WIREE JOU JOURNAL JUNE 2017
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50 RS YEA 8-2017 196
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5 YEA0R S 1968 -201 CONTENTS
7
Volume 50 | Number 6 | June 2017
Editorial . . . . . . . . . . . . . . . . . 6
FEATURES
Calendar . . . . . . . . . . . . . . . . 8 Industry News . . . . . . . . . . . 10 Patent Report . . . . . . . . . . . 18 Asian Focus . . . . . . . . . . . . . 22 People . . . . . . . . . . . . . . . . . 24 Fiber Watch . . . . . . . . . . . . . 26 Fastener Update . . . . . . . . . 28 WAI News . . . . . . . . . . . . . . 30
Wrapups: Interwire 2017 and the Global Ferrous Rod & Wire Symposium . . . . . . . . . . . . . . . 34
Technical Papers . . . . . . . 82-96
The largest such cable event in the Americas, these co-located events at the Georgia World Congress Center presented attendees a blend of technology, education and opportunity as well as the setting to mingle with their peers.
Products . . . . . . . . see feature
Testing & Measuring . . . . . . . . 68
Classified . . . . . . . . . . . . . . 101
If you attended Interwire 2017, there was no lack of testing and measuring equipment to consider. This feature presents some of what was displayed on the show floor.
Chapter Corner . . . . . . . . . . 32
Career Opportunities . . . . . 101 Advertisers’ Index . . . . . . . 103
TECHNICAL PAPERS Cyclic load effect on round strands made by twisted stacks of HTS tapes N. Bykovsky, D. Uglietti, R. Wesche and P. Bruzzone . . .82
Next issue July 2017 • Equipment • Wrapup: wire Russia
Experimental research of the life time of the cable vibration dampers Igor K. Mikhalkinа, Yury K. Ponomarev and Oleg B. Simakovc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86 Experiment Results of Failure Progression from Low Power Wires Mohammad Samie, Alireza Alghassi and Ian Jennions . . .92
Cover: The return to Atlanta for WAI’s 87th Annual Convention, Interwire 2017 and the Global Ferrous Rod & Wire Symposium proved to be quite memorable. Cover shot by WJI Graphic Designer Karren Muolo. JUNE 2017 | 3
CONTENTS
INSIDE THIS ISSUE Trade case splits AWPA members 10
A sign of the (industry) times
Now that the U.S. International Trade Commission has made a preliminary finding that U.S. producers were being injured by imports of carbon and alloy steel wire rod from 10 countries, the U.S. domestic manufacturers of steel wire products will be in a very watchful mode. The U.S. Commerce Department will continue its investigation into product allegedly being dumped by 10 countries and subsidized by two others. The case is one that finds some members of the American Wire Producers Association (AWPA) on opposite sides.
There was something for everyone at Interwire 2017 and the Global Ferrous Rod & Wire Symposium, held along WAI’s 87th Annual Convention at the Georgia World Congress Center. The Atlanta site has been a home-away-from-home venue so long that it is very familiar, yet the industry continues to change, and at each staging the thousands of attendees include a healthy percentage of first-time visitors. All of which makes the “welcome mat” for the event that much more important. The wrapup begins on p. 34.
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EDITORIAL EDITORIAL
Interwire 2017: a staff perspective This issue provides a great summary of the recently completed Interwire Trade Exposition. I encourage you to read it from beginning to end as it provides a genuine feel for the scope of the event, which included some 3,800 participants and 400 exhibiting companies. My objective here is to provide a quick staff perspective by the below “bullet point” thoughts. • This was my 9th Interwire and I can tell you with certainty that we (volunteers and staff) want everything to be perfect, and that includes attendance. • The Education Committee and staff were pleasantly surprised with the record attendance (149!) at the Fundamentals Course. We anticipated some walk-in registrations, but not 30. • Nearly 30 Southwire participants joined the Member Rewards Luncheon to honor two of their colleagues, Richard Miller and Tom Heberling. We couldn’t get another seat in the room and that was a good thing. • Rick Smith, our keynote speaker, made a passionate presentation on digital manufacturing. To be fair, we paid Rick, so you can’t compare him to other elements of the program. • Southwire opened two of its Carrollton facilities to tours during Interwire. There is nothing easy about hosting a large group. Thank you to Southwire for all of the work that went into this. • After a well-received 2015 Welcome Reception at the College Football Hall of Fame, I was disappointed that the venue was not available in 2017. However, I am convinced that taking a cycle off before returning there in 2019 will be good. • The Ferrous Symposium volunteer team busted their tails in producing this first-time event. A tremendous amount of time, energy, and expertise was directed at making this new program a success. • A special thank you is owed to all the Interwire exhibitors as they make it possible for us to create an amazing meeting place for the industry. The exhibit floor looked amazing from the windows of the show office as well as on the floor. Finally, I want to thank my colleagues and the large contingent of special volunteers. As amazing as automation and 3D printing may be, the efforts of such people are what truly makes an event like Interwire function.
Steve Fetteroll WAI Executive Director
6 | WIRE JOURNAL INTERNATIONAL
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CALENDAR
CALENDAR June 9-11, 2017: Wire & Cable Guangzhou 2017 Guangzhou, China. To be held at the China Import Export Fair Complex. Contact: Guangzhou Guangya Messe Frankfurt Co., tel. 86-2038251558, wire@china.messefrankfurt.com, www.wire-cable-china.com.
Nov. 7, 2017: CabWire World Conference 2017 Düsseldorf, Germany. To be held at the Congress Center, this event is organized by U.K.-based IWMA. Contact: IWMA, tel. 44-121-781-7367, info@iwma.org, www.iwma.org.
Sept. 19-21, 2017: wire Southeast Asia 2017 Bangkok, Thailand. To be held at the Bangkok International Trade & Exhibition Centre (BITEC), it is organized by Messe Düsseldorf. Contact: Messe Düsseldorf North America, tel. 312-7815180, info@mdna.com, www.mdna.com.
May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. This WAI event, to be held at the Gaylord Opryland Resort & Convention Center, includes the Association’s trade show, technical programs and 88th Annual Convention, www.wirenet.org.
Oct. 3-5, 2017: Wire South America São Paulo, Brazil. To be held at the Imigrantes Exhibition & Convention Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.
Nov. 27-29, 2018: Wire & Cable India Mumbai, India. This event will be held at the Bombay Convention & Exhibition Center. Contact: Messe Düsseldorf North America, tel. 312-781-5180, info@mdna.com, www.mdna.com.
Oct. 8-11, 2017: 66th IWCS International Cable & Connectivity Symposium Orlando, Florida, USA. Contact: Pat Hudak, IWCS, tel. 717-993-9500, phudak@iwcs.org, www.iwcs.org.
May 13-16, 2019: Interwire 2019 Atlanta, Georgia, USA. This WAI event, which will be held at the Georgia World Congress Center, includes its trade show, technical programs and 89th Annual Convention, www.wirenet.org.
WIRE ASSOCIATION INTERNATIONAL EVENTS June 16, 2017: Midwest Chapter 15th Annual Golf Tournament West Chicago, Illinois, USA. To be held at St. Andrews Golf & Country Club. Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org. September 12, 2017: New England Chapter 23rd Annual Golf Tournament Avon, Connecticut. To be held at the Golf Club of Avon. Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.
8 | WIRE JOURNAL INTERNATIONAL
September 21, Southeast Chapter 16th Annual Golf Tournament Conover, North Carolina, USA. To be held at the Rock Barn Golf and Spa, Conover, North Carolina. Contact: Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org. May 15-16, 2018: WAI Operations Summit & Wire Expo 2018 Nashville, Tennessee, USA. This WAI event, to be held at the Gaylord Opryland Resort &
Convention Center, includes the Association’s trade show, technical programs and 88th Annual Convention. May 13-16, 2019: Interwire 2019 Atlanta, Georgia, USA. This WAI event, which will be held at the Georgia World Congress Center, includes its trade show, technical programs and 89th Annual Convention.
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INDUSTRY NEWS
INDUSTRY NEWS Nokia plans to sell undersea cable unit; not considered a core business Finland’s Nokia plans to sell Alcatel Submarine Networks (ASN), a business worth an estimated $870 million. Reuters, citing two union sources and a French government source, reports that Nokia plans to sell the division, a major supplier of undersea cable network. ASN was bought last year as part of Nokia’s $17 billion acquisition
territories and African countries as well as plays a key role in cyber-surveillance and national security. ASN, which employs about 1,000 people, mainly in France and Britain, is managed as a separate business by Nokia. “Nokia’s intention to eventually sell ASN was expressed by Nokia on various occasions in talks with the state and relevant stakeholders, including the staff,” said one source cited in the report who added that ASN was not seen as a core business. Nokia’s management in France informed staff internally about the group’s intentions, two union sources told Reuters. No potential bidder was identified. The report noted that ASN’s future has been uncertain since 2014, as Alcatel once sought to divest it. The division’s chief rivals are Subsea Communications (SubCom), a unit of U.S. company TE Connectivity, Japanese companies NEC and Fujitsu, and China’s Huawei.
ITC supports trade penalties for steel wire rod imports from 10 countries The “Sold” sign isn’t posted yet, but Nokia is ready to sell the cable business it acquired via its Alcatel takeover. of French rival Alcatel. The French government deemed the business strategic for the country at the time, as it guarantees high-speed internet connections with overseas
Do you have an industry hotshot? A slew of “30 under 30” profiles of up-and-coming newcomers to a given field have become very popular in recent years. The WAI’s Board of Directors believes that such recognition should extend to professionals in the wire and cable industry. With that mindset, the WAI is issuing a call for Industry Hotshots. If you have someone in your ranks, under age 40, whose smarts and work ethic make that person a star in your ranks, we encourage you to nominate that person. If selected, the person will be profiled in the September issue of WJI. For details on the process, either call WAI Executive Director Steve Fetteroll at tel. 203-453-2777, ext. 115, or send him an e-mail at sfetteroll@wirenet.org. A link to an on-line application can be accessed at the home page of www.wirenet.org.
The U.S. International Trade Commission has made a preliminary finding that U.S. producers were being injured by imports of carbon and alloy steel wire rod from 10 countries. As a result, the U.S. Commerce Department will continue an investigation it launched in April into whether the product was being dumped by Belarus, Italy, South Korea, Russia, South Africa, Spain, Turkey, Ukraine, the UAE and Britain. It is also examining whether imports from Italy and Turkey are being subsidized. Gerdau Ameristeel US Inc, a subsidiary of Gerdau SA, Nucor Corp, Keystone Consolidated Industries and Charter Steel had requested the trade probe. The measures had been opposed by AWPA Executive Director Kimberly Korbel, who noted that AWPA members—whose member companies include the petitioners—overwhelmingly voted against the requested actions. In 2016, the United States imported an estimated $10.4 million of carbon and alloy steel wire rod from Belarus; $12.2 million from Italy; $45.6 million from Korea; $32.3 million from Russia; $7.1 million from South Africa; $40.7 million from Spain; $41.4 million from Turkey; $55 million from Ukraine; $7 million from the United Arab Emirates; and $20.5 million from the U.K.
SMS gets India order for copper wire rod plant, updates Saarstahl project Germany’s SMS Group reported that it has received an order from India’s Hindalco Industries, Ltd., for its most efficient copper wire rod plant.
Got news? E-mail it to the WJI at editor@wirenet.org.
10 | WIRE JOURNAL INTERNATIONAL
Diagram of the SMS wire rod plant. A press release said that the order from the company, based in Mumbai, is for a CONTIROD® plant, type CR 3500, that can cast and roll wire rod in one process. It has production capacity of 35 tons of copper wire rod per hour, which it said represents the largest such plant capacity in India. The plant will primarily produce ETP (Electrolytic Tough Pitch) copper wire. Commissioning is set for the third quarter of 2017. The company also reported that it has continued to make progress on a multi-stage project for Saarstahl AG at its Neunkirchen Works. Saarstahl has completed the first bar on the single-strand, wire rod mill supplied by SMS. In 2016, two phases were completed, including the commissioning of a new loop-cooling section.
Wire & cable in the news NEC: this fiber is both fast and very long No speed seems impossible to accomplish today for fiber optic technology, but NEC Corporation has gone one step further. Actually, a lot of steps, as NEC’s recent transmission capacity of 50.9 terabits (Tb) per second on a single optical fiber was done over a distance greater than 11,000 km. The company reports that this is the first time 50 Tb have been achieved over 10,000 km using C+L band erbium-doped fiber amplifiers (EDFA). That capacity, it notes, corresponds to a new record-breaking capacity distance product of 570 Pb-km (Petabit per second-kilometer). Pushing the benchmark 50Tb capacity to trans-pacific distances is in line with the current trend of increasing the reach of ultra-high capacity submarine cable segments, as the company explains below. Achieving such a high capacity, even with extremely wide bandwidth EDFAs, requires efficient use of the bandwidth at a level that is close to the Shannon limit,
A slew of “30 under 30” profiles of up-and-comInterwire,toofficials Beneke Company ingAt newcomers a givenatfield haveWire become announced the family has Board taken aof very popular that in recent years.business The WAI’s significant proactive that will should assure the Directors believes thatstep, suchone recognition company has all the redraw wire rod it extend to professionals in the aluminum wire and cable needs, and also help stabilize long-term health industry. With that mindset, thethe WAI is issuing a of thefor market. call Industry Hotshots. allowin your ranks, under age IfThis you deal have“will someone (us) to supply quality 40, whose smarts and work ethic make that person to the market a products star in your ranks, we encourage you to nominate place for another 49 the person will be profiled that person. If selected, Michael issue Beneke inyears,” the September of WJI. For details on the said. either call WAI Executive Director Steve process, For details, the Fetteroll at tel. see 203-453-2777, ext. 115, or send article on p. 36. him an e-mail at sfetteroll@wirenet.org.
