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ITSOL is now offering Clifford's versatile jig welder, which allows a single operator the ability to process welded parts seamlessly and without production stoppage. While the operator prepares the material for welding on the operator side of the table, the welder is welding the product on the other side of the table.
These Jig Welders offer:
Clifford started building CNC jig welders for wire products over 20 years ago and todate has well over 250 machines in the field world wide. Through these many years of experience and commitment to excellence, the latest range of Versatile Jig welders are even more, reliable and productive and user friendly.
Select form our simple entry level 2 axis units to multi-axis machines that can incorporate servo adjustable welding heights and servo rotating heads. We even offer a range of welding technologies to pick from that are best suited for your budget and needs. Including AC, DC, Medium Frequency DC, and high frequency modulated AC.
With standard features like:
Clifford's versatile welder electrodes can be designed and manufactured to specifically suit the product being welded. Electrode tips are interchangeable, allowing a single machine to weld a wide variety of different products. Varying the electrode configuration allows for multiple products to be run on the same jig
without having to write a separate program or change electrodes between products, reducing changeover times, and increasing operating efficiency.
Products with varying heights can be accommodated with Cliffords servo driven Z-Axis electrodes.
The machine is capable of welding up to 45 Cross wires per minute. This speed is dependent on numerous factors including, but not limited to, quality and consistency of material, line bar sizes, cross wire diameters, maintenance of the machine and operator abilities. The line would typically require two operators at the loading station and one at the welding portal/crosswire magazine. Other operators may be required for material handling to and from the machine. Many options are available including off coil load bar and cross wire systems, integrated shears and cutting systems.
The Clifford MESH WELDING LINE is modular in design allowing the customer to match different elements of the product range to suit their individual requirements. The drawing above assists in giving the customer an understanding of these different elements and how they fit together in order to simplify the selection process of the different aspects of the welding line.
The Clifford range of LARGE MESH WELDERS is differentiated based on customer requirements, mesh characteristics, mesh product type and investment sum available. Below find a table summarizing the three main types of Clifford welding portals. The welding portal forms an integral part of the mesh line and ancillary equipment which is again dependant on customer requirements are added to this portal to arrive at a suitable solution to customer needs. Such ancillary equipment includes line wire payoffs, line wire control, line wire feeders, cross wire insertion, mesh extraction, shears, stacking and turning, coilers, mesh transport and other such ancillary equipment which is detailed in the pages following.
A Typical Large Mesh Welding Line includes the following:
Other options not shown above include:
The Clifford MESH WELDING LINE is modular in design allowing the customer to match different elements of the product range to suit their individual requirements. The drawing above assists in giving the customer an understanding of these different elements and how they fit together in order to simplify the selection process of the different aspects of the welding line.
The Clifford range of LARGE MESH WELDERS is differentiated based on customer requirements, mesh characteristics, mesh product type and investment sum available. Below find a table summarizing the three main types of Clifford welding portals. The welding portal forms an integral part of the mesh line and ancillary equipment which is again dependant on customer requirements are added to this portal to arrive at a suitable solution to customer needs. Such ancillary equipment includes line wire payoffs, line wire control, line wire feeders, cross wire insertion, mesh extraction, shears, stacking and turning, coilers, mesh transport and other such ancillary equipment which is detailed in the pages following.
A Typical Large Mesh Welding Line includes the following:
Other options not shown above include:
The Clifford ULTRACUT and OPTICUT wire straightening & cutting machines are designed as modular lines to accommodate a range of wire straightening and cutting requirements, for the high speed production of straightened and cut wire.
These machines are of a robust modular design and are offered with a range of different payoff options to suit the presentation of the wire. The wire is driven by a series of feed wheels through a spinner assembly and is cut to length in a high speed flying shear. The shear is designed to give a flush, square end cut at maximum operating speed. Gearing between the feed and spinner drives ensures constant "spinner ratio" under all conditions to provide optimal straightness of the finished wires. The ULTRACUT can be supplied with three quick change spinners to cover a range of wire sizes from 2mm/0.079" - 12mm/0.472".
The machine is designed to reduce the process induced vibration as much as possible to increase maintenance intervals and reduce running costs.
Length is digitally programmed for very quick length setting and changeovers. Batches are digitally controlled in predetermined sizes. The ULTRACUT can be supplied with various modular measurement systems depending on customer requirements.
The IPC line is a fully integrated line for production of cold rolled, ribbed, straight lengths of high tensile steel bar for reinforcing purposes or for line/cross wires for welding into reinforcing mesh.
The wire is fed from a payoff system. The payoff type is dependant on feed speeds required and coil type. Refer to the pay off selections.
The machine has roller reducing units to provide the required reduction in cross sectional area and to introduce the profiling onto the wire. The final profiling rollers are driven by AC motors with frequency controlled drives resulting in reduced maintenance costs.
The wire is straightened in a conventional straightening arbor and is cut to length in a rotating shear assembly. Length is determined from an electronic length input control. Wires are discharged into a receiving tray with a pneumatic end alignment system. Extra features could include a bundle batching station.
