Concepts on “Industry 4.0”

March 2018 — Niehoff manufactures machinery for the wire and cable industry. At “wire” the company will exhibit a multiwire drawing line “MMH 121+RM 161”, a “D 632” double twist bunching system, an NPS double spooler “SV 402 D” and a a rotary braiding machine “BMV 16”.

On the upper floor of Niehoff’s booth at “wire” 2018, the company’s after-sales-service will be showcasing consumable / wear parts as well as its “Niehoff Original+” products. These products help increase the efficiency of Niehoff systems over the long term. There, the visitors will also learn how they can use Niehoff’s new digitization concept. 

In the implementation of concepts on the “Industry 4.0” topic, Niehoff will set completely new standards. Process monitoring and machine condition analysis are possible at all time because the most varied manufacturing data of modern Niehoff systems can be collected and analyzed. Thus, all details related to production technology are transparent and within the field of the user’s vision resulting in a further increase of effectiveness of Niehoff systems, a more efficient maintenance and shorter downtimes. Niehoff optionally offers for its machines additional sensor packages which are tailored to the application.

The multiwire drawing machine type “MMH 121” is designed to draw at one level simultaneously 16 copper wires (Cu hard) with a maximum diameter of 2.05mm (AWG 12) on a finished diameter of 0.15mm (AWG 34½ ) to 1.40mm (AWG 15) and can operate at speeds up to 40m/s (7870fpm).The machine is combined with an inline annealer type “RM 161”.The machine is operated by means of the standardized NMI (Niehoff Machine Interface), a network-compatible touchscreen which features a clear task and user-oriented navigation structure and enables an easy intuitive operation.The sensor technology of the machine makes it possible to use machine, production and process data according to Industry 4.0.

The MMH machines are particularly foreseen for copper and aluminum wires and of modular design. Therefore, these machines can be readily adapted to the specific requirements of the users. To date, more than 1,500 MMH lines are in operation world-wide. Wires drawn on this equipment exceed the most demanding specifications and processing requirements as far as electrical conductivity, surface quality and mechanical properties and can be processed to multiwire bundles with outstanding characteristics. The “D 632” type double twist bunching machine is able to produce strands with 0.09mm² to 6.00mm² (AWG 27½ ... 9½) cross section and a steplessly variable lay length of 6mm to 100mm. The maximum number of twists is 7,000twists/min and the maximum production speed 300m/min (984fpm). The machine is ideally suited for the manufacture of strands of copper alloy wires (e.g. CuMg alloys) for automotive wires. 

Equipped with energy-saving rotor drive

The D 632 is equipped with an energy-class IE3 energy-saving rotor drive and an adjustable fan drive in the sound proof cabin. A further special feature is the patented opto-electronic NBAT system (Niehoff Bunching Automatic Traverse) which allows spools to be perfectly spooled. Spooled wire can then be payed-off tangle-free at extremely high speeds with no damage. Other features include the service proven energy-saving single bow (Eco-Bow) design, the non-contact transmission of machine data within the machine and the NMI (Niehoff Machine Interface) touchscreen display with color user interface and simplified navigation structure. The sensor technology was implemented in the machine with particular regard to the requirements of Industry 4.0 capability and enables diameter measurement of the finished bunched strand as well as the continuous monitoring of the preset lay length. 

The NPS double spooler type “SV 402 D” is part of the Niehoff Package System (NPS), a highly efficient, safe and economic handling system for automotive wires. The spooler is foreseen for in-line operation with extrusion lines and can spool insulated wires with a cross section of 0.13mm² (AWG 26), copper wire strands with 0.22mm² … 6.0mm² (AWG 23½ … 9½) cross section and copper alloy strands and can be operated at a maximum speed of 1,800m/min (5,900fpm). 

The sensor technology of the machine makes it possible to use machine, production and process data according to Industry 4.0. The protected conical wire laying technology offers a secure, stable and tangle-free package on the NPS spools both when full or partially empty. Thus, NPS spools enable highest cable pay-off speeds into downstream processes. The most recent highlight of the NPS is the completely new developed NPS PP spool series. These collapsible multiway plastic spools are offered in the same dimensions as all NPS ABS spools at a very cost efficient price. The spools of the NPS PP series also offer the same production safety and the same application potential like all 3 million NPS spools made of ABS plastic and are fully compatible with them.

The 16-carrier lever arm rotary braiding machine “BMV 16” is designed for processing of bare or plated round or flat wire made form copper, aluminum or stainless steel with single-wire diameters ranging from 0.05mm to 0.3mm (40 … 281/2 AWG) as well as artificial yarn and fibers. Like all other models in the BMV series, this machine features infinitely adjustable electronic control of line speed and braiding pitch as well as an automatic central lubrication system. The machine demonstrated at the booth is equipped with the WTM (Wire Tension Monitoring) system:The tension at each spool carrier is measured by means of integrated measurement electronics at the dancer and transmitted to the control panel of the BMV. There, a visualization of the tension is carried out for each spool carrier. Mean values and extreme values are displayed to the operator who can quickly react to possible changes and impact positively on the quality of the braiding product. By means of other monitoring systems, some optionally available, BMV braiders can operate unattended for extended periods and without frequent operator intervention. Also for the braiding machines new functionalities have been developed according to the requirements of Industry 4.0. 

Complete solutions from a single source

H. Folke Sandelin AB (HFSAB) will also exhibit at the Niehoff booth. The company established in Sweden is the global market leader in the area of lead extruders and cable stripping machines. By means of a reconditioned screw of a horizontal lead extruder HFSAB demonstrates its capability to overhaul used machines and to bring them to a like-new quality level. Niehoff develops and builds with an experience of more than 60 years all machinery – with the exception of extruders – needed for the production of wires made from non-ferrous metals and the further processing into automotive, power, data and special cables. In addition, the portfolio contains technical assistance by professional specialists who speak the customers´ languages. The reliable supply with original Niehoff wear parts and spare parts, machinery inspection, refurbishment and maintenance measures as well as machine operator and maintenance training courses complete the range of services. Niehoff Group offers custom-tailored solutions from development and planning to turnkey projects of complete cable factories.

Konrad Dengler is a journalist and specialist translator

wire 2018, hall 10 booth C 06

Maschinenfabrik Niehoff GmbH+Co. KG
Walter-Niehoff-Strasse 2
91126 Schwabach/Germany
Contact person is Mr. Norbert Meyer
Tel. +49 9122 977-0

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