Sandvik Materials Technology intends to exit welding wire and stainless steel
Sandvik Materials Technology (SMT), part of Sweden’s Sandvik Group, announced that it plans to divest parts of its wire operations. A press release from Sandvik said that the company plans to divest its welding wire and stainless wire operations as part of its desire to further consolidate the product portfolio and improve its long term performance. the fundamental spectral efficiency limit of optical communications. There is more than one way to design modulation formats that can get close to the Shannon limit in the linear regime, however, most of them do not fare well when operated in the nonlinear regime, where they suffer more performance gap towards the nonlinear Shannon limit. To overcome this issue, NEC’s researchers developed a multilevel, linear and nonlinear constellation optimization algorithm. Through it, NEC obtained an optimized 32QAM (opt32) constellation that achieves close to Shannon capacity, but more importantly, has a higher nonlinear capacity limit, which is especially more relevant to submarine transmission. Moreover, this new modulation format is much easier to implement, as it does not require any iterative decoding or non-uniform coding. As such, opt32 modulation allowed NEC researchers to achieve an unprecedented spectral efficiency of 6.14 b/s/Hz over a trans-pacific distance. Company researchers developed a patent-pending bi-directional amplifier design that reduces the effective noise figure and the device complexity.
JUNE 2017 | 11
INDUSTRY NEWS
Beneke Wirean Company a Do you have industrymakes hotshot? big announcement at Interwire
INDUSTRY NEWS
“These businesses are subject to intense competition and SMT does not hold a No. 1-2 market position. In 2016 the wire businesses…to be divested, generated total annual revenues of about US$80 million.” The deal does not include its Kanthal operations, such as its industrial wire and other products, which will remain in SMT as they “are regarded as core businesses due to the strong market positions and growth potential.” In 2016 operations now transferred into the Kanthal product area had annual revenues of about US$91 million. “The divestment…will make SMT more focused on its core operations; advanced stainless steels and special alloys for the most demanding industries,” the release said. “A new organizational structure is being created, effective as from 1 July 2017, whereby each product area will be responsible and accountable for the entire value chain and its results.
Iran launches 1st phase of ambitious plan to deploy a country fiber network The country of Iran has launched the first phase of an ambitious plant to deploy optical fiber throughout the country. A report in Techrasa (Iran Startup & Tech Media) said that Iran has finally launched a project, called, TANOMA, during a ceremony that included Minister of Communication and Information Technology Mahmoud Vaezi and First Vice President of Iran Eshaq Jahangiri.
Prysmian Group wins major Verizon deal, plans a ‘significant investment’ Italy’s Prysmian Group reports that it has won a threeyear agreement from Verizon Communications, and that it plans to bolster its North American capacity. A press release said that Prysmian Group will supply the optical technology to Verizon “to support the company’s U.S. network expansion around a next-generation fiber platform that will speed the deployment of 5G services, while improving 4G LTE and other broadband capacity.” The contract, which calls for it to supply more than 17 million fiber km of ribbon and loose tube cables, was estimated to be worth approximately $300 million. “As the world goes wireless, wireless is drawn to fiber,” said Philippe Vanhille, senior vice president, SVP Telecom, at Prysmian Group. “Economic growth and consumer demand depend largely on superfast, gigabit broadband connectivity that is always available. Our pronouncement is that this is best delivered over a fixed optical network.” Per the release, Prysmian and Verizon expect to see continued demand for next-generation passive optical network (NGPON2) “that will last well beyond 2020 as new technologies like 5G and the IoT become reality.” It noted that Prysmian will make “a significant investment through 2018 in its US based optical cable organization to support this project and the growth of major telecoms carriers in North America.” Prysmian notes that the company has a strong heritage in manufacturing optical fiber and cable for a broad range of applications, with three telecom production sites in the U.S., two for the production of optical cable and one for optical fiber. It added that the Prysmian Group’s telecom division has qualified as an optical fiber, optical cable and connectivity solutions provider to Verizon for more than a decade.
12 | WIRE JOURNAL INTERNATIONAL
Telecommunication Company of Iran’s optical fiber goal is to make high-speed optical fiber a reality throughout Iran. TANOMA will be rolled out in Tehran and seven other populous provinces of Iran in the first phase. “With TANOMA, Fiber To The Home (FTTH) services are now available,” the report said. In this phase, the platform will connect 580k ports to the Internet and the National Information Network (NIN or National internet), which is an alternative network aimed to provide low cost, clean and secure internet launched initially in 2016. Of 580 ports, 245K were assigned to Tehran, 85K to Isfahan, 80K to Mashhad, 61K to Shiraz, 61K to Ahvaz, 28K to Karaj and 20K to Kermanshah. The project, it said, can provide a FTTH platform able to be used for distance learning, HD or 4K IPTV, and other multimedia services as well as high-speed Internet access for home users.
NEC reports that work has begun on the Hong Kong Guam Cable system Japan’s NEC Corporation reports that it has begun construction of the Hong Kong-Guam Cable system (HK-G), a project expected to be completed in late 2019. A press release said that the 3,900-km undersea cable is designed to provide 100 gigabit per second (Gbps) optical transmission capabilities, with overall capacity of more than 48 terabits per second (Tbps). NEC is partnering on the project with Singapore’s RTI-C, which was described as “neutral cable owners (that) develop global telecom infrastructure and large-scale data connectivity in selected markets.”
Austria’s Teufelberger Wirerope has completed its acquisition from a subsidiary of PAO Severstal of Redaelli Tecna SpA, a manufacturer of steel wire rope known for its ability to make the largest steel wire ropes. A press release said that, following the closing of the deal, which included an anti-trust review process, steel wire rope specialists Teufelberger and Redaelli Tecna can now “start shaping their common future.” The combined companies “are now among the world’s three largest manufacturers of high-performance steel wire ropes,” it said, noting that their respective product portfolios perfectly complement each other. “The merger...has provided us with a unique expertise concerning technical wire rope solutions as well as a global presence,” said CEO Florian Teufelberger. “Two great, powerful companies have created an outstanding corporate entity that is poised to become the world’s market leader.” Redaelli Tecna CEO Giuliano Ambroset agreed that the deal will help both companies. “We are now part of a company that, just like us, possesses a vast amount of expertise when it comes to developing, manufacturing and distributing high-performance steel wire ropes. This merger gives rise to new opportunities and solutions for our customers as well as our own employees.”
INDUSTRY NEWS
Teufelberger completes its ‘heavy weight’ purchase of Redaelli Tecna
In 2013, Guinness World Records recognized Redaelli as the producer of the world’s largest steel wire rope. The pictured Flexpack rope for offshore applications in deep waters is 4003 m long and weighs 438 metric tons. The combined companies had a workforce of approximately 1,300 employees and 2016 fiscal year revenues of 240 million euros, the release said.
Bekaert and ArcelorMittal extend their partnership deal in Brazil Bekaert and ArcelorMittal announced an agreement to integrate Bekaert’s currently wholly-owned subsidiary in Sumaré (Brazil) into the BMB (Belgo Mineira Bekaert Artefatos de Arame Ltd.) partnership.
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A press release said that, in line with the shareholding structure of the BMB joint venture, ArcelorMittal will be the majority shareholder (55.5%) of the steel cord entity in Sumaré and Bekaert will hold the remaining shares (44.5%). The transaction is subject to customary closing conditions and is expected to be completed in the second quarter of 2017. In 2013, the two companies invested in ArcelorMittal’s existing steel wire plant in Costa Rica and also built a new Dramix steel fiber manufacturing plant on the Orotina industrial site in Costa Rica.
General Cable becomes 1st cable company to win an Edison Award General Cable Corporation was chosen a Gold Winner for Innovation in the Energy and Sustainability Category of the 2017 Edison Awards. A press release said that at the April 20 event at The Capitale in New York City, General Cable President and CEO Mike McDonnell “joined hundreds of senior executives from some of the world’s most recognized companies to acknowledge the hard work and commitment of all of the 2017 Edison Awards winners.” “We are continuously investing in technology innovations that will enhance the performance, safety and reliability of our products,” said Srini Siripurapu, vice president, technology, General Cable. “This award is a culmination of the cross functional E3X® product development team’s perseverance and unwavering support from our Utility customers who have successfully deployed this technology.” The nominees were judged by a panel of more than 3,000 leading business executives including past award winners, academics and leaders in the fields of product development, design, engineering, science and medical. “Innovation has been at the core of our company culture for over 170 years,” McDonnell said. “Being named as an Edison Awards Gold Winner further validates General Cable as a leader and innovator of solutions to our customers’ needs for safer, more efficient and more effective transport of power and data. We are excited to be the first wire and cable company to receive this prestigious award in the 30-year history of the Edison Awards.”
Canadian wire die manufacturer now has new owners and a U.S. presence At Interwire, a new exhibitor, Canadian Wire Die Works USA (CWDW), announced that it recently acquired Canadian Wire Die Works, Ltd., of Sherbrooke, Canada, and is now operating in the U.S. 14 | WIRE JOURNAL INTERNATIONAL
At Interwire, CWDW Vice President Mike Martens with former company President Lorne Landry, who continues with the business on a consulting basis. CWDW, which will manufacture at its U.S. location in Philadelphia, Pennsylvania, is owned and operated by Joseph McCabe and Mike Martens. For now, it continues under the leadership of former company President Lorne Landry; his son, Ron Landry, and Plant Manger John Pierre. There are fewer than 10 employees now but the goal is to increase that to 15 by the end of this year. “We can make any product any wire manufacturer needs. Just send us your drawing and we’ll have a quote within a week,” reported McCabe, the president, and Martens, the vice president. At the show, the company was offering up to $10,000 of its dies on a 30-day trial basis. “We believe in our products and we want to share with all plants real proof of how good our tools are. We don’t think we are taking a risk here because we are confident that any plant that tries our tooling will want to keep it. Over time they will all realize the quality of our tooling. Our goal is to bring new ideas and techniques which will help keep the industry strong and growing.” Founded in 1950, CWDW offers extrusion tips, dies and other specialty parts, such as diamond-tipped wire guides in all sizes for thermoplastic extrusion of electric telephone and data cables. Half of its products are now made in the U.S., and more production will continue to be relocated there from Canada. The company can be contacted at tel. 267-571-5035, cwdwusa@gmail.com, www.canadianwiredieworks.com.
Company to launch subsea fiber-optic cable to connect Toronto and U.S. Crosslake Fibre announced that it plans to build a new subsea fiber-optic cable that will run from Toronto, Canada, to Buffalo, New York, through Lake Ontario. A press release said that the cable will be the first submarine cable system across Lake Ontario to directly connect Toronto and the U.S., with a route length of some 131 km. The supplier of the cable has not been chosen yet, and if the permitting and regulatory process goes well, the project should be able to go forward next year.
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The system, the release said, will have a high fiber count and be physically diverse from other routes between Toronto and Buffalo while being shorter in length, enabling lower latency connectivity between Toronto and other markets in the U.S. “We are excited to announce this project publicly as it’s a very unique build,”said Mike Cunningham, chief executive officer of Crosslake Fibre. “The cable system will help fuel the massive and growing demands for wholesale bandwidth and cloud connectivity in the Greater Toronto Area and the Buffalo Niagara Region.”
Allied Wire & Cable reports that it has won a small business exporter award
Work is nearly done producing cable for l4,000 km transpacific cable system As of press time, Hawaiki Submarine Cable and TE SubCom announced that more than 90% of the 14,000 km Hawaiki transpacific cable system has been manufactured. The cable system will link Australia and New Zealand to the mainland U.S., as well as Hawaii and American Samoa, with options to expand to several other South Pacific islands. Per Hawaiki Submarine Cable, the manufacturing progress—as well as continued advancement with the installation permitting process in New Zealand, Australia and the U.S.—keeps Hawaiki on schedule for completion by mid-2018.
Allied Wire & Cable reports that it was a recipient of the 2017 National Small Business Exporter’s Summit Award as an Outstanding Exporter. The summit recognizes top U.S. small and medium-sized business exporters. Company President and CEO Tim Flynn has said that serving new international markets through exporting goods allows the U.S. to provide more jobs and build up the economy. The company previously won the Presidential “E” award in 2014.
