001 designation is an important tool for excellence in service for our customers in Spain and Portugal. We will practice continual improvement in our quality system for the benefit of our valued customers.” Roger Santasusana, general manager of Euromadem, agreed: “We are very satisfied to have implanted ISO standards in record time, a sign that we were on the right track. Now we will be sure to maintain our quality system and continual improvement processes to ensure a quality product and satisfied customers.” On 12 th May 2010, Madem Reels USA, located in Chattanooga, TN sold all assets to the Sonoco Group headquartered in South Carolina. According to Gino Mazzoccato, president of Madem Group, the sale of assets to Sonoco hails the return to an old strategic partnership formed in 2000. It is thought that the deal will strengthen both companies, keeping them competitive during a very difficult time of high raw material costs in lumber and steel and low demand. The terms of the transaction were not disclosed. Madem Group has forests, sawmills, plywood plant and manufacturing plants in Brazil, Spain, Bahrain and Romania with more than 600 employees and produces more than 500 containers/trucks of knock down reels per month. Euromadem Spain is a subsidiary company of Madem SA Brazil.

2010 September

21-24 wire/Tube China 2010 Shanghai, PRC

Contact Messe Düsseldorf GmbH Fax: +49 211 4560 7740 Email: wire@messe-duesseldorf.de Website: www.wirechina.net

20–23 wire China Conference Shanghai, PRC

Contact Shanghai Electric Cable Inst. Fax: +86 21 6549 1182 Email: secri@stn.net.cn Website: www.secri.com

2010 November

18-20 Wire & Cable India 2010 Mumbai, India

Contact Messe Düsseldorf GmbH Fax: +49 211 4560 7740 Email: ryfischd@messe-duesseldorf.de Website: www.wire-india.com

2011 January

8-11 Tekno/Tube Arabia Dubai, UAE Contact Al Fajer

Email: alfajer@emirates.net.ae Website: www.alfajer.net

Madem SA – Brazil Fax : +55 54 3462 5900

2011 May

Email : sales@madem.com.br Website : www.madem.com.br

3-5

Interwire Atlanta, Georgia, USA Contact WAI Fax: +1 203 453 8384 Email: info@wirenet.org Website: www.wirenet.org

Forthcoming IWMA Social Events

23-26 wire/Tube Russia 2011 Moscow, Russia

IWMA 40 th Anniversary Drinks Reception Thursday 23 September 2010, IWMA stand, wire China 2010, Shanghai

Contact Messe Düsseldorf GmbH Fax: +49 211 4560 7740 Email: info@wire-russia.com Website: www.wire-russia.com

IWMA Dinner Dance 2010 Friday 26 November 2010, Royal Garden Hotel, London, UK

2011 September

13-15 wire/Tube Southeast Asia 2011 Bangkok, Thailand

Contact Messe Düsseldorf Asia Pte Fax: +65 6332 4633 Email: wire@mda.com.sg Website: www.wire-southeastasia.com

IWMA AGM & Industry Lunch 2011 Wednesday 2 February 2011, Mere Golf & Country Club, UK

IWMA Golf Day 2011 Wednesday 8 June 2011, Fairhaven Golf Club, Lytham St Annes, Lancs. UK

2011 October

4-6

WiCAB/Tubotech 2011 S ã o Paulo, Brazil Contact CIPA

Please contact the IWMA office for further details, Tel: +44 1926 834680 Fax: +44 1926 314755 Email: info@iwma.org or visit the website www.iwma.org

Email: cipa@cipanet.com.br Website: www.cipanet.com.br

3

WCN Issue N° 43 www.iwma.org

Winding up, and winding down

WGH Wire Drawers sold

•

Techna International is the UK agent for Meccanica Nicoletti equipment. The range includes a selection of winding machines to suit almost every cable winding application, from the smallest manual bench-top models, through motorised and s em i - a u t oma t ed units, up to fully automated cable handling systems for large-scale operations.

WGH Wire Drawers Ltd, based in the UK’s West Midlands area, has been sold after twenty-seven years in production. As a result the company has a range of wire drawing and ancillary plant for sale, including rod breakdown machines, finishing blocks (both heavy duty and smaller to cover size range from 20mm to 1mm), gravity blocks, coilers, die sizing machine and a stock of both diamond dies and tungsten carbide dies. There is also a wide range of lifting equipment including cranes, hoist, Pellaby swinging jibs and overhead track. The full range of equipment for sale can be seen on the WGH website, www.wgh.netai.net The non-ferrous business in brass, copper, phosphor bronze and aluminium wires is now being produced by fellow IWMA member Fox Wire and the steel wire business by Boswell Rod & Wire Ltd. Fox Wire Limited – UK Fax : +44 114 288 4874 Email : info@foxwire.co.uk Website : www.foxwire.co.uk Boswell Rod & Wire Ltd – UK Fax : +44 1384 480223 Email : kevin_perry@btconnect.com Website : www.boswellrod.co.uk

