Electrical Overhaul and Process Integration on the F13R Roughing Machine – Giovinazzo
The project was designed to modernize a plant whose mechanical systems are still reliable, by increasing its productivity, integrating new in-line process steps, and automating end-of-line logistics.
Operating Results:
- Reduction in cycle time
- Ergonomics and Safety
- Increase in OEE
The Project
The project involved a complete electrical overhaul and an upgrade of the control architecture of an F13R model Rod Breakdown Machine. The project was designed to modernize a plant with mechanical components that are still reliable, increasing its productivity, integrating new in-line process steps, and automating end-of-line logistics.
Wire Drawing Dynamics and Axis Control
The line is designed for the first stage of cold reduction of copper wire rod, starting from an input diameter of 8 mm and ending with final cross-sections ranging from 1.5 mm to 0.37 mm. INTECH Automazione Sistemi engineered the control system to manage the progressive stages of the production line (with cross-sectional reductions calculated between 0.55 mm and 1 mm per step). Optimization of the drives has made it possible to push the kinematics to the limits of their mechanical capabilities, stabilizing the process speed within an operating range of 6 m/s (minimum) to 20 m/s (maximum).
Integration of Continuous Annealing
The revamping included the addition and configuration of a continuous annealing furnace downstream of the rough drawing stage.
The automation system controls the Joule heating process, managing currents of up to 2500 A at low voltage (to prevent electric arcs from igniting). This stage restores the ductility and electrical conductivity of the copper, which have been altered by the work hardening caused by drawing.
To prevent oxidation (blackening) of the heated conductor, the system continuously monitors the injection of a protective water-based emulsion, ensuring that critical sections of the conductor remain oxygen-free. Through the operator panel (HMI), the line supervisor can enable or disable the annealing module via a simple logical bypass, configuring the system to produce “unannealed wire” intended for subsequent fine-drawing processes.
End-of-Line Automation: Static Wrapper
The output product is collected by a static bell-type coiler (Drop Coiler). In this configuration, the take-up reel does not rotate, eliminating the high inertia associated with rotating masses: the system provides only vertical lifting to ensure proper layering of the wire, while the deposition motion is achieved by the rotation of the outer bell (flyer).
INTECH Automazione Sistemi’s solution has automated the format changeover sequence. The feed roller conveyors autonomously manage material buffering: they unload the full reel and position the empty, pre-prepared reel in place.
Operating Results
INTECH AUTOMATION SYSTEMS
Design and production of systems for industrial plant automation and enterprise energy transition
Our industrial plant design and automation activities are always thought out to the individual customer’s specifications. We support designers, technologists and plant engineers from the very first stage of work, so that we can network all the skills involved in the production process.
We design and manufacture electrical control panels. We study the best solutions based on the customer’s requirements to have the most efficient and quickest commissioning of the industrial automation system. Skilled technicians follow the whole realization of the switchboard up to installation.
Through revamping, the useful life of a machine can be extended by as much as fifteen to twenty years, with an average cost around half that of buying a new machine. Revamping can involve an entire industrial plant, a production line, or a single machine.
We use solutions and components by choosing from the most reliable brands on the market to have certainty of quality and full mastery of the machine. Components purchased externally are chosen from the most reliable partners on the market to ensure, in addition to high quality, easy availability of spare parts.
Request a consultation
Tel: +39 0542 640007
Mail: commerciale@intechsrl.biz
Technical contact
Tel: +39 0542 640007
Mail: technical-dept@intechsrl.biz