Here at Guill we are proud to introduce The Bullet II™, the latest in extrusion tooling technology. This extrusion head will speed up production with its easy to use design that eliminates fastening hardware. The taper body and deflector design were specifically developed by our engineers here at Guill to make cleaning and changing the tooling quicker and easier.
Hawaiki Submarine Cable reports that, at SubCom’s USA facility, more than 13,000 km of cable for Hawaiki has been manufactured, along with more than 150 completed repeaters. All installation permits for Australia, New Zealand and Oregon are completed, and are progressing as expected in Hawaii. Horizontal directional drilling (HDD) for the cable landing in Pacific City, Oregon has commenced and will be completed in the coming weeks. In Sydney, the construction of the land duct route is progressing, with more than half of the conduits already installed, and the HDD operations are scheduled to start in early June. The first cable load including 7,000 km of cable will begin this month, it said.
Industry report: Levant region to see steady power cable growth to 2024 The Bullet II® Cam Lock Design
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16 | WIRE JOURNAL INTERNATIONAL Guill Ad5162 “Bullet” WJ 2016
A report from Global Market Insights projects that the market for power cable will remain strong in the Levant area, a region on the eastern coast of the Mediterranean Sea north of the Arabian Peninsula and south of Turkey, that usually includes Israel, Jordan, Lebanon, Palestine and Syria. A press release said that the 115-page report outlines drivers for power cable, which represents more than US$3 billion in 2016, and is expected to increase by 8% by 2024. In 2016, low-voltage and medium-voltage power account-
Making Light Work
New name for Fiber to the Home Council Americas The Fiber to the Home Council Americas, the largest and only trade association in the Americas dedicated to the pursuit of all fiber optic network infrastructure to the home, now has a new name. A press release said that the organization is now known as the Fiber Broadband Association, a name that
customers that rely on our measurement systems every day to improve quality, increase productivity and deliver manufacturing savings. We are committed to your success. In-Process Gauging Off-Line Inspection Quality Cable Testing
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JUNE 2017 | 17
INDUSTRY NEWS
reflects its mission, ed for over 75% of the Levant power cable market share which is “to help while the high-voltage power cable market is set to exceed providers make 8% by 2024. Utility application share in 2016 accounted informed decisions for over 25% of the Levant power cable market. Rising about how, where, concern towards the refurbishment of T&D assets will and why to build exaggerate the industry size. The report cited the followbetter broadband ing market drivers. networks with “Growing investments towards infrastructure developfiber optics while counting on its members to lead the ment among war-affected countries including Syria and organization forward, collaborate with industry allies and Iraq will drive the Levant power cable market size. Per propel fiber optic deployment forward.” Since 2001, these the United Nation, investment of over US$180 billion companies, organizations and people have worked with is required to rebuild Syria economy to pre-war levels. communities and consumers in mind to build a better Similarly, Anbar Province in Iraq alone require US$22 bilbroadband future here and around the world, it said. For lion for reconstruction. more details, go to www.fiberbroadband.org. Increases in electricity consumption, coupled with expansion of transmission and distribution electric networks and more focus on clean technology will further fuel the Levant power cable market share. Power cable market is anticipated to exceed USD 5 million by 2024 subject to its wide adaptability across the utility applications. Regulator and public utilities are jointly developing action plans to re-establish T&D network with modern safety features to provide reliable electricity to end consumers. Growing infrastructural spending to rebuild war affected public assets will further boost the product demand. Growing measures to re-establish the communication networks including telecom will propel the demand for data and control cables. Introduction of IoT and other smart communication networks across manufacturing, mining and upstream O&G will positively drive the Levant power cable market. Growing demand for high capacity and efficient transmission network to meet the industrial electricity need will boost the product landscape. Precision Measurement and Control Solutions For more details, contact GMI at The Beta LaserMike brand has been faithfully serving the wire and sales@gminsights.com. cable industry for over 50 years and we have thousands of satisfied
PATENTS
Patent REPORT Technical advances are a necessity for any industry, and to that end, companies invest considerable resources in R&D. This monthly section will list the abstracts of recently approved U.S. patents. Most are direct to wire and cable while a few may be more indirect/downstream. Flat cable winding device and assembling method thereof U.S. Patent No.: 9,653,902 Patent date: May 16, 2017 Filed: Aug. 14, 2014 Assignee: Yazaki Corporation, Japan Inventors: Takahiko Katsuramaki, Ryo Hamada Provided is a flat cable winding device and an assembling method thereof, which can prevent slack of a flat cable and achieve smooth winding and leading out of the flat cable. A flat cable winding device includes a rotating table, a plurality of rollers, and a central shaft rotatably and pivotally supporting the rotating table. The central shaft includes an auxiliary wound portion in which the flat cable is wound for at least one turn. An inner wound portion is formed along an outer circumference of the auxiliary wound portion, and an outer wound portion is formed along outer circumferences of the plurality of rollers, thereby preventing the slack at the inner wound portion when leading out the flat cable.
Flat cable winding device and assembling method thereof U.S. Patent No.: 9,653,864 Patent date: May 16, 2017 Filed: April 25, 2013 Assignee: Sumitomo Electric Industries, Ltd. Japan Inventors: Tatsuya Mizutani, Yoshiakia Hattori A wire straightening apparatus that straightens kinks of a wire that is fed along a wire feeding path includes one or a plurality of straightening mechanisms. Each straightening mechanism includes a plurality of first straightening rollers
and one or a plurality of second straightening rollers. Each roller has a groove along its outer periphery, the groove gradually deepening toward a bottom portion. The bottom portion of the groove of each first straightening roller is spaced from the wire feeding path in a first direction, and the bottom portion of the groove of each second straightening roller is spaced from the wire feeding path in a second direction opposite to the first direction. With this structure, the wire can be made to follow a path that meanders as viewed from a direction perpendicular to axes of the straightening rollers.
Wire harness, wire harness manufacturing method and wire harness manufacturing apparatus U.S. Patent No.: 9,653,197 Patent date: May 16, 2017 Filed: June 13, 2014 Assignees: Sumitomo Electric Industries, Ltd.; Sumitomo Wiring Systems, Ltd. and Autonetwork Techologies, all Japan Inventor: Osamu Sato A wire harness manufacturing method prevents inadvertent deformation of thermoplastic material and separation of thermoplastic material. A predetermined part of an electric wire 91 is accommodated in a through hole of a tubular body formed by connection between a first and second nest members (123, 124) of a nozzle (12), by integrally connecting first and second case body members (121, 122) of the nozzle (12), with the predetermined part of the electric wire 91 therebetween. An approximately tubular covering member (92) covering the predetermined part of the electric wire (91) is molded integrally with the thermoplastic material, by discharging thermoplastic material plasticized by a material plasticizing unit (11) from thermoplastic material discharge orifices (1213) and (1223) in the nozzle (12) to the outer periphery of the electric wire (91), while moving the electric wire (91) and the nozzle (12) relatively to each other.
Shielded electrical cable U.S. Patent No.: 9,653,195 Patent date: May 16, 2017 Filed: Aug. 12, 2016 Assignee: 3M Innovative Properties Company USA 18 | WIRE JOURNAL INTERNATIONAL
Fiber optic ribbon cable U.S. Patent No.: 9,651,753 Patent date: May 16, 2017 Filed: June 13, 2016 Assignee: Corning Optical Communications LLC, USA Inventors: Carl Hurley, Kenneth James James Luther, Radawan Ripumaree
A fiber optic ribbon cable includes a stack of fiber optic ribbons, strength members surrounding the stack, and a jacket defining an exterior of the cable. The jacket forms a cavity through which the stack and the strength members extend. The stack has a bend preference, but the strength members are positioned around the stack or are flexible in bending such that the strength members do not have a bend preference. Furthermore, the jacket is structured such that the jacket does not have a bend preference. The cavity is sized relative to the stack in order to allow the stack to bend and twist within the cavity with respect to the jacket as the cable bends, facilitating movement of the optical fibers of the fiber optic ribbons to low-stress positions within the cavity and decoupling the bend preference of the stack from transfer to the jacket.
Spring performance tester for miniature extension springs U.S. Patent No.: 9,651,464 Patent date: May 16, 2017 Filed: Sept. 4, 2014 Assignee: Sandia Corporation, USA Inventors: Bradley Salzbrenner, Brad Boyce A spring performance tester and method of testing a spring are disclosed that has improved accuracy and precision over prior art spring testers. The tester can perform
JUNE 2017 | 19
PATENTS
Inventor: Douglas Gundel A shielded electrical cable includes conductor sets extending along a length of the cable and spaced apart from each other along a width of the cable. First and second shielding films are disposed on opposite sides of the cable and include cover portions and pinched portions arranged such that, in transverse cross section, the cover portions of the films in combination substantially surround each conductor set. An adhesive layer bonds the shielding films together in the pinched portions of the cable. A transverse bending of the cable at a cable location of no more than 180 degrees over an inner radius of at most 2 mm causes a cable impedance of the selected insulated conductor proximate the cable location to vary by no more than 2 percent from an initial cable impedance measured at the cable location in an unbent configuration.
PATENTS
static and cyclic testing. The spring tester can provide validation for product acceptance as well as test for cyclic degradation of springs, such as the change in the spring rate and fatigue failure. ... The results of static spring tests show whether or not a spring has been constructed to design specifications (max and min force values, spring rate, initial tension, etc). These results are very important as miniature springs are used in applications such as biomedical devices, firing and failsafe devices, compact electronic controls, firearms, precision instruments, pharmaceutical delivery devices, petro-chemical processes and aerospace and marine components. A spring being used in these components that does not conform to strict design specifications could cause catastrophic damage.)
Aluminum alloy wire rod, aluminum alloy stranded wire, coated wire, wire harness and manufacturing method of aluminum alloy wire rod U.S. Patent No.: 9,650,706 Patent date: May 16, 2017 Filed: March 17, 2016 Assignee: Furukawa Electric Co., Ltd., Japan Inventors: Shigeki Sekiya, Sho Yoshida, Kyota Susai, Kengo Mitose An aluminum alloy wire rod has a composition consisting of 0.1-1.0 mass % Mg; 0.1-1.0 mass % Si; 0.01-1.40 mass % Fe; 0.000-0.100 mass % Ti; 0.000-0.030 mass % B; 0.00-1.00 mass % Cu; 0.00-0.50 mass % Ag; 0.00-0.50 mass % Au; 0.00-1.00 mass % Mn; 0.00-1.00 mass % Cr; 0.00-0.50 mass % Zr; 0.00-0.50 mass % Hf; 0.00-0.50 mass % V; 0.00-0.50 mass % Sc; 0.00-0.50 mass % Co; 0.00-0.50 mass % Ni; and the balance being Al and incidental impurities, wherein at least one or none of Ti, B, Cu, Ag, Au, Mn, Cr, Zr, --Hf, V, Sc, Co and Ni is contained in the composition. A dispersion density of an Mg.sub.2Si compound having a particle size of 0.5 .mu.m to 5.0 .mu.m is less than or equal to 3.0.times.10.sup.-3 particles/.mu.m. sup.2. In a sectional structure, a concentration of each of
Si and Mg other than a compound is less than or equal to 2.00 mass %.