Meccanica Nicoletti winders from Techna International ▲ ▲

For large cable facilities a further Nicoletti development is the Automat 300, providing fully automated cable handling including payoff, electronic cable stretching control, drums supplied on pallets, fork-lift or conveyor, guide rollers for correct cable feeding, cable diameter measurement, winding and coiling (only one winder required), keyboard drum positioning and drum marking. The system can be integrated with customer order and service software and hardware for a remote system inspection.

Working on drums, coils, coils to drums, coils to coils, drums to coils and drums to drums, these units are designed to provide consistent and reliable winding and unwinding operations, from the most basic to the most sophisticated requirements. Stand or bench-mounted coil winders and unwinders Twin function stand-mounted take-ups and payoffs (Bob-Mat and CD series) Avomat 16 series PC-controlled take-up and coiler Linap series of semi-automated, high speed drum winding and unwinding systems • • • • The range includes:

Techna International Ltd – UK Fax : +44 1923 219700 Email : sales@techna.co.uk Website : www.techna.eu

Taiwan innovation, Shanghai manufacture

Important notice for members concerning Wirefirst.com Wirefirst.com, linked from the IWMA site, is an indispensable tool for tens of thousands of unique potential customers, researchers and industry professionals who visit the directory site every week. IWMA member companies are entitled to an entry, totally free of charge, in the Wirefirst.com online directory. If your company is an IWMA member we invite you to check that its details are recorded in the directory or, if already there, that they are fully up to date. Please contact the IWMA immediately with any changes or with your company information, if not yet included, using the submission form that can be downloaded from the website. For more information about the special members’ free package and optional extras, please visit: www.wirefirst. com/register.php

Shanghai Yessjet Precise Machinery Co Ltd was founded in 2002 by a technical team from Taiwan, and specialises in complete extrusion lines, auto-coiling and packaging systems for the wire and cable industry. Shanghai Yessjet has professional technical teams always looking to innovate and improve the user-friendly interface and flexible design of automatic wire and cable equipment. To provide technical service to the market, the Taiwan innovation department cooperates with Taiwan JYI Sheng Engineering Co Ltd, a company with over 30 years’ experience in production and machinery. The companies work together to improve and produce twisting and stranding machines for wire and cable. Shanghai Yessjet Precise Machinery Co Ltd – Taiwan Fax : +86 2169790811

Email : sales@yessjet.com Website : www.yessjet.com

4

WCN Issue N° 43 www.iwma.org

Single-phase AC welders facing extinction?

Single phase AC welders are under pressure of extinction due to new regulations coming up from several electric companies that require high demand customers such as customers that use electric resistance welders to have balanced loads on their electric systems. Another reason that we all have to respect is efficiency and conservation of energy. An unbalanced electrical load/system is not efficient and therefore losses of electric energy occur. The most commonly used AC welding control technology is single-phase. The majority of users try to balance the loads by connecting resistance welders to different phases, but this is commonly misinterpreted. When a single-phase resistance welder is used, the load can increase from zero to over 1,000 Amps only at a single phase. It is difficult to synchronise multiple resistance welders to weld at the same exact time for the same exact period of time unless all the welders are connected with a main control. This cannot be accomplished when these different welders are welding different material because the welding times and parameters are governed by each jobs’ material physical properties. The solution to this problem is the use of three-phase welder controls. The three electric phases are converted to DC and then passed to the welding transformer. The result is balanced load. Another very important attribute of the DC welder is that the time of the weld can be controlled very accurately. On the AC welding control the minimum weld time is a cycle, for example, on a 60Hz system, 1/60th of a second. On the DC welder controlling the welding time is easy as low as a millisecond (1/1000th of a second). There is also tighter control of the electrical parameters and therefore we can produce better quality welds for less energy. DC welding provides more consistent and enhanced quality welds than the older AC technology, resulting in increased performance. MEMBERS: PLEASE SEND YOUR EDITORIAL FOR FREE PUBLICATION IN THE FIRST WCN NEWSLETTER OF 2011, AND FOR INCLUSION ON THE IWMA WEBSITE, AT ANY TIME BETWEEN EDITIONS OF WCN One of the benefits of belonging to the IWMA is the facility to publish editorials in WCN, both the hard copy and electronic versions, completely free of charge and so reach more than 10,000 hard copy and countless electronic readers worldwide. In addition to worldwide distribution WCN is freely distributed at all major industry trade fairs and IWMA technical events. The next important upcoming exhibitions are Interwire, 3 rd –5 th May 2011, and wire Russia 2011, 23 rd –26 th May. WCN will be circulated during these exhibitions, a valuable additional and totally free marketing tool for members! Members should also bear in mind that the IWMA website can accept their editorials at any time during the year. NEXT ISSUE DEADLINE: 24 th November 2010

