Can anyone suggest on how to minimize the overlap wires on bunching machines?

Hello,

If "overlap wires" is excess wire length being bunched up, it would seem to me that your pay offs are not tensioned or controlled correctly.

If "overlap wires" means something else then please define the problem clearly. Thank you.

Regards
Peter J. Stewart-Hay
Principal
Stewart-Hay Associates
www.Stewart-Hay.com
519 641- 3212

Good day!

I have checked the tension of our bunching machines in our other plant and the tensions are good (3 bars).
The overlap that I was referring to is one wire is above the other wires when we are doing bunching process.
We are having too much problem once we are doing extrusion process because are encountering wirebreaks since we are using pressure toolings.

Thanks again for your reply.

Joseff

Good day!
I have checked the tension of our machines and it is good. All of them have the same tension.
The overlap that I was referring to is that one of the wires is above the other wires. Once this thing happened then we are encountering wirebreaks on our extrusion machines.
Thanks!

Joseff

Hello again,

The formal definition of a bunched wire is individual wires twisted together in a non-geometric (open helix, non-layer) configuration to form a flexible electrical conductor.
- Is your bunching as per the above definition exactly what you are doing?
- Are you using a single twist machines or double twist machines?
- We noted that you advised that the tension on the wires was OK by indicating brake air pressure. That is subjective. You should be measuring the wire tensions on each pay off.
- We indicated that your pay-off tensions may not be controlled correctly. If you can see that the wires are snagging and bouncing around between the pay off and the buncher, then there is clearly a problem with some or all of the pay offs.
- Are you using live (rotating) pay offs or dead (stationary) pay offs?
- Is your other plant having similar problems as well or is it using different machines and processes?
I also think you should read these WAI Forums threads:

www.wirenet.org/forum/viewmessages.cfm?Forum=8&Topic=609
www.wirenet.org/forum/viewmessages.cfm?Forum=8&Topic=560
www.wirenet.org/forum/viewmessages.cfm?Forum=8&Topic=557

Regards
Peter J. Stewart-Hay
Principal
Stewart-Hay Associates
www.Stewart-Hay.com
519 641- 3212

Greetings from Toronto,

Vettecoupe make a number of very valid points especially when you are producing on double twist machines. As Peter stated please check topics:

www.wirenet.org/forum/viewmessages.cfm?Forum=8&Topic=560
www.wirenet.org/forum/viewmessages.cfm?Forum=8&Topic=557

These will give you a pretty good idea what to look for.
In our industry pay-offs are notoriously neglected and generally do not provide good tension control.

Check the use of a tension equalizer for your application. This device (if you are running single wires) will make the operator’s job much easier and provide you with significantly better tension control over your product.

www.howarequipment.com/products/wire_pay...ensioning_equipment/

We would all appreciate if you could provide the answers to Vettecoupe’s questions allowing us to better understand the problem and possible solutions.

Best Regards,

Willy Hauer
Howar Equipment Inc.