Wire electric discharge machine including control means for holding wire electrode at desired angle U.S. Patent No.: 9,649,708 Patent date: May 16, 2017 Filed: Jan. 8, 2014 Assignee: FANUC Corporation, Japan Inventor: Hisanori Koudi A relationship between a weight of a reel supported by a column of a wire electric discharge machine when a wire electrode is wound around the reel, and an amount of slanting of the wire electrode when the wire electrode extended between an upper wire guide and a lower wire guide becomes slanted as a result of the column being deformed by the weight of the reel is stored. The weight of the reel is determined during electric discharge machining, and the amount of slanting of the extended wire electrode is determined from the weight of the reel. A compensation amount for the slanting of the wire electrode is determined from the amount of slanting, and the slanting of the wire electrode is compensated by the compensation amount. (section cont’d. on p. 98)
20 | WIRE JOURNAL INTERNATIONAL
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ASIAN FOCUS
ASIAN FOCUS Complaint of bad cable leads to closing of company, call for nationwide reviews
state officials. The China Daily account said Aokai's main owners as well as several managers were detained. Per Aokai’s website, the company has worked with subIt began not with a disaster but with a social media way and railway companies in several other cities—such posting about a cable quality problem. In short time, it as Chengdu and Chongqing in southwestern China—and resulted in an investigation, company denials then apolohas provided services for other state-owned enterprises. gies, the “oddity” of the contract, the closing of the comAokai was founded in 2012, and its first contract was for pany and ultimately a call for a nationwide search. Below Line 3 of the Xi’an subway. are excerpts from some of the multiple reports that ran in Three contractors involved in the Chengdu’s subway China Daily, Sixth Tone and CGTN. system, which used Aokai cables, said they would replace On March 13, an anonthe cables and had canymous net user claiming celed plans to work with to be an employee of Aokai on a new tram line. Shaanxi Aokai Cable Co., Since China’s first Ltd.(Aokai), posted on subway line was built online forum Tianya that in Beijing four decades the Xi’an subway wiring ago, more than two dozen on Line 3, which opened Chinese cities currently last year, was substandard. operate subway systems, The original post was later and a dozen other cities deleted, and the identity have begun planning or of the poster could not be construction of their first confirmed, but the message subway lines. spread online: “Do you The office of General still dare to take the Xi’an Administration of Quality Shaanxi Aokai Cable Co., Ltd. CFP photo. subway?” It claimed that Supervision, Inspection the thinness of wiring was and Quarantine ordered a fire hazard, and implied that the company owner got the provincial quality inspection departments to inspect deal due to connections to Xi’an Metro, the state-owned electric wires or cables produced by Aokai. Metro syscompany that runs the city’s subway system. tems in Chengdu, Sichuan Province, and in Hefei, Anhui Three days later, the provincial party committee of Province, were also found to have used cables from northwest China's Shaanxi Province held a special sesAokai. Xi'an Metro and Chengdu Rail Transit announced sion that ended with a call for a thorough investigation. that they will replace the substandard cables. Hefei Urban An Aokai representative initially said that the company's Rail Transit Co said it would launch an investigation into cables had passed tests from the local Administration of the issue. Quality and Technology Supervision, and that the claims A representative for China Railway Corp. reported were “an attack on our business reputation.” that once the railway operator heard the media reports, Xi’an Deputy Major Lü Jian ordered testing. “All of it investigated which rail lines used the products. Those the five samples of the low-voltage cables from subway cables have subsequently been replaced for lines conLine 3 failed to meet set standards,” said Jin Qun, deputy necting Baoji, Shaanxi Province to Lanzhou, Gansu head of the National Wire and Cable Products Quality Province; Xi'an, Shaanxi, to Chengdu, Sichuan Province; Supervision and Test Center. Chongqing to Guiyang, Guizhou Province; and Lanzhou Wang Zhiwei, legal representative of Aokai, apologized to Chongqing. Three metro lines in Chengdu were also and knelt down in an interview with Xi'an Television affected, according to Chengdu Rail Transit. Station. He admitted that the company won its bid to The administration said that provincial regulators should supply metro systems with a low price that was possible also look into production permits, quality assurance sysby cutting down on materials to increase profits from the tems, raw materials, and whether companies cut down on $4.3 million contract. The bid had topped six others. materials in the production process. “People suspected Yang Xin, the secretary of the city’s commission for of breaking the law and producing substandard products discipline inspection, said that after the test results were should be transferred to judicial departments,” it added. released, the police shut down the company’s operations Yang Xin, head of the commission for discipline inspecand took eight people into custody. Yang said that the tion in Xi’an, the city’s top anti-graft authority, said an investigation would examine all past projects that Aokai investigation examined the project’s data and documents, took part in and look into potential abuses of power by
22 | WIRE JOURNAL INTERNATIONAL
ASIAN FOCUS
and looked into the supervision work by administrative bodies and law enforcement departments. This is not the first time the company’s cables have proved to be substandard. Between Oct. 12, 2015, and Nov. 17, last year, the Bureau of Quality and Technical supervision in Xi’an conducted four quality inspections of the cables to be used for the line, sampling six batches of cables provided by Aokai: three were below the required standard, and one had a forged quality report. “Yet despite the ensuing administrative punishments, the company has still managed to keep providing faulty cables for the Xi’an subway system and even extended its business to Chengdu, capital of Southwest China’s Sichuan Province,” one report said. “It is only fair to assume some rent-seeking was involved in the cable manufacturer’s success in winning the tenders for these projects. Further investigations should also be made to uncover those involved in the power-for-money chain that enabled the company to provide defective products. These rent-seekers who feasted on public money at the risk of compromising people’s safety must be held accountable.” The reports also noted that Aokai received the order for the cables just two months after it began production. “At that time, it was hardly known in the market but the Shaanxi Administration for Industry and Commerce put it on its list of ‘well-known brands’. How could that happen? Was there any deal behind the scene? Was there
A Xi’an Metro subway car. CTGN photo. any official involved? All these are questions that need answering.” On a positive note, there was praise from some “netizens” for the swift reaction by Xi’an’s new Party secretary, Wang Yongkang. “This is the efficiency revolution that started with picking up cigarette butts,” a Xi’an net user wrote on microblog platform Weibo, referring to previous news of Wang personally collecting discarded cigarettes to clean up the city. Wang has been in office since December.
JUNE 2017 | 23
PEOPLE
PEOPLE Herbert Freyre, who joined Miltec UV as a manufacturing engineer, has been promoted to manufacturing engineering manager. He has years of experience in several industries, including aerospace and oil and gas. He holds a B.S. degree in mechanical engineering from Catholic University of Peru, and an MBA. Based in Stevensville, Maryland, Miltec UV provides UV technology to fields that include wire and cable. Jonathan Faia has joined Laboratory Testing, Inc., as director of quality assurance for the company’s material testing, non-destructive testing and calibration lab. He will also oversee preparation of certified test reports, administer the industry specifications program for testing and calibration, and Faia lead continuous improvement activity. He has more than 30 years of experience, working his way up from serving as a U.S. marine and aircraft technician to director of quality at a manufacturer of specialized fluoropolymer products for the automotive and aerospace industries. He held his last position for over 15 years. He holds a B.S. degree in technical management from Embry-Riddle Aeronautical University. He replaces Frank Peszka, who retired at the end of 2016, but continues to serve in a consultant role. He joined the company in 2004 as a quality assurance specialist with more than 30 years of experience, and was promoted to quality assurance manager in February 2006. Based in Hatfield, Pennsylvania, USA, Laboratory Testing, Inc., is an independent materials testing and metrology laboratory that serves sectors that includes wire and cable. WAGO made a personnel item earlier this year. Patrick Butler has been named a regional sales manager for the company in Canada, serving Southwestern Ontario. An Ontario native, he previously spent 16 years with Phoenix Contact, where he served as district application specialist, a regional sales manager Butler and a regional channel manager. Based in Germantown, Wisconsin, USA, WAGO supplies a range of spring pressure connection technology as well as an extensive range of interconnect, interface and automation solutions.
24 | WIRE JOURNAL INTERNATIONAL
OBITUARY Joseph William Scher, whose wire and cable industry career spanned more than a half century, died April 30, after a brief illness, at age 82. Fondly known in the industry as “Bill,” he joined Weber & Scher Mfg. Co., Inc., in 1957, and over the years became a highly respected and instrumental figure in the wire and cable industry. Prior to that key step, he earned a degree in engineering from Dartmouth College in New Hampshire, then a master’s degree in mechanical engineering from the Thayer School at Dartmouth. He also became a licensed Professional Engineer in New Jersey. Directly after his studies, Bill Scher joined the company, which had been co-founded as a tool & die company in 1915 by his father, George Scher, and Otto Weber. He immediately became responsible for the sole operation of the company. He advanced the technology by adapting and standardizing the equipment so it could be used in the diverse environments of independent U.S. cable manufacturers. That technology continues to be widely used today in the worldwide production of optical fiber cables, copper teleAn early day picture of Joseph phone cables, power William “Bill” Scher at work. cables and more. Bill Scher also served as a consultant to the wire and cable industry, in his early years, serving companies such as Indeco Peruana in Peru, Accevenca in Venezuela and ITT in New York. His services extended to the complete development of cable manufacturing facilities. His efforts in the 1960s and 1970s led to the company serving established and newly emerging markets throughout the world, including the Far East as well as central Europe, eastern Europe, and the Middle East. In 2007, Bill was awarded the WCTI Technical Achievement Award for his 50+ years of involvement in the wire and cable industry. He was also a member of the American Society of Mechanical Engineers for many years. Bill is survived by his wife of 62 years, Joan; and two sons who each continue the family legacy: Douglas, who serves as vice president and COO, and Gregory, who serves as president/COO; and six grandchildren.
FIBER WATCH
FIBER WATCH Prysmian Group to supply range of fiber to Italian cable manufacturer The Prysmian Group reports that it has entered into a contract to annually supply its standard and special optical fiber to Tratos, an Italian manufacturer whose products include telecom cables. A press release said that the fiber—to be used by Tratos in its cables to development of ultra-broadband and FTTH networks in Italy and abroad—will be manufactured at Prysmian Fibre Ottiche Sud (FOS) plant in Battipaglia. That site, it said, annually produces more than 25% of the approximately 35 million km of fiber that is made by the overall Prysmian Group. “This contract represents an important collaboration between the two major Italian firms producing passive telecommunications components,” said Carlo Scarlata, chief commercial officer at Prysmian Cavi e Sistemi Italia. “This is a way for Italy to show that it can act independently in building the infrastructure needed to achieve the European goals.”
Tratos, one of Europe’s largest independent cable manufacturers, has five manufacturing facilities in Italy and the U.K. “The agreement between our company and Prysmian Group is founded on a strong desire for an ongoing, long-term partnership, supported by the experience and mutual esteem built in the two companies’ more than 30-year relationship, with the aim of making a shared contribution to Italy’s digital development and growth,” said Trato Chairman Albano Bragagni. The release said that growth prospects in Italy’s broadband network have been boosted with investments in FTTH and next-generation technologies (5G) by manufacturers and the Ministry of Economic Development. The European Commission’s Digital Agenda 2025 set a goal to be able to offer by that year at least one Gigabit per second. The goal is to target uninterrupted 5G coverage in all urban areas for all European households, and connections that offer download speeds of at least 100 Mbps in rural and urban areas. “Fiber optic networks are currently the only possible technological solution to achieve these ambitious targets.”
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26 | WIRE JOURNAL INTERNATIONAL
5/17/17 5:40:59 PM
FASTENER UPDATE
FASTENER UPDATE Lindstrom acquires Hodell-Natco’s packaged fastener business
Harbour Group and the Lindstrom team are uniquely suited to accomplish our goal.”
Lindstrom, LLC, has acquired the packaged fastener business of Hodell-Natco Industries, a leading distributor of fasteners and related products with six U.S. branches. A press release said that Hodell-Natco, based in Cleveland, Ohio, provides more than 23,000 packaged products to fastener distributor customers. “Packaged fasteners have been part of our core business since the acquisition of Titan Fasteners in 2014. Packaging is now one of Lindstrom’s specialties and we are excited to offer more products to our distributor customers,” said Lindstrom President Mike Wrenn. The deal, the release said, will bolster Lindstrom’s ability to provide hard-to-find fasteners, kits and assortments; specialty plating and other secondary process, special lengths, thread pitches and other custom fabrications for inch and metric sizes as well as custom packing. Hodell-Natco President Kevin Reidl said that the deal made sense for both parties. “Our focus at Hodell-Natco is to continue growing our core end user business. When we determined that the packaged fastener business was no longer core to our long-term vision...we began the search for a partner that we knew would be diligent in their care for our highly valued packaged fastener customers.
Simpson Strong-Tie expands fastener product scope with purchase of Gbo
28 | WIRE JOURNAL INTERNATIONAL
Earlier this year, construction connector manufacturer Simpson Strong-Tie acquired Gbo Fastening Systems AB, a Swedish company with more than 200 employees in Sweden, Poland, Norway and Romania. A press release said that the acquisition will provide Simpson with Gbo’s complete line of CE-marked structural fasteners and unique fastener dimensioning software for timber applications. Based in Sweden, Gbo’s sales are primarily on the professional construction and DIY markets within the Nordic countries, Eastern Europe and Russia. In addition to premium quality nails, screws, collated fasteners, mechanical and chemical anchors and connectors, Gbo is known for its high-level technical support, logistics support as well as a broad selection of merchandising solutions for retailers. The acquisition benefits both Simpson and Gbo, said Simpson Strong-Tie CEO Karen Colonias. “Both companies share the same passion for high-quality, innovative products and have consistently focused on providing exceptional customer service.”
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WAI NEWS
MEET YOUR PEERS. ACHIEVE YOUR GOALS. JOIN WAI TODAY. The following individuals either recently joined WAI or became Platinum Members through their companies. Rajat Agrawal Excel Craft Pvt. Ltd. Robert A. Archambault Director of Engineering Judd Wire Inc. Maxime Auclair ArcelorMittal Montreal Inc. Melissa Botti Product Marketing Manager, Ground Rods and Conductors Pentair Rebecca Cranford SVP Sustainability, EHS & Quality Southwire Co. Bob Frasetto Vice President of Sales Shingle Belting RaĂşl G. Garcia Director Technical Center Viakable
Greg Holder Engineer Pentair Cameron William Hoyle Owner Fibrefield Industries Ltd. Michael S. Kahl Analytical Chemist Encore Wire Corp. Markley Ligon Operations Manager Rea Magnet Wire Karl Lind Sales Engineer EVG Patricia J. Moore President/Owner Wire Products Supply Lesli Nichols Supply Chain Manager Champlain Cable Corp.
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Paul J. Pugsley Sales Manager Primetals Technologies Ltd. Donald Reed Director of Operations TE Connectivity Marc Rheaume Strategy & Continuous Improvement Manager ArcelorMittal Montreal Inc. Mark L. Roden Vice President/ General Manager SCR Technologies Southwire Co. Steven D. Schor Marketing Manager Elektrisola Inc.