AIMwelder in action ▲ ▲

The drawback to this technology is initial cost, which, following the basic rules of economics, hopefully will decrease as demand and supply increases. The automatic welder option installed on AIM equipment uses a DC mid-frequency control that allows the user to define the weld times in milliseconds. Welding schedules and parameters for each individual job are saved with the job data on a single file, thus providing time savings for setup. The AccuForm product line, and its options, is offered for both 2D and 3D capabilities with wire bending capacities up to 16mm (5/8") and carries a two-year limited warranty.

AIM Inc – USA Fax : +1 630 458 0730

Email : info@aimmachines.com Website : www.aimmachines.com

Communicating important messages worldwide • Attracting interest from the important North American • and Russian markets Advising customers of personnel changes • Announcing major new developments • Celebrating winning of new contracts/orders • Staying one step ahead of the competition • Please send us your editorials (not advertisements) with supporting photos to:

info@iwma.org

If marketing and public relations is not your area of responsibility please make sure that the relevant department/person is aware of this information.

Thank you!

DEADLINE DATE IS 24 th NOVEMBER 2010 TO CATCH THE EARLY 2011 EDITION IN TIME FOR INTERWIRE 2011 AND WIRE RUSSIA 2011

6

WCN Issue N° 43 www.iwma.org

WiCAB with Tubotech 2011

The new WiCAB event will run concurrently with Tubotech 2011, the largest trade fair for the pipe and tube industry in South America. Over 16,500 trade visitors attended Tubotech 2009, the pipes, fittings and components international trade fair held every two years in São Paulo, Brazil. The fair featured the latest products and services in pipe, pipe making machines, raw materials, measurement and control technology as well as process technology tools, secondhand machines and test equipment. Some 420 companies from 15 different countries participated in the 2009 exhibition. Tubotech provides industry customers in Brazil and the surrounding countries with an excellent opportunity to gather information in their own continent and also offers international exhibitors a gateway to the major and very important Latin American market. The fair’s joint organisers are Grupo CIPA, Brazil and Messe Düsseldorf GmbH, Germany. Since 2004 Tubotech has been sponsored by the IWMA’s sister organisation the International Tube Association (ITA) and the ITA will again be supporting the 2011 edition that will take place in October at the well appointed Imigrantes exhibition site near Congonhas Airport in São Paulo. Hitherto, the two major sectors of cable and wire have not featured specifically as standalone exhibitions in the Brazilian calendar of trade shows. Now a new event, WiCAB 2011 – International Wire and Cable Fair, is set to be a key

Balloffet at Tubotech/Metaltech 2009 ▲ ▲

meeting point in South America for a huge industry that generates billions of dollars annually, as well as thousands of jobs, and is crucial for the development of Brazil. Previously wire drawing was included as a sub-sector at the concurrent Metaltech exhibition, which was supported by the IWMA. The IWMA has now confirmed its support for WiCAB 2011, which will be held in São Paulo from 4 th to 6 th October 2011 in conjunction with Tubotech. This combination of concurrent tube and pipe and wire and cable exhibitions is certain to heighten overall visitor interest as has been clearly evident in other venues around the globe in China, Russia, Southeast Asia and of course in Düsseldorf, home of the world’s largest and most important industry event. For preliminary details about these joint events please contact the organisers. Alternatively, the IWMA and ITA Secretariat can give practical information and advice about exhibiting. The associations hope to be able to offer special exhibitor packages for Tubotech and WiCAB later this year.

Grupo CIPA – Brazil Email : cipa@cipanet.com.br Website : www.cipanet.com.br

Wafios booth at Tubotech/Metaltech 2009 ▲ ▲

Siechem Technologies to implement CableBuilder ©

CableBuilder is the popular and powerful cable design software developed by Cimteq Ltd, the industry partner of InnoVites. InnoVites is the exclusive reseller in India.

InnoVites BV has announced that Siechem Technologies of India has selected CableBuilder © to further boost the efficiency and quality of its design and quotation processes. Siechem designs and produces a wide variety of specialised cables utilising state-of-the-art technology that includes an electron beam irradiation facility. Its products meet RoHS norms as per European standards. Siechem’s strategy is to be a partner for the design and production of specialised cables, so its design capabilities need to be at the highest levels of quality and efficiency.