VITARI AUTOMATIC STRAIGHTENING and CUTTING MACHINES:
The new Vitari series of straightening machines are electronic, compact, modular and capable of processing a wide range of smooth or ribbed wires in steel grades ranging from mild steels to high tensile as well as non-ferrous with processing speeds up to 180 m/min (3 m/s). All machines have independent motors which control the wire feed, the straightening spinner and the cutting unit which guarantee precision cut lengths. The high-level electronics installed allows the operator to programme production using the integrated touch-screen on the ergonomically positioned control panel. The operator can save all setting parameters of different wire batches as well as production data. The machine can also be equipped with a modem for world-wide on-line technical assistance. The machines are modular and all the tooling is interchangeable between the different models. All machine models are available in right and left handed modes allowing for face-to-face set-up with considerable production and logistic advantages.
ITSOL has recently introduced and new highQUALITYyet veryAFFORDABLErange of wire straightening & cutting machines. Our new straighteners are manufactured by CONET in China and are extremely well built, yet at a very affordable price, while not compromising on any features or manufacturing quality. In fact CONET has taken their design to the next level for wire straightening machines, offering features that are not even available on the most expensive machines in the industry. Including features like, a servo cutter, inverter controlled feed and spinner speeds, and a unique runnout that is mechanically tied to the servo cutter to ensure super fast operation, allowing a running speed of up to 590 ft/min. These are just some of the features, but as sales people, we understand that words are cheap and that the proof is in seeing, so why not make an appointment to come see our new straightener in action. We often keep stock machines on our show room floor.
EUROLLS Tungsten Carbide Rolls:
With decades of experience Eurolls has developed a deep knowledge of rolls for many different applications made of special steels and sintered materials. Apart from the quality that comes built into any Eurolls Roll, the industrialist can be assured that the manufacture with these rolls will give the best output of any roll available on the market, effectively reducing roll cost per ton produced as well as reducing down time due to maintenance and roll changes.
Eurolls wire rolling cassettes:
Microcassettes The microcassette replaces the die in multi-pass lines. It is absolutely compact and suitable for particular productions where tight tolerances are required. The maximum reduction that can be achieved is evaluated on the basis of the specific product. The use of microcassettes can be fully compared to the use of dies. The products that can be obtained are: low, medium and high carbon steel wire, copper, titanium, stainless steel, welding wire, etc. The quality of the outlet material is assured by the special finishing of the roll profiles. This guarantees a perfect roundness and dimension of the product obtained as well as a perfect polished surface. These cassettes can quite easily replace traditional dies thanks to their compact dimensions. The advantages of this system are many, starting from the longer roll working life compared to that of traditional dies, time-saving tooling changes, less machine down-times, possibility of working at higher speeds, reduction from 10 to 20% in absorbed power, lower lubricant consumption and consequently an increase in productivity. These cassettes are similar to dies with regards to production and work processes; as a matter of fact, when the rolls are worn out, they can be ground to the next size and therefore the cassette is used in the previous pass, exactly the same procedure used with dies
Cold rolling line - Vertical and Horizontal blocks
The cold rolling line for the production of smooth and/or ribbed wires for reinforcement is extremely compact, versatile and equipped with independent horizontal or vertical axis bull blocks complete with stands for the EUROLLS cold rolling cassettes. This simplifies installation and guarantees better performance of the line. The machine is equipped with protective covers to safeguard the operator as well as to ensure that the minimum of mill scale and dust pollutes the factory environment.
Also included in the machine is the descaling panel integrated with a pinch roll to help during the feed in operation as well as the rod lubricating unit.
Using independent bull blocks guarantees the maximum flexibility and versatility with regards to the distribution of the necessary wire reductions (no fixed reduction between bull blocks required). The cold rolling line can be composed of one, two or three bull blocks and these can be mounted in a vertical or horizontal plane. Using optimum design, the space occupied by the line has been reduced to a minimum even with the use of multiple bull blocks required for larger diameter reduction.
The line can be equipped with spoolers with horizontal or vertical axis, and be automated depending on the specific requirements of the client.
LINE FOR TREATMENT OF LOW RELAXATION STEEL WIRE FOR PRESTRESSED CONCRETE AND STRUCTURAL REINFORCEMENT
High carbon steel wire is used as structural reinforcement in a wide field of applications such as big industrial and civil engineering works (beams and structures of multi-storey buildings, pillars, bridges, structures, docks, highway barriers, rail sleepers for high speed trains, concrete pipes, huge suspension cables for cable-stayed bridges, etc.). To fulfil efficiently the features of load and reinforcement this steel wire must have characteristics of LOW RELAXATION when it undergoes the continuous application of high axial loads (especially if combined with concrete). To produce such type of wire a tension relief treatment is necessary, obtained by placing the wire under a load equivalent to 40 % of its tensile while being heated to a temperature of approx. 400 C with further quick cooling.
Steel ropes made of high carbon wires mainly in assembly with 2, 3 and 7 wires (1+6 ), but today also in assembly with 19 wires (1+6+12) are more and more frequently used as structural reinforcement in a wide field of applications where it is needed to bear very heavy and continuous loads.