Ryan Schuelke Vice President Sales Enercon Industries Juergen Seybold President Lutze Inc. Dakota Shaffer Sales Southern Industrial Equipment Chris Skidmore Nonferrous Marketing OmniSource Bryan Sullivan National Sales Manager-Strand Bekaert Corp. Walter C. Wolff President W.C. Wolff Co.
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32 | WIRE JOURNAL INTERNATIONAL
It’s near tee time for Midwest Chapter annual golf tourney; 3 others to follow Time is very, very short for anyone wanting to sign up for the WAI’s first Chapter’s golf tournament. WAI’s Midwest Chapter will hold its 15th Annual Golf Tournament on June 16 at the St. Andrews Golf & Country Club in West Chicago, Illinois. Last year, Donald Stephanie and Robert Robinette, both from Western Engineered Products, shot a sparkling 11 under par to grab top honors. Three other WAI chapters will hold their golf tournaments. The New England Chapter will hold its 23rd Annual Golf Tournament on Sept. 12, at the Golf Club of Avon, Avon, Connecticut. The WAI’s Southeast Chapter will hold its 16th Annual Golf Tournament on Sept. 21 at the Rock Barn Golf and Spa, Conover, North Carolina. The Ohio Valley Chapter will hold its 14th Annual Golf Tournament on Oct. 5 at the Grantwood Golf Course in West Chicago, Illinois. Each of the above golf tournaments offers a range of sponsorship opportunities. They also serve as fundraisers for their respective chapter college scholarships, so taking part is not just fun, it’s supporting a good cause. For information on any of the above chapter events, contact WAI’s Steve Fetteroll, tel. 203-453-2777, ext. 115, sfetteroll@wirenet.org.
So why do golfers go through all this? Because, on any given day, glory may await, as it did last year for the Southeast Chapter golf tourney’s winning team of Jason Morrow, Tim McElhany, David Cabe and Ricky Rudisill. A key to their final score of 56 was an amazing double eagle. It was Hole 7, 444 yards out and the conditions were damp. Ricky hits a strong tee shot, then David (shown) holes out from 195 yards. Oh, utter bliss!
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INTERWIREPREVIEW PREVIEW INTERWIRE Many Interwire exhibitors reported that attendee quality was especially good, with genuine interest in specific projects.
Interwire 2017: a multi-level success From the exhibits to the technical programs to the social events, the results were positive for the Americas’ wire and cable industry fair, which included the Interwire trade show, the WAI’s 87th Annual Convention and its first Global Ferrous Rod & Wire Symposium. Held May 8-11, 2017, at the Georgia World Congress Center (GWCC) in Atlanta, a total of 3,807 people participated. “Interwire was a success and it accomplished a number of our objectives,” said 2017 WAI President
The Mordica Lecture by Hal Moss traced the evolution of continuous casting, an arduous time of trial and error. 34 | WIRE JOURNAL INTERNATIONAL
David Hawker, who cited a list of achievements: the training and technical programs and the new ferrous symposium helped educate a cross section of industry professionals; the sold-out exhibit floor offered attendees lots of technology and services; and there was tremendous involvement of corporate sponsors and an incredible level of volunteer participation. All of that, he said, points to the health and commitment of WAI’s support network.
Gib Grooms, director of training, doubled as one of the guides for the tour of two Southwire Company plants.
INTERWIRE PREVIEW The Fundamentals of Manufacturing program set another record (149 participants!) for attendance. See p. 46. The event got off to a record start before the full schedule started on Tuesday, May 9. The day before, 149 people took part in the Association’s day-long Fundamentals of Wire Manufacturing program. See p. 46. Other attendees took part in the tour of two Southwire plants. Participants were impressed by the vast scope of the operation, and by the well-prepared tour guides. Turing both sites required the use of vans to follow the processes in the one-million sq-ft utility products plant and the 750,000-sq-ft building wire plant. The trade show saw a wide range of wire and cable products, machinery, ancillary equipment and services from more than 400 exhibitors from 25 countries that were represented on 110,000 sq ft of exhibition space. Companies that exhibited equipment fared especially well.
Presenter Tzyy-Shuh Chang at the Global Ferrous Rod & Wire Symposium.
John Barteld had attendees look to the skies for inspiration at his Manufacturing Management Workshop.
Attendees gather prior to the opening of the show floor at Interwire 2017 in the Georgia World Congress Center.
JUNE 2017 | 35
INTERWIRE WRAPUP
“This was one of the best Interwires on record!” said MGS Director of Sales and Marketing Jeff Swinchatt, whose company displayed the FAT820 SFL Series fully automatic dual take-up. “We were excited to see all our friends from the industry and meet some new ones. This year’s event highlighted serious conversations and enthusiasm for our newest system capability. It was a great opportunity to show off our latest accomplishments and catch up with our friends.” He added that MGS had sales at the show, which was both remarkable and much appreciated. Exhibitor Orlando Martinez of Davis-Standard LLC agreed that the event was fruitful. “The overall impression of the D-S team is that Interwire 2017 was a solid show and provided us with good leads. We learned about good projects we did not know about, and we had a chance to meet with customers we’re currently working with in a more relaxed setting. Atlanta is such a great venue for this show.” “Many existing and potential new customers visited us during the successful three days and we were
proud to present the leading cable manufacturing technology to them,” said Maillefer’s Veikko Nieminen, director, sales and marketing, wire and cable business line. “It was great to see the positive atmosphere among the North American cable producers. The economy in the U.S. is still on a growing path, generating new business opportunities for our customers.” The July issue of WJI will present a range of capital equipment offered by exhibitors. The 2017 staging of Interwire saw the introduction of a new companion event, a “conference within a conference”—the Global Ferrous Rod & Wire Symposium (GFRWS)—an added element that was first introduced in 2011 when Interwire saw the successful introduction of the Global Continuous Casting Forum, which was also (Cont’d on p. 41)
From l-r, Beneke Wire’s Michael Beneke, President Ken Downs and V.P. Sales & Marketing David Sledge.
Beneke Wire agreement is key in aluminum redraw rod mill At Interwire, Beneke Wire Company announced that the relationship between it and Vista Metals Georgia has produced a new aluminum rolling mill that will assure that Beneke Wire will always have ready access to all the redraw rod it needs. The news, said Michael J. Beneke, assistant vice president of sales and marketing, is meaningful on multiple levels. Besides securing access to aluminum redraw rod, he said that Beneke Wire is following a path established long ago by Charles J. Beneke, his grandfather and company co-founder. “My grandfather was instrumental in the building of the rolling mill at Reynolds Metals in Listerhill, Alabama, and to think that 65-plus years later, I am now part of a team that is involved in giving the U.S. a rolling mill is very gratifying. 36 | WIRE JOURNAL INTERNATIONAL
This is exciting news as this action will bolster our company’s outlook and longevity. I’m sure my grandfather would approve.” The new mill, which will produce ingot cast and rolled hard and mechanical alloy redraw rod, is located at the campus of Vista Metals Georgia in Adairsville, Georgia. The installation of the casting and rolling facilities is complete, and the facility itself is the most technologically advanced rolling mill in the U.S. for hard and mechanical alloys, Michael Beneke said. “After decades of suppliers exiting the aluminum hard alloy market, the addition of this new supplier to the industry will help stabilize the market.” After qualification of the products at its plant in Louisville, Kentucky, Beneke Wire will distribute and
support the hard alloy product in the field. Beneke Wire has exclusive rights to the produced redraw rod, and it will make excess capacity available to the global market. Beneke Wire will also offer technical and customer service to support the redraw rod. Michael Beneke said that Vista Metals is an ideal partner: both companies are non-union shops and family-owned, and they were even founded the same year (1968). Further, their business philosophies mirror each other: Vista Metals’s slogan is Excellence Always while Beneke Wire’s is Better By Beneke. “This mill and partnership will allow Beneke Wire Company to supply quality products to the market place for another 49 years,” Michael Beneke said.
INTERWIRE WRAPUP
Glimpses from the show floor
JUNE 2017 | 37
THANK YOU FOR YOUR SUPPORT sponsors
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WAI acknowledges the following contributors to the Interwire 2017 technical program The educational program at Interwire 2017 was the result of the combined efforts of dozens of experts, volunteers, and special guests. This year’s successful program would not have been possible without their dedication to the Wire Association International’s educational mission.
Authors/ Presenters Vincent Arbet-Engles Dane Armendariz John Barteld Anand Bhagwat Michaela Boockmann Carmelo Maria Brocato Patrick De Bruyne Terry Carroll Enrico Conte Boris Dardel Kevin Doyle Karen Duff Brian Frame Albert Groothedde Doug Grover Dan Howard
Justin Hrbacek Kevin Johnson Michael Kahl Juho Kalliokoski Stefano Lodolo Hidetoshi Nagashima Joao Norona Mark Plantier Nicola Pontoni Horace Pops Robert Prevatt Galen Quinsey Juha Säily Ryan Schuelke Ali Shehab Willem Sundblad Shintaro Takamiya Kazunari Yoshida Alberto Voltolina
Moderators Dane Armendariz Steve Bonnell Brian Burr Mark Garretson Tracy Gooding Bill Jarae Jason Jones Erik A. Macs Nick Marchioli Brian Parsons Ben Paschal Bill Reichert Gary Spence Andy Talbot Tim Wampler
Fundamentals Instructors Anand Bhagwat Peter M. Blackford C. Richard Gordon David Gzesh Erik A. Macs Jack McAfee Stacy Martin Thomas Maxwell Jr. Horace Pops
Guest Speakers Hal Moss Rick Smith
The Wire Association International, Inc. 71 Bradley Road | Suite 9 | Madison, CT 06443-2662 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org
INTERWIRE WRAPUP
Glimpses from the show floor
40 | WIRE JOURNAL INTERNATIONAL
INTERWIRE WRAPUP Wire Foundation’s John Drummond and WireLink Scholar Bruce Jones.
Zumbach Electronics Corp. was among the exhibitors that saw a lot of activity at their booth.
held in 2015. The GFRWS, a discrete program, focused exclusively on topics of interest to the ferrous industry. The schedule, running concurrently with Interwire, offered technical presentations on processing, equipment improvements, testing, quality, and measurement techniques. It also featured a reception at the College Football Hall of Fame. For a wrapup, including the thoughts of the individual most responsible for making the event possible, see p. 42. The WAI Member Rewards Luncheon covered a multiple aspects, from saying “thanks” to WAI members, to honoring certain individuals to holding a fun raffle and
serving as a lead in to the keynote speaker. It proved to be a very busy event, led off by Hawker. “The level and stature of the attendees confirm that Interwire is a core event in our industry,” he said. WAI Past President Andy Talbot said that having spent the 37 years of his life working in the wire industry, he enjoyed his time contributing to the Wire Association International, and encouraged others to follow. In presenting the President’s Award that recognizes contributions by a WAI member, Hawker told the audience that he felt compelled to do something unprecedented: (Cont’d on p. 48)
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A group shot of attendees at the first-ever staging of the Global Ferrous Rod & Wire Symposium.
New steel sector event has solid start Creating a technical event from scratch is no easy feat, but due to sterling efforts by WAI members—led by Bhaskar Yalamanchilli, Gerdau Long Steel North America, the event driver—the overall reaction from participants in the first Global Ferrous Rod & Wire Symposium (GFRWS) was positive, enough so that it may well be repeated. The event—co-located with Interwire 2017, and scheduled so attendees would also spend time on the show floor—saw presentations made over two days. It also included a keynote speaker and a reception. A total of 65 attendees took part, a number that, while modest, met the goals of the organizers. “We knew that starting a new event would not be easy but the results really were quite good,” said Yalamanchilli. “I’m optimistic that we are on a good path for the indus-
Bhaskar Yalamanchilli, Gerdau Long Steel North America, welcomes attendees to the GFRWS. 42 | WIRE JOURNAL INTERNATIONAL
try. Our goal was to provide a forum and gathering place for the ferrous sector, and the Global Ferrous Wire & Rod Symposium did that. We will be meeting soon to discuss our future plans.” Sessions included presentations in four areas: High Carbon Processing, Processing & Equipment Improvements; Property & Testing Advancements; and Quality Monitoring. Individual presentations were made from representatives from Cascade Steel Rolling Mills; CBMM North America, Inc.; Colorado School of Mines; Danieli & C. Officine Meccaniche SpA; Howar Equipment, Inc.; Lamar University; LAP Laser LLC; Minova USA, Inc.; NV Bekaert SA; OG Technologies, Inc.; Plasmait GmbH; Primetals Technologies USA LLC; SMS Meer GmbH; Sterling Steel Co.; and the U.S. Air Force Academy.
L-r at the GFRWS luncheon; speaker Frank McGrew IV, WAI Past President Andy Talbot, Mid-South Wire; WAI Executive Director Steve Fetteroll; 2016 WireLink Scholar Andrew Bettin, Sterling Steel Co., Nichole Garza, Sterling Steel Co., and Jeff Kramer, Cascade Steel Rolling Mills.