InnoVites BV – Netherlands Fax : +31 318 541 966 Email : info@innovites.com Website : www.innovites.com

Siechem Technologies Pvt Ltd – India Website : www.siechem.com

7

WCN Issue N° 43 www.iwma.org

INTERNATIONAL WIRE & MACHINERY ASSOCIATION

EDUCATIONAL TRUST FUND SCHOLARSHIPS

W I R E & C A B L E I N D U S T R Y

40 Years of Excellence

THE IWMA EDUCATIONAL TRUST FUND – MAKING LEARNING PAY TODAY FOR THE TECHNOLOGY OF TOMORROW Walter Niehoff scholarships are worth up to £24,000 over two years to an individual trainee, student or apprentice engaged in study, research or training activities related to the wire, cable or wire product industries. Awards can also be made to industry institutions or establisments that offer training in the wire and cable sector.

LEARNING PAYS!

知识带来回报

DET ÄR VÄRT ATT LÄRA SIG! СТОИТ УЧИТЬСЯ! LERNEN ZAHLT SICH AUS!

IMPARARE PAGA! APPRENDRE, ÇA PAYE!

OPPIMINEN KANNATTAA!

¡APRENDER PAGA!

FOR MORE DETAILS PLEASE VISIT www.iwma.org/education.php

Tradition combined with innovation August Hildebrandt Cable Drums, established in 1868, is among Europe’s largest cable drum producers with more than 130 employees and six facilities.

Steel drums with a diameter of between 1,200mm and • 6,000mm with a maximum capacity of 100,000kg August Hildebrandt can assist in developing new con- structions relative to user needs to save costs, and offers various options for wooden drums including iron tyres, cable exit hole, ramps or heat treatment (ISPM 15/IPPC), pressure impregnation, painting, marking and many more. August Hildebrandt guarantees a high quality product certificated with the DIN ISO 9001 and DIN ISO 14001. This capability, and the long tradition of August Hildebrandt GmbH, qualifies the company as a solid business partner for the cable, wire, tube and belt producing industry. IBA enters an exclusive agreement with Dasheng IBA has extended its offering by adding the Dasheng Electron beam accelerators to its portfolio of high current IBA-Dynamitron ® (formerly called RDI Dynamitron ® ). As of 1 st April 2010, IBA will be the exclusive distributor of the Dasheng E-beam accelerators outside of China. IBA will also be responsible for providing installation and support services to Dasheng E-beam accelerator customers outside of China. “Not only will this collaboration extend our IBA Dynamitron portfolio but Dasheng will also bring in the collaboration its expertise in cable and heat-shrink products, reel-to-reel under beam systems, irradiation process and related compounds,” said Serge Lamisse, president of IBA Industrial. “Our customers will have access to both product lines. Dasheng E-beam accelerators are mainly targeted for R&D facilities or lower current applications, while the original IBA Dynamitron will focus on high current, high throughput applications,” he explained. “Entering such collaboration with IBA allows us to extend our geographical coverage while offering our users the support and the service of IBA around the world,” added Mr Kenneth Hsiao, CEO of Dasheng. Dasheng E-beam accelerators and IBA Dynamitrons are high technology accelerators designed for both industrial processing and research applications. Wire and cable insulation crosslinking with electron beam improves cable insulation strength, durability and resistance with higher standards than any other technology. Every year, a greater percentage of automotive and aeronautics cables are treated with electron beam processing. August Hildebrandt GmbH – Germany Fax : +49 385 645 3064 Email : contact@cabledrum.com Website : www.cabledrum.com

Tradition and expertise are combined with innovation and the latest state-of-the-art production of modern drums. Customers are provided with technical assistance, individual solutions and a broad area of expertise. The flexibility of production and design enables August Hildebrandt to produce drums according to individual customer specification. Drums are supplied assembled or as kits for container shipment. The August Hildebrandt product range includes: Wooden drums with a diameter of 600mm – 4,500mm • with a maximum capacity of 50,000kg Plywood drums of 300mm – 1,500mm diameter • Plastic drums of 250mm – 800mm diameter • Why not take advantage of the IWMA’s educational award scheme? Every two years the IWMA funds an Educational Trust Scheme that provides a financial award of up to $24,000. The award is paid to an institute, training organisation, university, college or similar establishment for the benefit of an individual trainee, student or apprentice engaged in study, research or training activities related to the wire, cable or wire product industries. Awards can also be made to industry institutions or establishments that offer training in the wire and cable sector. Members are invited to submit an application, which, when received with supporting documentation, will be judged by the Educational Trust Fund Council. Applicants may be employed by a company or be students, apprentices, individuals at colleges, institutions, universities or other places of research and learning who are introduced by an IWMA member. They should be committed to the study and future employment in the field of engineering applicable to the wire, cable or wire product industries. Applications from educational and training establishments can also be considered as described above. Previous individual award winners are not eligible to apply. Applications should be received before 31 st December 2010. For more information please visit: www.iwma.org/ education.php or contact the IWMA Secretariat. Walter Niehoff Scholarship

