Magnetostrictive position transducers for precise control of coil winding on wire drawing machines for copper, aluminum and alloy wires
Find out how to to improve wire position monitoring during winding, ensuring accurate and consistent positioning
With HYPERWAVE WPG-A absolute magnetostrictive position transducers, it is possible to transform raw material into wire with minimized cycle times. WPG-A offers:
- precise positioning requirements (within ±0.1 mm) over a stroke of 250 mm
- high resistance to vibration
- better price/performance ratio than other magnetostrictive transducers
- ability to read spool position in real time, providing accurate feedback for effective synchronization.
Overview
- Application: Correct widing system for the coil spiral.
- Products: HYPERWAVE WPG-A absolute magnetostrictive position transducers
The process
Drawing machines represent the initial stage of the wire production process, which begins with the drawing of the rod. Through the use of drawing machines, the raw material is transformed into wire by reducing its cross-section and altering its shape using a drawing die, with the essential aid of a lubrication process. During this process, drawing machines can also increase increase the wire’s temper or hardness.
The single-wire drawing line is generally used for intermediate drawing, as well as for fine and superfine wire intended for specific applications. It is specially designed for processing special materials, such as bare copper wire, annealed copper, and tinned copper.
The challenge
Winding is a coiling solution designed for copper, aluminum and alloy wires, ideal for optimizing drawing systems, including those from other manufacturers.
The quality of the wire winding on the spool must be flawless, and cycle times minimized (automatic spool change).
Winders must offer several advantages, including:
- Integration of a dancer arm to further reduce space requirements
- Possibility of winding into metal or cardboard support containers
- Automatic container replacement at full speed, without operator intervention
- Wide range of available conveyors
- Optional wire cooling and drying system for raw wire production
- Easy integration with existing lines
Product benefits
WPG-A Magnetostrictive sensor – “General” series
- Non-contact transducer based on magnetostrictive technology that detects the position of a magnetic cursor mechanically attached to the moving part of the machine;
- low-profile aluminum housing for reduced space requirement;
- environmental protection rating (IP67);
- WPG-A offers:
- Greater robustness and durability compared to potentiometers
- Better price/performance ratio compared to other magnetostrictive transducers
Solution
In the final stage of the process, the drawn wire is wound onto a spool with special attention to uniform distribution. A sensor is used to precisely monitor the position of the wire during winding, ensuring accurate and consistent placement.
Requirements:
- Precise positioning (within ±0.1 mm) over a 250 mm stroke;
- resistance to cursor vibrations caused by high-speed movements;
- cost effective sensor solution.
Product used: WPG-A
WPG-A linear magnetostrictive sensors enable real-time reading of spool position, providing accurate feedback for effective synchronization between the various units along the production line.
Gefran offers a complete range of linear magnetostrictive sensors, available in different configurations to suit various application needs.
The WPG-A series represents the best cost-performance compromise within the available product range.
Main technical features:
- Independent linearity within ±0.1 mm for strokes up to 250 mm;
- sliding or floating cursors, depending on installation constraints;
- multiple analog output options available;
- M12 connector with IP67 protection rating.