Speaker Frank McGrew IV at the GFRWS luncheon.
Willie Hauer discussed plasma heat treatment processes.
“The program ran very smoothly, and that’s really a testament to the diligence and foresight of the planning committee,” said Director of Education Marc Murray. “The small group of volunteers who put this together were very conscientious through the lengthy planning process. They were meticulous about designing a cohesive program of topics and presenters to ensure the audience got the best practical and technical information available. Everyone who benefitted from the program owes a debt to Bhaskar Yalamanchili and Pete Power from Gerdau, and Bruce Kiefer and Wade Krejdovksy of Primetals. Their support, and the support of their companies, was above and beyond generous.” Topics included: tensile and shear loading on indented PC strand cable bolts; development of high-quality wire rod through steel mill continuous improvement; H-C grades for wire rod lines; microstructural characterization of H-C wire steels; thermo-mechanical rolling to improve utilitarian properties of electrode wires; SMS solutions for high-quality/productivity wire rod mills; modernization of Kroman wire rod mill; capital projects/continuous improvement at Sterling Steel Co.; H3 wire rod mills; quenched and partitioned steel wires; production develop-
ment for steel wire rod; heat treatment of flat and profiled wire made of austenitic/ferritic stainless steels; and evaluation of properties of wire rod by shear punch test. Another presentation was presented by luncheon speaker Frank McGrew IV, a managing partner at McNally Capital/Merchant Banker, who had a positive message for attendees. His talk, “Made in the USA – The Next Industrial Revolution,” offered reasons to believe that, with ingenuity and a sound approach, manufacturers can still be competitive and successful. The reception at the College Football Hall of Fame, which previously hosted the Interwire 2015 reception, proved to be an enjoyable gathering place for attendees. Observed one attendee, industry veteran and frequent presenter Walther Van Raemdonck, the event was quite good for a first-time staging. “It was very well organized, all documents were available and hard copies distributed, which allows for making some interesting notes during the presentation. There was a good selection of papers, and even the equipment suppliers found a balance between commercial talk and technological background.” He added that he especially liked the Danieli presentation as it was “very well documented and entertaining!”
Topics for attendees were presented in four sessions.
Bruce Kiefer, foreground, of Primetals Technologies. His company had three presentations. JUNE 2017 | 43
Thank you to our
2017 SPONSORS The Wire Association International, Inc., thanks all of its Global Ferrous Rod & Wire Symposium sponsors for their support.
STEEL LEVEL
GOLD LEVEL
SILVER LEVEL
WAI acknowledges the following contributors to the Global Ferrous Rod & Wire Symposium Authors/ Presenters Andrew Bettin Anand Bhagwat Thad Boudreaux Tzyy-Shuh Chang Radek Cieslar Karel Milan ÄŒmiel Maicol Cimolino Leonardo Radicchi S. Cunha Emmanuel De Moor Steven Derycke Primoz Eiselt Claudio Fabbro Mario Fabro Nichole Garza Ramesh K. Guduru
Willy Hauer Craig Hlady Howard Huang Steven Jansto Stephanie Kaster Jeff Kramer Wade P. Krejdovsky Christophe Mesplont A. Mestroni Likhith Nalluri A. Olsson Roberto Perez Peter Power P.J. Pugsley Franz Resch Igor Rogelj Jianjun Shi
Larry Smith Stephen C. Tadolini A. Taurino Walther Van Raemdonck Bhaskar Yalamanchili
Moderators Anand Bhagwat Emmanuel De Moor C. Richard Gordon Walther Van Raemdonck
Guest Speakers Frank A. McGrew IV Rick Smith
The Wire Association International, Inc. 71 Bradley Road | Suite 9 | Madison, CT 06443-2662 USA | Telephone: (001) 203-453-2777 | Fax: (001) 203-453-8384 | www.wirenet.org
INTERWIRE WRAPUP
Fundamentally speaking, it was quite the experience Fundamentals of Wire Manufacturing has continued to attract larger audiences, this time a record 149 participants. WJI asked some attendees if they would be willing to share their thoughts after Interwire ended. Below are their responses. WJI: Have you been to the Fundamentals program before? Did you ask to go or were you sent? It was my first time attending the Fundamentals course and my first Interwire show as well. I asked my manager to attend once I saw a brochure that had details about it. I realized the course subjects (ferrous track) are things I deal with every day as a manufacturing engineer supporting the wire drawing department at our company. David Killmeyer, manufacturing engineer, Rochester Wire & Cable, LLC. I joined NEWTC last September, I asked to go to learn more about wire and cable production. Rick Larson, director of research and development, New England Wire Technologies. This was my second time attending the Fundamentals program. I had been asked to go. Shane Weller, design and processor engineer, diversified products, East Penn Manufacturing Co. This was my first time attending the Fundamentals program. I was asked to attend this program. Justin Werley, DBE supervisor, East Penn Manufacturing Co. I am new to the wire and cable industry and am trying to learn as much as I can. I asked to go because it seemed to offer a great introduction to the field. Laura Thoma, Ph.D., commercial development engineer, Corporate Research, ARKEMA Inc.
46 | WIRE JOURNAL INTERNATIONAL
WJI: Was one element most helpful/interesting? The problem solving segment was a nice change of pace from some of the more technical sessions. It really got me to think about the problem solving process as a whole and how effective it can be. Sometimes we drift away from the process and react more to the glaring potential cause rather than diving into a full problem-solving analysis. Shane Weller, East Penn Manufacturing Co. The presentation on wire breaks and how to use the information to determine root-cause was the most interesting. The presentations which discussed the influence of die approach angle were very helpful. ... This was a good use of my time. Rick Larson, New England Wire Technologies. The die course was really helpful. It covered the general use of dies as well as offering some basic troubleshooting of what can go wrong. The “Wire Breaks & Surface Damage� visuals were great. It definitely takes a practiced eye to distinguish between all the different breaks and identify their causes. Laura Thoma, ARKEMA Inc. In the morning sessions, the drawing dies portion was very beneficial. During the lecture, I was diligently taking notes on things we really need to try at my plant. Some of those we have briefly discussed, but just never put into action. Hearing it from an expert like Thomas Maxwell of Die Quip confirmed how we can make strong process improvements for our machines. David Killmeyer, Rochester Wire & Cable, LLC. I was particularly interested in the trouble shooting session. Learning about the details and intricacies of die and tip manufacturing. Justin Werley, East Penn Manufacturing Co.
WJI: Did you find this day-long program of value? I thought that the day long program was a good use of my time. I liked that the two tracks were combined in the morning for topics applicable to both tracks, and then split into ferrous and nonferrous for the afternoon. I definitely
Yes, it was a good use of my time and I would recommend it to a person that is new to the wire and cable business. The presentations were a good overview, but some presenters should have reduced their more than two hour talks into a more coherent 40-minute presentation. Rick Larson, New England Wire Technologies. I felt the program was very informative and a great use of my time. I would certainly recommend the program to others. Shane Weller, East Penn Manufacturing Co. The program was definitely a good use of my time while in Atlanta for the Interwire Trade Expo. I would recommend this program for anyone new to the industry. Justin Werley, East Penn Manufacturing Co. This was an excellent use of my time. My manager arrived Monday evening (he attended the exhibit portion only) and throughout our entire dinner all I could talk about was what I learned and how I can apply the ideas at our facility. In fact, we discussed who else at our plant (most likely the wire mill supervisors and shift lead oper-
ators) would also benefit by attending the course. David Killmeyer, Rochester Wire & Cable, LLC.
WJI: Anything else you’d like to add? Even though this was my second time attending the fundamentals program, and the third or fourth time I heard some of the speakers, I was still able to take in something new from each of them. Shane Weller, East Penn Manufacturing Co. Having the slide shows printed out in a binder for everyone was helpful due to some of the speakers having to rush through their slides due to time constraints. Justin Werley, East Penn Manufacturing Co. The entire show was a great way to meet others in the industry who are working through or have already achieved success in problems I’m currently dealing with. The extensive assembly of manufacturers and suppliers gave me numerous contacts to assist in productively resolving obstacles in the wire mill and beyond. It also triggered ideas that I can apply, either using purchased equipment or custom designs, which will lift the wire mill to a whole new level of safety, quality, and production... I’ll definitely be attending the show in Nashville. David Killmeyer, Rochester Wire & Cable, LLC. Solid overview. What should be added is a presentation on latest technology advancements related to wire and cable production as well as what may be coming within the near future. Rick Larson, New England Wire Technologies.
Fundamentals Sessions
Session instructors Rick Gordon, above, and David Gzesh.
JUNE 2017 | 47
INTERWIRE WRAPUP
learned a lot and would recommend it to others. Laura Thoma, ARKEMA Inc.
INTERWIRE WRAPUP At the Awards Ceremony, top l, WAI President David Hawker with General Cable’s Tim Wampler and Southwire’s Tom Heberling, who each won the President's Award. WAI 1st VP Richard Wagner at the ceremonies. Below, Mordica Memorial Award winner Harold Moss with son, Brian; wife, Marjorie; and daughter, Kim Ritthaler. (Cont’d from p. 41) to present the award to two individuals: Tim Wampler of General Cable and Tom Heberling of Southwire, who had co-chaired the Member Relations Committee, and in doing so had done an utterly remarkable job. “The seven prior awards were all made for a single person,” he said. “We felt that Tom and Tim each deserved the award, and we could not separate them because of the remarkable partnership approach these two professionals brought.” He noted that in leading committee efforts they did a great deal of grunt work, including meeting together on Sundays to make sure that efforts to bolster membership worked. 2015 WAI President Bill Reichert introduced the 2017 Donnellan Memorial Award Winner, Richard R. Miller, outlining not just his career, but his spearheading Southwire’s ambitious 12 for Life Program that offers direction and possibilities for young students at risk. Miller began by admitting that he was not big on getting industry honors, and that he deliberately did not want to have prepared
48 | WIRE JOURNAL INTERNATIONAL
remarks. Instead, he talked about what mattered to him, putting his career experience in context. “I’ve been doing this two thirds of my life. I appreciate it. It means a lot to me. It wouldn’t be possible without Southwire.” The experience is more than just work, he said, as the industry is a community, one where even competitors can be friends. “I’ve also been married two thirds of my life,” said Miller, whose life-service analogy—family, community and industry—was moving. He said that he found great satisfaction in supporting the wire industry through his volunteer work at WAI, and encouraged others to follow. “You need to be committed to what you do. ... Get involved. It’s an extension of your job, and if you do it right, it’s also fun.” Gary Spence, a retired Encore Wire executive who was the driving force behind the creation of the first Global Continuous Casting Forum in 2011, introduced Harold Moss, the Mordica Memorial Award winner. “I’ve known Hal for 45 years and consider him an industry icon,” he said, explaining that Moss served in a key pioneer role that is hard to appreciate today.
INTERWIRE WRAPUP Above: individuals recognized by Dave Hawker at the luncheon included, l-r, Richard Miller, Andy Talbot, Tim Wampler, Harold Moss and WireLink Scholar Bruce Jones. Absent is Tom Heberling. Right: a meeting of past and present WAI presidents. Donnellan Memorial Award Winner Richard Miller encourages people in the wire and cable industry to be active on multiple levels.
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INTERWIRE WRAPUP 2016 WAI President Andy Talbot, l, with a photo collage presented to him by 2017 WAI President David Hawker.
WAI Past President Tom Moran, National Standard Co., with Board Member James York, Leggett & Platt.
Moss, who quipped that it was a special moment for Spence as he “had never seen me in a suit,” then presented his Mordica Lecture. He traced the evolution of continuous casting and rolling to its present day acceptance as the worldwide standard for producing copper rod. He outlined the big picture of how it happened. Back in the early 1960s, Western Electric, the manufacturing arm of AT&T and a big consumer of U.S. copper, wanted a better way to produce copper rod. Multiple discussions with the leading copper companies fell on deaf ears. Western then considered alternatives, one of which was to produce higher-quality 10,000-lb coils, 40 times the traditional size. A joint venture was entered into with Properzi, Southwire and Western Electric. A two-year study concluded that it was feasible. Southwire and Western went their own ways. Western installed a Properzi line in its Staten Island scrap reclamation plant. At that point there was only a caster and mill, no auxiliary equipment. What followed, from ground zero, was a story of innovation—lots of trial and error—and discovery. One of the biggest challenges on a continuous process was improving component life and reliability, which was overcome by taking it one day at a time working through each concern. One of the initial obstacles was caster wheel life to which it was ultimately discovered that changing to a different
alloy wheel material would solve this issue. “Every day was an adventure,” Moss said. Wire Foundation President John Drummond reported that Bruce Jones, the 2017 WireLink Scholar, got to see a good spectrum of the U.S. industry during his two week visit. “It was a fantastic week, and to all who let us in your plants, I say thank you.” He then introduced Jones, technical account manager for wire rod for British Steel, who thanked everyone involved in making his memorable experience possible. His report will be in the July WJI issue. WAI held two raffles, one at the WAI Members Reward Luncheon for WAI Members only, which had neat prizes, including a drone, and a second one, held shortly after the luncheon at the end of the keynote presentation by 3D printing guru Rick Smith. See p. 54. The conference program included more than a dozen technical and practical presentations on nonferrous and general topics. In addition to the Fundamentals of Wire Manufacturing primer course, there was a panel presentation on Industry 4.0. Three presenters in different aspects of providing technology that fits into a “Smart Factory” approach spoke to some 50 attendees. The panelists said that they believe the topic that is likely to become of greater interest as the technology, which is more focused in Europe, finds greater traction in the Americas.