IBA Industrial – Belgium Fax : +32 1047 5992

Tel : +44 1926 834680 Email : info@iwma.org

Fax : +44 1926 314755 Website : www.iwma.org

Email : industrial.eu@iba-group.com Website : www.iba-industrial.com

9

WCN Issue N° 43 www.iwma.org

Success at wire 2010 British company Pressure Welding Machines (PWM), which designs and manufactures high performance cold pressure welding equipment and dies for the world market, reported excellent visitor traffic and sales at wire 2010.

Niehoff opens new factory Maschinenfabrik Niehoff has opened a new factory building in Schwabach, Germany, close to the company’s headquarters. The building includes the assembly department, paint shop, test rig and testing area, the packing and shipping department, offices, recreation rooms, building services and training workshops. Production has 170,000ft² more space than before, enough to sustain a throughput of 100 drawing lines a year, with 15,000ft² dedicated to offices and auxiliary rooms. The 40-foot high production areas, and the office and other rooms, have radiant heat ceilings and air-conditioning systems and a sensor-controlled natural lighting system. The building meets low-energy standards, and features the latest in plant design, building management technology, and energy efficiency. The architecture, interior furnishings, geothermal heat systems, heat pumps, pneumatic system compressors, drives of production machines and other devices are designed so that energy consumption is kept to a minimum and the heat dissipated by the equipment can be recovered.

PWM’s stand at wire Düsseldorf 2010 ▲ ▲

Steve Mepsted, managing director of PWM, said: “Visitor traffic was much better and more consistent than we had anticipated and the quality was excellent. We noted a marked increase in the number of visitors from India, Iran and Turkey. Our large EP500 and P1500 rod welders attracted a high level of enquiries from manufacturers looking for a reliable, energy efficient method of welding large copper and aluminium rod sections. “We sold the EP500 rod welder at the exhibition to a Brazilian wire and cable producer, and the P1500 machine was purchased by a Portuguese company. Our versatile portable models, especially the M101 and HP100, also proved popular with buyers. The show generated a substantial number of positive sales leads.”

PWM will be exhibiting at Wire & Cable India in November.

A new testing area at the Schwabach facility ▲ ▲

Maschinenfabrik Niehoff GmbH & Co KG – Germany Fax : +49 9122 977 155 Email : info@niehoff.de Website : www.niehoff.de

Pressure Welding Machines – UK Fax : +44 1233 820591 Email : pwm@btinternet.com Website : www.pwmltd.co.uk

The AZ 1040 is the successor of the tried and tested AZ 2004 timing belt drive, introduced by Uhing in 1991 and a bestseller ever since. The AZ 1040 is made of an undivided profile with integrated carriage guide. This design allows for a greater free stroke in comparison to the predecessor. Mounting and integration possibilities are also enhanced due to the integrated headpieces made of the same profile. The tried and tested T-slot principle has been adopted for securing attachments. Customers can take advantage of the technical improvements, modern design, and a 30% price deduction. New timing drive belt from Uhing

Joachim Uhing KG GmbH & Co – Germany Fax : +49 4347 906 40 Email : weber@uhing.com

Website : www.uhing.com

The new AZ 1040, successor to Uhing’s AZ 2004 ▲ ▲

10

WCN Issue N° 43 www.iwma.org

How will wire/Tube Düsseldorf 2012 compare with this year’s event?

However, the most important fact was that a very high proportion of visitors came with serious intent to review and purchase equipment once again as the world economic situation improves. One IWMA board member reported that wire 2010 had greatly exceeded his expectations and had been more successful for him than the previous two editions. Many other exhibitors shared this experience and the IWMA itself enjoyed a more fruitful exhibition than 2008. Membership applications at the IWMA stand in hall 11 were up by 100% compared to two years ago. Once again the IWMA’s facilities were well patronised by members. Apart from hosting the Educational Trust’s John C Hogg Travel Awards ceremony on 14 th April the stand was also the venue for several important meetings: a delegation from Sinosteel Zhengzhou Research Institute of Steel Wire Products, the IWMA’s representatives in China; with the Shanghai Electric Cable Research Institute (SECRI) to discuss cooperation with a technical conference at wire China 2010 and a board meeting of the IWMA Educational Trust.

