Optimum process technology and energy saving

NIEHOFF’s new MSM 86 rod breakdown concept (with an application example).

At an in-house exhibition in Spring 2014, Maschinenfabrik NIEHOFF introduced its new completely developed type MSM 86 rod breakdown machine designed for wires made of copper, copper alloys, aluminum, aluminum alloys and other non-ferrous materials.

Design features

Being of modular design, the MSM 86 with electronic controls offers users more options in terms of process technology. The controls allow drawing/annealing with minimized slip, resulting in high quality wire surfaces and maximum energy savings. The optimized wire path, the innovative high pressure cooling of the drawing die holders and the optimized reliable fully submerged drawing basin for lubricant cooling, all contribute to the high wire surface quality. Capstans which are not in use are switched off. In addition, design changes have been made to reduce maintenance requirements and improve access to the different operation and maintenance areas. A quick drawing die change system reduces downtime when changing the machine setup for different dimensions and enhances productivity. The drawing machine also features a highly reliable drawing emulsion and gear oil separation system using mechanical sealing. The result is an ergonomic, user-friendly system which is easy to maintain and requires less frequent maintenance.

Operation

Like all other new machines built by NIEHOFF, the MSM 86 rod break down line is operated by means of the newly designed and standardized NMI (NIEHOFF Machine Interface), a network-compatible color touchscreen which features a clear task and user-oriented navigation structure and enables an easy intuitive operation.

Energy efficiency and performance

The total energy consumption of the new MSM 86 machines is up to 10% lower than of its predecessor model MSM 85 and 20% lower than of conventional rod breakdown machines. The MSM 86 is designed to be combined with the new R 502 continuous resistance annealer. With an annealing power of 600 kW, the R 502 is the most powerful annealer made by NIEHOFF to date. Power consumption is reduced by 20% compared to state-of-the art DC annealers due to the newly developed voltage control system NAC (NIEHOFF Annealing Controller) and the AC annealing principle.

Application example

The rod break down line presented at the above mentioned in-house exhibition (a 13-draft two-wire MSM 86 + R 502 + SND 801 + SPH 1001 rod breakdown line) is capable of producing, for example, two wires with a diameter of 2.6 mm at a production speed of 24 m/s resulting with an output of 8 tons per hour.
The SND 801 automatic double spooler is designed for a bigger wire range (diameters of 0.8 to 4.5 mm for copper wire and 1.0 to 6.0 mm for EC grade aluminum wire) and can transfer the wire automatically from full to empty spool with a very high successful transfer rates. Another special feature is that the threading of the wire process has been streamlined. Foundations requirements and machine installation have also been simplified.
The SPH 1001 automatic single portal spooler features automatic spool changing for increased productivity of the overall line. The SPH 1001 spoolers are built in two versions: Fully automatic and semi-automatic. Both versions are suitable for spools with 1000 mm flange diameter or less down to 630 mm. In this case a lifting table is necessary. The difference between both spoolers is their degree of automation: While the fully automatic version works with automatic wire and spool handling, the semi-automatic version is characterized by manual wire handling and automatic spool handling. The electrical system with independent PLC enables flexible integration of the spooler into existing or new lines.

Technical data MSM 86 line, two-wire version

Max. production speed 40 m/s
Max. production output 45,000 t/a (For 7,000 hrs operation and 80% utilization)
Max. inlet diameter 2 x 8.00 mm
Finished wire diameter 2 x 1.20 – 2 x 3.80 mm, 1 x 1.20 – 1 x 5.00 mm