WAI’s board of directors discussed a range of topics, from content for future events to the Association’s online presence.
50 | WIRE JOURNAL INTERNATIONAL
INTERWIRE WRAPUP Horace Pops and Anand Bhagwat had the answers. Dr. Horace Pops, the industry guru of wire breaks, held a workshop on fines and annealing. He also was part of another new program, “Ask the Experts,” which saw Pops and Anand Bhagwat team up on the show floor on Thursday to answer questions. Also on Thursday, industry veteran John Barteld, who previously held the top posts at both the International Cable Makers Federation and IWCS, presented a Manufacturing Management Workshop. See next page. Meanwhile, behind the scenes, the WAI’s different bodies met to plan out the Association’s future focuses and directions.
At the Member Relations Committee meeting, l-r, are Chairman Jay Munsey, Ken Hardin and Dave Ferraro.
At the Executive Committee meeting, l-r, are WAI 2nd Vice President W.T. Bigbee, Past President Andy Talbot and WAI 1st Vice President Richard Wagner. JUNE 2017 | 51
So, who was lucky at the show?
John Barteld started his Manufacturing Management Workshop by asking participants to create a duck from bags of Legos. A few minutes later, he asked everyone to look at what others had done. “You’ll notice that everyone’s duck is different,” he observed. He then showed pictures of geese flying in a V formation, noting how they switched positions so that the flock as a whole flew more efficiently. Each bird has to be in tune with the others for the collective unit to work well, he said, explaining that understanding the value of cooperative efforts and displaying mutual respect for what others contribute is part of the managing experience. Barteld then focused on the challenges presented to management as the nature of the workforce undergoes historic changes. “Millennials, those born between roughly 1980 and 2000, are the largest generation in the workforce, and will represent in excess of 50% of all workers in the next few years. The challenge lies in the very different perspective of this generation, their approach to work, and their long term view of the role of jobs in their lives.” Barteld referred back to the ducks and the geese to show that “different isn’t necessarily wrong,” and that ultimately, working together is the key to organizational success. “Management roles and styles may have to be amended to deal with the clear realities of the changing workforce as it can no longer be expected that a new employee will simply adapt to the history and culture of the organization.”
Chris McGill, l, an operations manager for Southwire, won a bicycle, and Doug Weber, Keystone Steel & Wire, won a $500 Southwest airfare card, presented by Dave Fisher, James Monroe Wire & Cable Corp.
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INTERWIRE WRAPUP Keynote speaker Rick Smith declared that 3D printing is the ultimate disruptor, and that businesses must be ready for it.
Keynote speaker: the 3D world is already here Keynote speaker Rick Smith, a 3D printing expert and best-selling author, had the full attention of the audience during his talk: “Our 3D Printed Future: How to Position Yourself and Your Organization to Successfully Navigate this Historic Shift.� Smith challenged the audience to cast away conventional expectations when it comes to long transition periods for new technology. He noted that one industry, hearing aids, in a remarkably short time, saw production
of hearing aids by 3D printing go from zero percent to 100 percent. Only the traditional suppliers that adapted to 3D printing remain in that market. The practical aspects of 3D printing, Smith said, are just too staggering to not embrace. For instance, a basic nozzle used for a jet engine has 21 parts, including a seal, and it can still have leaking problems. Replacing that with a single 3D-printed piece that weighs less and is five times stronger is inevitable, he said. Further, costs are coming
Attendees heard that 3D printing can be a dominant manufacturing force, including for niches such as springs. 54 | WIRE JOURNAL INTERNATIONAL
INTERWIRE WRAPUP Smith traced the evolution of 3D printing, which he explained is unique in its ability to force market changes. down and the products being made are no longer just “trinkets.” Advances have been seen for products from replacement knees to lattice structures. Complex parts and small production runs are difficult and expensive for manufacturers, but 3D printing undoes those shackles, Smith said. It also can do the impossible, such as “drilling” a hole in a curved heat exchanger. Also, consider all the inventory savings as many parts will no
longer need to be warehoused. Instead, they can be printed on demand, and done so a half a world away. Major companies are investing in the technology because they see the potential, Smith said. He noted that H-P alone is investing a billion dollars. “3D printing will be the biggest change in manufacturing since the Industrial Revolution began 300 years ago,” Smith declared.
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INTERWIRE WRAPUP
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INTERWIRE WRAPUP
Production Solutions: Paramount Die
Industry 4.0 panel: interest continues to grow
Show service had universal appeal
Viakable: most photogenic attendee group
58 | WIRE JOURNAL INTERNATIONAL
INTERWIRE WRAPUP
Meeting of 2 family businesses at Interwire The show floor at Interwire was the setting for an industo talk shop. There also was a lot more to talk about betry story at Booth 151, where key representatives of two cause of how the venture—which in 1991 became a subiconic family businesses met for the first time at Interwire sidiary of Ernst Koch—had evolved. Today, Morgan-Koch since their respective companies founded Morgan-Koch Corporation supplies Koch & WiTechs wire drawing Corporation 30 years ago. machinery and OEM parts for all makes and models of The story of how the joint venture came to be exempliVaughn & Morgan wire drawing machinery, as well as fies the possibilities that exist when companies respond to serving as the U.S. representatives for FIB, Krollman, circumstances and opportunity. In this case, it was GermaM+E, R. Lisciani Trafilerie, SKET and Sirio Wire. ny’s Ernst Koch & ComJochen observed that the pany, a premier supplier of industry culture in Germany wire drawing technology, has long been a strength for and Morgan Construction Ernst Koch. The strong focus Company, a specialist in on engineering and apprentice rod mills founded in 1888. programs, and partnering with A key figure for each comlocal wiredrawing companies pany met for the first time has helped it remain a leader at Interwire: Flip Morgan, in its field. The added adwho was president and vantage for both it and MorCEO of Morgan Congan-Koch, he believes, is that struction Co., for 23 years they remain a family-owned before the fifth-generation business. “More OEMs now business was sold to Sieare owned by larger compamens in 2008, and Jochen nies that tend to focus on the Koch, who for 32 years bottom line, the ROI, whereas has worked for the family we do that, but with a focus Jochen Koch, l, and Flip Morgan at the Morgan-Koch business, where he serves on continued innovation.” Corporation booth at Interwire. as managing director. For Flip—a Harvard gradFlip Morgan said that the venture between the two uate who remains active outside the industry—returning companies made sense: Morgan thrived on wire rod to the show floor after all these years was an enjoyable technology, whereas Ernst Koch had superlative drawing experience. He ended up taking part in talks with repretechnology. Jochen said that Ernst Koch could supply sentatives from companies such as Insteel, Taubensee, top-quality wire drawing technology, but its marketing Leggett & Platt, Davis and Sivaco. “I was impressed by efforts in the U.S. had not been as successful. Merging the quality of the customers,” he said. He added that he the technical know-how of Koch and the marketing and sees potential, noting that even though the steel sector is connections of Morgan Construction was a concept that in challenging times, it could be feasible for some wire worked well for both companies. manufacturers to open their own rod mill. It was literally a return to old times for Flip Morgan, Technology will always continues to advance, but Jowho was returning to Interwire after a 20-year gap. At Inchen Koch and Flip Morgan agree that having the right terwire, he and Jochen met with attendees and found time culture is essential to a company's long-term success.
60 | WIRE JOURNAL INTERNATIONAL
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INTERWIRE WRAPUP
GFRWS Reception at the College Football Hall of Fame
From l-r: Raymond Bacco, Anand Bhagwat, Bhaskar Yalamanchilli and Bill Jarae.
Industry veteran John Hugens and his wife get a close-up look at one of the many displays.
Mid-South Wire’s Andy Talbot; WAI President David Hawker and wife, SueEllen; and Steven Ford, Southwire.
Enjoying the event are WAI staffers Karren Muolo, l, with her husband, Dan, and Jennifer LaValley.
62 | WIRE JOURNAL INTERNATIONAL
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INTERWIRE WRAPUP It's all a matter of location and timing. Southeast Chapter members once again took advantage of the Atlanta event to hold a meeting.
Past President Art Deming receives a clock from current President Jim Perdue.
Southeast Chapter hails Deming & 2017 scholarship winners The WAI Southeast Chapter supported the Interwire Trade Exposition by hosting a reception for the third time. Chapter President Jim Perdue, Southwire, recognized the long service by Immediate Past President Art Deming, of Nexans, who headed the chapter from 2011 to 2016 and noted that he had done a fine job. The chapter has 119 members from Georgia, the Carolinas and Florida. WAI Executive Director Steve Fetteroll praised Deming for stepping in as Chapter President following the sudden death of Steve Vannais. “Like any organization, the Chapter was at a crossed road when it lost Vannais,” he said, adding that it was fitting that, under the leadership
of Deming, “the Board immediately named the outing in Vannais’ name, and grew it into a special event.” The reception also provided an excellent opportunity to announce the winners of the 2017 Scholarship winners. The Chapter began the scholarship program in 2008, and with the 2017 awards, the Chapter has now bestowed 25 scholarships. Full details will appear in the July issue. On hand to receive the award certificate was William Roden, the son of Mark Roden, vice president & general manager, SCR Technologies, Southwire. Receiving the award on behalf of his daughter, Elizabeth, was Joe Hammontree of Temple Terrace Industries.
Theory meets treachery on the show floor Theoretically, a trade editor may occasionally be challenged trying to keep track of a camera, a camera bag and a notebook in the exhibits. Said theoretical editor may have left a notebook at one booth, and while searching elsewhere for it had to stop to take a photo at another booth, then another, and backtracked and finally found said notebook only to realize that said camera was now
lost in the warren of booths. Said editor may have discovered that an exhibitor—who saw all this, and could not restrain a devious sense of humor—may have swiped said camera and used it to take a photo of his “neighbor” and himself. Theoretically, that person could be Richard Rae, Jr., ERA Wire, but rest assured, no respectable trade editor would ever share such news or images.
Folks at the United Wire Co., Inc. booth are all smiles in a photo, illicitly snapped, that can never appear.
Per an editor’s alert, authorities are seeking this “person of interest,” wanted for 2nd-degree, show floor treachery.
64 | WIRE JOURNAL INTERNATIONAL
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INTERWIRE WRAPUP
Interwire Reception at the Omni Hotel Atrium
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INTERWIRE WRAPUP
Looking forward The Association’s next event will be its 88th Annual Convention and Wire Expo, to be held May 15-16, 2018, at the Gaylord Opryland Resort & Convention Center. And, it’s never too early to get that long-term minder out to pen in a return to Atlanta. The dates for that are May 13-16, 2019, and May 14-16, 2019, for Interwire.
JUNE 2017 | 67
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Testing & measuring equipment
For attendees at Interwire 2017, there was no lack of testing and measuring equipment to inspect and company representatives to talk to. Below is a range of the technology that was on display, as provided by the companies. ACM AB/Howar Equipment Sweden/Canada At Interwire, ACM AB, represented by Howar Equipment, displayed its latest version of KSM offline technology that allows manufacturers to accurately determine not only the value of over-dimensional cost on their products but also which one represents the biggest loss, which line the specific product was made, which shift produced the greatest additional cost, etc.
(KSMAnalyze) allows the user to precisely determine which of the products has the largest over-dimensional cost. As noted above, cable manufacturers over-insulate their products, and the KSM system can allow them to reduce that waste by 4 to 6%. Considering that a typical 2.5 in. extruder annually processes approximately 2,500,000 pounds of PVC, savings from $100,000 to $150,000 a year are realistic. For more details, contact ACM AB’s Stefan Askenfors at stefan@acmab.com or Howar Equipment’s Willy Hauer at whauer@howarequipment.com.
Aeroel Srl Italy
Howar Equipment’s Willy Hauer and ACM’s Stefan Askenfors at Interwire 2017. This is important because cable manufacturers can over-insulate their products by as much as 7-10%. The diligent use of the KSM system will allow a significant reduction of over-insulation. The system has four main components: a highly accurate measuring system with back-lit sample carrier and the appropriate number of digital imaging camera. Each camera allows for a size range up to ~1:4, depending on the particular application. The measuring software carries out the actual measurement at unprecedented accuracy and repeatability, with results displayed in a report sheet and stored in the included summary report database (KSMDB). Use of full optional Database Software (KSMLDB) allows for instant comparison of the measured sample values with specification data, which also makes over-insulation cost, trending, Cpk and Sd available. Finally, an optional analysis software 68 | WIRE JOURNAL INTERNATIONAL
At Interwire, Aeroel Srl showcased an innovative device: the Handy Wire Scanner HWS1, a portable handheld gun to measure wire diameter. The device allows for accurate and quick check of any product from 0.1 to 6 mm. It is non-contact, which makes it possible to check fast-moving or soft products, like drawn metal wire, magnet wire or small extruded cable. The instrument incorporates a number of patented features, like a smart optical design to compensate any error/ misalignment in the wire positioning, as well as an intuitive 3D-like display to assist the operator.
