EuroWire March 2023

Focus on Germany

Investing in new machines can pay off Does it pay to invest in new wire and cable machines when existing ones, which are written off, are still working perfectly? Konrad Dengler, on behalf of machinery manufacturer Maschinenfabrik Niehoff, looked at this question in relation to the company’s equipment. The MSM 86 + R 502.2 RBD line

down coilers can draw two copper wires to a final diameter of 2.6mm at a speed of 24m/s, corresponding to a production output of 8t/h. Compared with older lines, whose production speed is limited to 21m/s, the application of an MSM 86 + R 502 drawing line reduces production times by 12.5 per cent, which corresponds to a considerable cost-saving potential. For example, with an annual production time of 7,000 hours and an hourly production line rate of €180, this savings potential amounts to €157,500 per year. These cost saving potentials indicate that it is worthwhile for wire and cable manufacturers to invest in new machines, even if the old ones still operate adequately. Niehoff is currently working on a new continuous annealer that requires less input energy for recrystallisation of the wires passing through. The company will present the next development stage – the RBD MSM 88 + R 503 line – at the wire 2024 trade fair. Maschinenfabrik Niehoff

A further 12 per cent reduction in energy consumption results from combining an MSM 85 with an R 502 annealer, which is designed to use the annealing energy more efficiently than its predecessor and avoids eddy currents in the annealing housing. The latest result of the technical development is the drawing line MSM 86 + R 502.2, which allows an additional six per cent of drive energy to be saved by using smaller drawing capstans and directly coupled drive motors in the fast part of the machine. For drawing, annealing and spooling 8mm-diameter wire to a final diameter of 2.05mm, an M 85 + R 500 + S 630 D line requires around 210 kWh/t. An MSM 86 + R 502.2 line needs only 129 kWh/t – 38 per cent less. Considering an annual production of 48,000t and an industrial electricity price of €0.27/kWh, the saved amount of energy of around 80 kWh/t is equivalent to an annual cost saving of more than €1mn. As modern RBD lines can be reliably operated at higher production speeds, their application reduces production times for a given production quantity. For example, an RBD line consisting of an MSM 86 drawing machine, an R 502 annealer and two WF 801 automatic

Such worthwhile when new machines that represent the latest technology help users save operating costs. Niehoff, a manufacturer of machinery for drawing and further processing of wires made of non-ferrous metals, can show this by means of rod breakdown (RBD) lines. Significant cost savings result from a reduced need for drive energy and shorter production times. Niehoff introduced the RBD machine type M 85 to the market in 1962 and has since continuously developed the technology. In 1998, it launched the MSM 85 model with electronically controlled individual drives, and in 2013 the RBD machine type MSM 86. The technical progress concerning these machines, and the drawing lines built with them, is that increasingly less drive energy has been needed. When considering an RBD line consisting of an MM 85 drawing machine, a two-wire version of the M 85 and an R 501 continuous resistance annealer as a basis for comparison, the RBD line MSM 85 + R 501 needs around 20 per cent less drive energy. This saving mainly comes from the electronically controlled direct drive of the drawing capstans and the resulting slip minimisation. investments are

GmbH & Co KG www.niehoff.de

Quality control in extrusion lines with X-ray technology Sikora has been producing X-ray measuring systems for more than 20 years. For single-layer applications, the company has developed the X-Ray 6000 Pure. The new X-Ray 6070 Pure and X-Ray 6120 Pure models are available for measuring cables from 6 to 65mm and 10 to 110mm, respectively. In addition to single-layer products, the total wall thickness of many multi-layer cables can be measured. In combination with the Ecocontrol Pure, a processor system with a high-resolution 15" touchscreen display, the measured values are displayed for further analysis. For measuring up to three layers, Sikora also offers the X-Ray 6000 Pro. The X-Ray 6000 Pure is a safe and powerful alternative to conventional measuring technologies. The system allows the wall thickness to be constantly monitored and reduced to the minimum tolerance value. Safety margins can be reduced and the automatic control keeps the dimensions within specification. Sikora AG www.sikora.net

The new X-Ray 6000 Pure is used for measurement of single-layer cables

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March 2023