Drama is the only word that can sum up the final two days of the 2010 wire Düsseldorf exhibition. During the course of Thursday 15 th April details of the Icelandic volcanic eruption and its implications for air travellers became known and many visitors and exhibitors alike turned their thoughts to the problem of returning to base.

The IWMA Executive Board takes a bow at the anniversary dinner ▲ ▲

The IWMA has always considered wire Düsseldorf to be the very best organised industry trade fair and has great respect for the professionalism of the organisers. Having masterminded what by common consent was an excellent exhibition, Messe Düsseldorf worked hard in its last two days to assist stranded participants as much as possible by encouraging car sharing for overland travel in Europe as well as facilitating the extension of visas. Many tales of epic return journeys and considerable delays waiting for flights reached the ears of the IWMA. All concerned are to be commended for their patience in the face of an uncontrollable event of Mother Nature. Despite this nothing should detract from the undoubted success of the 2010 exhibition. The bare facts do not tell the complete story. There were 1,219 exhibitors from 52 countries, an increase of 7.3% over 2008. Despite this increase the amount of exhibition space was down with exhibitors carefully trying to control costs following the economic meltdown of 2008/2009. Visitor numbers were also down slightly, with the organisers reporting a total of 69,200 from over 100 countries for wire and Tube combined.

Some of the 270 guests at the IWMA anniversary dinner at wire Düsseldorf ▲ ▲

Members of the IWMA executive board were able to thank Sinosteel’s president Mr Yang Jianhua personally for his organisation’s excellent efforts in securing many new members in China and to give the association’s full support for further development in the People’s Republic. At the meeting with SECRI the IWMA Technical Sub-Committee agreed to source at least six international technical papers for a morning session at the wire China supporting conference on 22 nd September 2010. It was also agreed that the conference would be held at the exhibition venue, the Shanghai New International Exhibition Centre (SNIEC), and the international papers session would be chaired by the IWMA. Away from the IWMA stand other gatherings during wire 2010 included the IWMA’s 40 th anniversary dinner at the Congress Centre on 13 th April and an important meeting with the Wire Association International (WAI) and ACIMAF to review last year’s Istanbul conference and discuss possible venues for future technical events.

IWMA Educational Trust John C Hogg Travel Award winners pictured on the ▲ ▲ association stand with Stephen Wood (centre left), Joachim Schafer (back centre) and Friedrich Kehrer (centre right)

12

WCN Issue N° 43 www.iwma.org

wire/Tube Düsseldorf 2010

In a moving tribute that produced a standing ovation Stephen Wood made a special presentation to Don Tucker for his 40 years involvement with the IWMA and his many years of service on the Executive Board, as a past chairman (1980-83) and as chairman of the TSC (since 1984). Don first became involved with the IWMA through his then employer and IWMA founder member Warbrick (Engineering Specialities) Ltd before setting up his own business, TM Associates, in 1981.

The anniversary dinner attracted more than 270 members and VIP guests, including the one surviving founder of the WMA (the original name of the IWMA) Bill Merchant, who was the guest of honour. In his speech at the dinner IWMA chairman Stephen Wood recognised and paid tribute to the representatives of other important industry organisations, to the travel award winners and to Messe Düsseldorf’s key personnel. Together with Technical Sub-Committee (TSC) chairman Don Tucker he presented the 2010 Harry W Bennett Non-Ferrous and Ferrous speaker awards respectively to: Sean Harrington of Ceeco Bartell Machinery Systems, winner of the Walter ▲ ▲ Niehoff Non-Ferrous Trophy Sean Harrington, Ceeco Bartell Machinery Systems, • Canada, for his paper at the Istanbul Cable & Wire conference in November last year: “Reducing cost in manufacturing compact conductors using roll form stranding”

Düsseldorf 2010 was a very eventful exhibition – in more ways than one. The next edition, wire/Tube Düsseldorf 2012, will be held slightly earlier in the year from 26 th to 30 th March 2012. Within days of the end of this year’s trade fair the IWMA was already receiving requests for reservations of space in the association’s exhibitor group area, clearly demonstrating the continuing importance of this exhibition and that it will take much more than volcanic dust to diminish wire Düsseldorf’s reputation as the pre-eminent show for the wire industry. Don Tucker, recipient of a special award from the IWMA for 40 years of ▲ ▲ outstanding service to the association

C Coffin, D King, H Depamelaere, W van Raemdonck • (who collected the award on behalf of all the co-authors), NV Bekaert sa, Belgium, for their paper also at Istanbul last year: “Evaluation of high temperature behaviour of Zn and ZnAl coatings on core wires and strands for ACSR, ACSS and alike overhead power conductors.” IWMA Technical Sub-Committee chairman Don Tucker (left) with chairman ▲ ▲ Stephen Wood and Walter Niehoff Ferrous Trophy Award winner Walther van Raemdonck (right), representing NV Bekaert at the anniversary dinner