To minimize elongation under continuous load a tension relief treatment is necessary.
KEY BENEFITS
The treatment lines for PC Wire and PC Strand offered by Eurolls guarantee a technological process with very high performance and excellent quality, as a result of great technical knowledge and long experience in this field.
Internal diameter > 1220 mm
Welded joints: Not accepted
Strecker Buttwelding Machines:
For over 75 years, AUGUST STRECKER GmbH & Co. KG has been a specialist in the development and production of butt welding machines for almost any application in the wire and cable industry.
The product range includes machines for butt welding solid wires, flat conductors, rings, chain links, stranded wires and conductors as well as special parts:
Type TD and type DSD Wire drawing machines
Eurolls has two families of dry-drawing machines, particularly suitable for the production of wires of low-carbon steel, high-carbon steel, stainless steel and special alloys, using both reduction by die and reduction by cold-rolling. The TD machines are traditional multipass lines with die or cold rolling cassette reduction, with tilted blocks and speed control by means of sensing rolls. Rotation of capstans is obtained through AC Motors, connected by means of gear-boxes. The DSD machines instead are an innovative design and differ from the traditional TD machines mainly because of the use of multi-pole (usually 8 to 32) AC Motors permanent-magnet synchronous type, connected directly to the capstan shafts, therefore eliminating the use of belt transmissions or gear-boxes.
Standard configuration of Eurolls dry-drawing machines includes sturdy, vibration-free, modular steel frame, tilted capstans made of forged steel C50, tempered and induction hardened to 62 HRC, coated on the lower-band in contact with the wire by black ceramic or TC hard facing. Capstan cooling using high-turbulence water flow is even more efficient thanks to our very own patented solutions. It is possible to use rotating or fixed die-boxes, and interchangeable with Eurolls cold-rolling cassettes.
KEY BENEFITS
SPECIAL APPLICATIONS
Lines can be supplied with many optional elements such as for example
The main characteristics and performances of the two families of machines are shown in the tables above, but with the competence and experience of their engineers, Eurolls is able to offer special machines made according to the most demanding requirements of our customers.
| TD200 | TD300 | TD400 | TD560 | TD630 | TD710 | TD760 | |
|---|---|---|---|---|---|---|---|
| Capstan Diameter (mm) | 200 | 300 | 400 | 560 | 630 | 710 | 760 |
| Max no. of blocks | 16 | 16 | 16 | 14 | 12 | 10 | 10 |
| Max motor power ( kW ) | 5 | 11 | 22 | 45 | 75 | 90 | 90 |
| Wire inlet range Low C (mm) | 1.0-2.5 | 1.0-3.5 | 2.0-4.5 | 5.5-7.0 | 5.5-8.0 | 5.5-12 | 5.5-12 |
| Wire inlet range High C (mm) | 1.0-2.0 | 1.0-3.0 | 2.0-4.0 | 5.5-6.5 | 5.5-7.0 | 5.5-9.0 | 5.5-9.0 |
| Min output diameter (mm) | 0.10 | 0.25 | 0.50 | 1.00 | 2.00 | 2.50 | 3.00 |
| TD900 | TD1200 | TD1500 | DSD560 | DSD630 | DSD760 | |
|---|---|---|---|---|---|---|
| Capstan Diameter | 900 | 1200 | 1500 | 560 | 630 | 760 |
| Max no. of blocks | 10 | 9 | 6 | 12 | 10 | 8 |
| Max motor power | 130 | 160 | 250 | 40 | 55 | 70 |
| Wire inlet range Low C | 5.5-16 | 8.0-20 | 8.0-26 | 3.0-5.5 | 5.5-8.0 | 5.5-12 |
| Wire inlet range High C | 5.5-13 | 6.5-16 | 8.0-21 | 3.0-5.0 | 5.5-7.0 | 5.5-9.0 |
| Min output diameter | 3.00 | 3.50 | 4.50 | 1.00 | 2.00 | 3.00 |
Slitting Lines:
Thanks to its expertise developed over 50 years, FIMI has the capability to offer a wide range of Slitting, Recoiling & Coil Inspection lines, that can be summarized as follows:
FIMI Slitting, Recoiling & Coil Inspection lines give to the customer the advantages of high productivity with easy-to-use equipment and personnel reduction thanks to the high degree of automation.
Thanks to its expertise developed over 50 years, FIMI has the capability to offer a wide range of cut to length lines that can be summarized as follows:
FIMI CTL lines give to the customer the advantages of high productivity with easy-to-use equipment and personnel reduction thanks to the high degree of automation.
Thanks to its expertise developed over 50 years, FIMI has the capability to offer a wide range of ERW Tube Mills that can be summarized as follows:
CTL FIMI ERW Tube Mills give to the customer the advantages of high productivity with easy-to-use equipment and personnel reduction thanks to the high degree of automation.
Thanks to its expertise developed over 50 years, FIMI has the capability to offer a wide range of cold forming lines that can be summarized as follows:
FIMI CTL lines give to the customer the advantages of high productivity with easy-to-use equipment and personnel reduction thanks to the high degree of automation.