Friedrich Kehrer (left) and Joachim Schafer (centre) of Messe Düsseldorf help ▲ ▲ IWMA chairman Stephen Wood cut the birthday cake they presented to the association at its wire Düsseldorf anniversary dinner

13

WCN Issue N° 43 www.iwma.org

Ajex & Turner offers a wide range of dies and machinery, including its horizontal type in-house polishing and re-cutting machine, TCD-11. It is said to be an ideal solution for grinding and polishing a range of tungsten carbide dies, extrusion dies, cold heading and round wiredrawing dies. The TCD-11 consists of a heavy solid base with X-axis, Y-axis table and a five-inch chuck for holding the die, along with a high-speed grinding spindle. There is also a vertical type machine, the TCD-12, as well as machines for polycrystalline and diamond dies; an ultrasonic machine; plus single-head, twin-head and six-head wire die polishing machines. The machine is designed for working the bearing position and reduction angle in one setting. The company’s wiredrawing dies, shaped and pressure dies, are suitable for manufacturing copper, stainless steel, medium- and high-carbon steel, brass, bronze, nickel, tungsten and aluminium products. The company provides PCD and natural diamond dies in sizes ranging from 10micron to 35mm, and tungsten carbide dies in sizes from 0.1mm to 150mm. These dies are mounted in powder metallurgy for support on all sides, allowing the dies to be used in hot wiredrawing. This process also allows the dies to withstand the drawing forces encountered, thereby reducing die breakage and improving die life. Wire dies and die shop machines

For quality control Ajex & Turner is equipped with the Conoptica die profiler, through which the inner geometry of the die is provided along with every die supplied. Ajex is a distributor of Metalube and TKT wire drawing lubricants for copper, aluminium and steel.

Ajex & Turner Wire Dies Co – India Fax : +91 11 239 40226 Email : sales@ajexturner.com Website : www.ajexturner.com

3-axis detector The InteliSENS LN series, 3-axis lump and neck detector is the latest product from Proton Products International, designed to detect, alarm and report surface quality defects as they happen. Applications include braiding, cable insulating and jacketing, rewinding and coiling. Three-axis coverage significantly increases the probability of lump and neck detection, covering a greater circumferential area and significantly reducing the minimum fault size that can be detected by older two-axis methods. Three LED constant light sources cover the complete circumference of the product. The LED optical receivers detect any immediate change in the surface profile, alarming and reporting the height, length and location of lumps or neck-downs along and around the product. The InteliSENS LN series can be supplied with an audible/visual alarm and fault printer, which alerts the operator and records the type, size and position of the fault and the time the lump or neck was detected. InteliSENS LN series can be used as a standalone device. The AiG-2 display unit can be connected directly to the gauge head or can be positioned up to 100m away using the interconnection cable. Alternatively the InteliSENS LN series gauge can be connected to a host PC or PLC using Ethernet IP, Profibus, Devicenet or other popular digital or analogue communication.

Proton Products International – UK Fax : +44 1494 670808 Website : www.protonproducts.com

14

WCN Issue N° 43 www.iwma.org

Wire screening technology In addition to stranding fibre optic elements and insulated conductors, Rosendahl offers an SZ technology solution for the stranding of single wires for screening applications. For the cable manufacturer this offers the opportunity of a wire screen over cables of nearly every product size.

New products for 2010 Huestis Machine Corporation has provided precision made machinery and solutions to manufacturing problems for over eighty years. Made up of two divisions, one serves the medical industry while the industrial division serves the military, wire and cable and other industrial sectors. Ever changing with the times and to meet the expectations of design engineers, Huestis Industrial has launched new product lines for 2010 to maintain the customer’s competitive edge. New products for 2010 include: Ceramic “Air Miser” air wiper – a full length, replaceable ceramic insert that provides wear resistance and protection from misalignment, and human error. “Down drafter” air wiper – with drying jets front and rear and a bottom drain in the centre. The drain is threaded for a fitting and pipe or hose to capture and return the process liquid to the system. Optional metering valves are available for balancing the airflow between the front and rear jets for the most beneficial mix for each product application. The down drafter is available from 1/16" to 1". This unit also employs the Air Miser jet system that reduces the air usage and consumption. Shaftless payoff and take-up – to address the previously overlooked circuit size market. Huestis cold welders – to handle all needs from superfine to rod breakdown in hand-powered manual units. Huestis Industrial – USA Fax : +1 401 253 7350

SZ-process for screening applications ▲ ▲

The machinery is equipped with a number of stranding discs, driven by a central torsion shaft. The design concept facilitates a wide range of wires without any changes on the machine. The machine design is laid out to reach a high number of twists in one direction with a minimum overall length. The complete unit is prepared to run high production speeds controlled by a high dynamic AC motor. This SZ stranding process is beneficial for continuous cable production. Combined with the filling and jacketing process a one-step-production is secured. The equipment can be integrated into existing sheathing lines.

Rosendahl Maschinen GmbH – Austria Fax : +43 3113 5100 59 Email : office@rosendahlaustria.com Website : www.rosendahlaustria.com

Email : sales@huestis.com Website : www.huestis.com

Solid leads for Pave Automation from wire 2010

Pave Automation, the UK-based designer and manufacturer of high performance wire forming machines, found that wire 2010 exceeded expectations. “The stand was busy throughout the show, and the fair proved an excellent opportunity to meet clients and make new contacts,” said Pave’s managing director, Tony Perna. “We had a lot of visitors from Europe and the Baltic states, as well as from India, who were looking to acquire reliable, high output, low cost wire forming units for a variety of applications. “The event provided an ideal platform to showcase our innovative user-friendly touch screen technology which reduces downtime and operator training costs, and we obtained some solid leads and requests for trial runs of our competitively-priced machines.” Pave Automation Ltd – UK Fax : +44 1733 563500 Email : pave@enterprise.net Website : www.pave-wire.com

16

WCN Issue N° 43 www.iwma.org

New aluminium conductor plant starts production in Turkey In January 2010 A Kablo Sanayi ve Ticaret AS in Istanbul completed an aluminium conductor plant. ESM AS designed the project for aluminium rod and conductor production. There is a growing demand for aluminium conductors, due to a rapidly increasing copper price in the market, but there is a bottleneck for the supply of aluminium conductors. More details of the completed project: Project: Aluminium and alloy rod and conductor production in Istanbul, Turkey. Owner: A Kablo Sanayi ve Ticaret AS, sister company of Sahinler Metal, Turkey. Capacity: 24,000 tons per year of aluminium and alloy rod with continuous rod casting and rolling line, and 18,000 tons per year of aluminium and ACSR conductor production. Production condition: The plant began production in January 2010 and achieved full capacity in May 2010. Supplier: The main production lines and machinery were supplied by ESM AS, products of Pioneer Machinery Co Ltd, Taiwan. The main production machines and lines were a continuous rod casting line, four rod breakdown machines, two tubular stranders (1+6/630mm), one rigid strander (1+54/630mm) and two rewinding machines and accessories. This new plant is designed to meet some of this demand.

Achieving higher speeds In line with the philosophy of continuous development at PS Costruzioni, the engineers at PS have been working on improving production speeds.

Improved PS 200/6-B spools 25% faster ▲ ▲

The automatic coiling line, model PS 470/16, handles NYM cable from 2x1mm 2 up to a maximum of 4x6mm 2 . The first goal of the engineers was an increase in linear speed. Compared to the previous PS 470/16, linear speed has been increased by 15% (to 20,000 metres per hour). The machine will now produce 3.35x100m coils of 5x2.5 NYM cable. The second goal was to reduce the need for mechanical maintenance. To achieve this the main motor has been installed in axis with the winding plates. This removes the need for mechanic transmission, and consequently less maintenance is needed. The double head automatic spooling line, model PS200/6-B, handles cable within the range of 16AWG to 10AWG. Again, the goal was to increase the linear speed. Now producing 4 x 152m spools per minute for 12AWG (the equivalent of 36,500m per hour) means that linear speed has been increased by 25%, compared to the previous PS 200/6-B.

China-based, with European outlook PS Costruzioni Meccaniche Srl – Italy Fax : +39 03968 98769 Email : ps@pscostruzioni.com Website : www.pscostruzioni.com

Launched by the Gauder Group in 2008, Daloo is the first low cost wire and cable machinery manufacturer located in China but backed by European experience. Daloo offers rotating machines with basic functions, of simple design and steady quality. The company will exhibit a rigid frame strander at wire China 2010, as well as components such as a payoff/take-up and pulling caterpillar. wire China stand W3C01 Daloo Machines – PR China Fax : +86 519 8548 3557

A view inside the A Kablo plant ▲ ▲

ESM Elektro Sistem Muhendisligi AS – Turkey Fax : +90 212 222 4642

Email : mad@esm-as.com.tr Website : www.esm-as.com.tr

Email : sales@daloo-machines.com Website : www.daloo-machines.com

17

WCN Issue N° 43 www.iwma.org