Aeroel Srl’s Antonio Spizzamiglio by the HWS/.1 model.
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The measurement results are stored in the memory of the HWA1 and can be downloaded through a USB port that is also used to charge the internal battery. The measuring position or the machine number can be added to each measured result by reading an RFID tag incorporated on a bracket mounted on the machine itself. Using this new and revolutionary instrument, it is now possible to check the product in-line, during manufacturing, without stopping the process. Also, it is much easier to check the full manufacturing process by sampling the wire at different positions along the machine, as for example in a multiple-layer magnet wire enameling process. For more details, contact Aeroel Srl at tel. 39-0432671301, aeroel@aeorel.it, www.aeroel.it.
AESA Cortaillod Switzerland
Denis Milz, AESA S.A., explained the benefits of the ResTest family of measurement systems.
At Interwire 2017, AESA Cortaillod staff had a goal: to show attendees that one can attain cost reductions without losing quality. This was demonstrated with the AESA ResTest family of bridges that permits high precision measurement of linear electrical resistance of large cross-section conductors, including aluminum-based conductors with stringent measurement requirements. The use of hydraulic jaws associated with a new mechanical design, and a touchscreen interface, provide
a unique combination for mastering measurement uncertainties. This leads the way to conductor size optimization and, consequently, significant cost savings while ensuring compliance to technical standards and allowing for process supervision, fine tuning and optimization. AESA provides a full set of high precision resistance bridges for class 1, 2, 5 and 6, round or sector shaped, bare or insulated, copper (Cu) as well as aluminum (Al) conductors. Due to its unique hydraulic compaction and G Model FUSION-9402;
No. of Pages 4
Testing and measuring begins in the R&D discovery stage 2
The vast majority of testing and measuring focus is for long continuous production of established products, but R&D testing and measuring takes place across the board, both direct and indirect, as reflected in the three technical papers in this issue. • “Cyclic load effect on round strands made by twisted stacks of HTS tapes,” by N. Bykovsky, D. Uglietti, R. Wesche and P. Bruzzone, EPFL-SPC, Superconductivity Group, Switzerland. Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050. This paper investigates cyclic load degradation in the HTS cable prototype. During the cycling test, where the field was set at 12 T and the current was applied in a cyclic manner from 0 kA to 50 kA, a gradual decrease of the performance with the number of cycles has been observed (as shown in next column in Fig. 1. See p. 82 • “Experiment Results of Failure Progression from Low Power Wires,” by Mohammad Samie, Alireza Alghassi, Ian Jennions, IVHM Centre, Cranfield University, U.K. This paper presents a test rig and possible test techniques that can be used for testing the failure progression of wires and interconnections. See p. 86. • “Experimental research of the life time of the cable vibration dampers,” by Igor K. Mikhalkinа and Oleg B.Simakovc, INFOTRANS, and Yury K. Ponomarev, Samara State Aerospace University, all; Russian
ARTICLE IN PR
N. Bykovsky et al. / Fusion Engineering and Design x
Fig. 1. Distribution of the von Mises stress in the cable operating at 60 kA in 12 T background field for the different stacks orientations.
Federation. This paper explains why testing of the cable vibration damper resource is an intensive procedure because of a huge amount of parameters,which often cannot be defined as the quantitative values. See p. 92. JUNE 2017 | 69
Fig. 3
Table 1 Parameters o
Tape’s man
Cross-sect
Width of t Thickness Number of
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pulling system, its latest ResTest 210 product demonstrates the ability of overall resolution below 0.1% for Aluminum class 2 conductors up to 1200 KCMIL and below 0.3% for conductors up to 3000 KCMIL. For class 1 conductors, a hardware option sold along with the ResTest bridges allows precise measurement of the resistivity/conductivity of the material itself, an intrinsic property of paramount importance when devising cables. For on line measurements, AESA offers a set of unique test systems based on AC measurements and current transformers to withstand parasitic currents flowing into the production line. Specific heaters allows for fast measurements, achieving accuracy of ~0.2% for cross-section up to 2500 KCMIL. For more details on the above as well as the full line of AESA Cortaillod test equipment, contact Denis Milz, area sales manager, dmilz@aesa-cortaillod.com, www.aesa-cortaillod.com.
Beta LaserMike (An NDC Technologies brand) The Beta LaserMike Products Group from NDC Technologies debuted several new products at Interwire show with expanded capabilities in connectivity, communication and control. Designed with Industry 4.0 in mind, the new Beta LaserMike LaserSpeed® Pro non-contact length and speed gauge, UltraScan Pro cable wall thickness and concentricity gauge, and BenchMike Pro off-line diameter and ovality measurement system integrate more easily into production networks, providing the real-time data exchanges and tight processing efficiencies that today’s manufacturers need to deliver true product quality. “The Beta LaserMike LaserSpeed Pro and BenchMike Pro gauges have long been the preferred measurement solutions for quality-conscious wire and cable manufacturers Jay Luis, marketing manager, Beta everyLaserMike, an NDC Technologies brand, where,” by a BenchMike Pro model. said Jay Luis, global marketing communications manager for NDC Technologies. “These gauges set the industry standard with the highest accuracy and repeatability, and are installed at more plant locations worldwide than all other
70 | WIRE JOURNAL INTERNATIONAL
manufacturers combined. And now, these industry-leading solutions are even better with added performance advantages, and they are primed for Industry 4.0!” The new Beta LaserMike gauges provide the most comprehensive communications platform with expanded Ethernet connectivity. For example, the new LaserSpeed Pro and UltraScan DSP Pro support ModBus TCP, Ethernet/IP and Profinet IO, plus fieldbus support for Profibus DP and DeviceNet (on UltraScan DSP Pro). While the BenchMike Pro offers Ethernet and USB connectivity, these new platforms also lay the foundation for future wireless connection and offer other extended connectivity options for improved operational control and enhanced processing capabilities for efficient production performance. For more details, go to www.betalasermike.com.
Clinton Instrument Company At Interwire, the Clinton Instrument Company exhibited new DC equipment, updated to the “B-Series,” with models for all DC applications from 1kV all the way up to 50kV.
Kristy Carroll, Clinton Instrument, had updates to share with attendees. Two years ago, at Interwire 2015, Clinton—specialists in high-voltage pinhole detection and the inventor of the High-Frequency Sine Wave Spark Tester—introduced its newest high frequency spark tester, model HF-15B, the first of the B-Series and their flagship model. Building on the success of this unit, the company has redesigned its entire line of DC equipment, adding all of the advanced features of the B-series to the DC platform. B-Series features include: a large bright removable display, fault type differentiation, advanced connectivity across a variety of industrial communications platforms, and easy to use front panel system configuration. All of the B-Series spark testers, including the new DC equipment, can be automatically calibrated using Clinton’s
Conoptica A/S Norway For more than 20 years, Conoptica A/S, from Trondheim, Norway has provided the wire industry with advanced and extremely accurate instruments for measuring the inner geometry of drawing dies. The introduction of CU11 in 2013 added full bearing asymmetry measurements to complete the range of die control tools. The product selection includes many different configurations to measure dies from 0.02 mm to 54 mm. During Interwire 2017 in Atlanta, Conoptica introduced the new model CU11s. The CU11s increases the mea-
surement speed from three to six times while keeping the perfect precision of CU11. Bearing asymmetry measurements with the CU11 have mainly Conptica A/S’s Kjell Johnson and been a Espen Stenberg. feature used in the laboratories due to measurement times of 2-3 minutes. With the CU11s, this measurement now finishes in less than 30 seconds. Conoptica now expect bearing asymmetry measurements to become a practical tool for production and plant managers as well. With the CU11s it is practically possible to provide customers with
JUNE 2017 | 71
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STCAL Calibration System, which was also shown and demonstrated at the show. With the STCAL, and the B-Series spark test equipment, calibration couldn’t be simpler. Following the pictorial instructions on the supplied tablet computer, make the required electrical connections. Then press a button: the STCAL takes all pre-calibration readings, makes adjustments when necessary, retests and prepares a calibration certificate that can be stored electronically or printed out as necessary. The entire process is fully automatic and takes about five minutes. Certified, in-house calibration no longer requires technicians with special training. For more details, contact: Kristy Carroll, tel. 860-669-7548, klanglety@clintoninstrument.com, www.clintoninstrument.com.
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full bearing asymmetry reports as a part of the drawing die production process. During Interwire 2017, visitors to the Conoptica stand voiced an increased interest in measuring shaped dies. A fully customizable measurement module is available for shaped dies, offering full control to measure a multitude of different die geometries. The highest priority for Conoptica in the coming years is to continue developing highly useful tools to increase the efficiency for die and wire manufacturers alike, while maintaining and refining the well-known high accuracy and quality standards their users have come to expect. For more details, contact: Kjell E. Johnsen, Conoptica A/S, kjell.johnsen@conoptica.com, www.conoptica.com.
Dino-Lite Scopes U.S. At Interwire, Dino-Lite explained to attendees why their companies should have Dino-Lite microscopes, the key being the role they plan in meeting basic industry needs. Before placing any components into a critical system, all outlined specifications and requirements need to be met; verification of reliability is crucial. Dino-Lite microscopes are a simple and cost-effective solution for any business looking to accelerate their product testing and measurement capabilities. The portable microscopes use optical magnification to provide high-quality microscopy images and video, interfacing to various platforms like PC, Mac, Android and iOS. The professional Edge series
Jonathan Limon was ready to explain what was being shown on the screen at the Dino-Lite booth. models contain an enhanced sensor for improved image quality, and powerful features such as Extended Depth of Field (EDOF), Extended Dynamic Range (EDR), Automatic Magnification Reading (AMR), Long Working Distance (LWD), and Flexible Light Control (FLC). Most models provide 10 x to 220 x magnification, with higher magnification, ranges up to 500 x and 900 x. The included software offers a full suite of simple to use, yet powerful tools. Capturing photos and video is as simple as a single click of the mouse, and accurate measurements
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can easily be performed live on a screen by using lines, circles, angles, arcs and much more. Users can annotate and draw for labeling and categorization, and export to over 15 different image and video formats. Dino-Lite offers a wide selection of microscopes and accessories to that help us meet the needs of any company, large or small. This indispensable tool can be used for a simple task like quick inspection or rigorous quality assurance. For more details, contact tel. 310-618-9990, sales@dunwell.com, www.dunwell.com.
FMS USA, Inc. U.S. At Interwire, FMS USA showcased the company’s innovative line of tension measurement/ control products to interested show attendees. Potential customers sought out FMS at the show to learn more about the company’s RTM X42 Wireless Tension FMS Director of Sales Steve Leibold Monitoring spread the good word about the compaSystem, ny’s RTM measuring line. designed for monitoring individual strand tensions in rotating wire processing machinery. At the heart of the system is the highly regarded FMS Force Measurement Sensor, which is specially designed for use in rotating applications and provides accurate, trouble-free performance. The RTM X42 System provides for the collection of tension data for up to 42 individual wire strands, which is then processed and wirelessly sent off of the rotating part of the machine to a receiver. Once these signals are received, the tension data can then be monitored on a PC (as pictured) for alarming, graphing, or sent over a fieldbus network to a PLC. New capability includes the RTM X42.BC Brake Control System, which utilizes a battery powered actuator, acting on an existing band or rope brake, at each cradle to provide closed loop tension control via wireless signals from off of the machine. Another important product that was well-received at the show is the RTM MP Telemetry System that provides telemetry (encoder, tension, and additional I/O) capability for bow-type wire processing machinery. Overall,
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the FMS RTM MP Wireless Tension Monitoring System offers a compelling solution to OEMs and End Users who have a requirement for such process monitoring and control without the use of slip rings. For more details, contact Steve Leibold, FMS USA, Inc., tel. 847-519-4400, fmsusa@fms-technology.com. www.fms-technology.com.
iiM AG Measurement + Engineering Germany At Interwire 2017, iiM AG with its VisioCablePro® brand, presented its well-proven VCPX5 cable measuring device, together with the noteworthy sample preparation devices of the O-Ring Cutter family, which together allow shadow-free and reliable measurements without user influence. Samples of any common shape, size and multiple layers are possible with up to three camera sensors in one standard device (0 – 5.12 in. OD). Due to the thin, parallel and quick sample preparation with the ORCs as well as the bottom-up default set camera system of the VCPX5, measurements are always fully focused without operator influence. Combined with the database connection software VCPEasy, the offline measuring process is fully automated with an immediate pass/ fail feedback, either with the homemade CAQ system ProCable or any other system, e.g. ADVARIS®.
iiM AG’s Heiko Freund and Edward Wark presented the VCPX5 at Interwire 2017. With this approach, a large time efficiency is gained compared to conventional methods. Due to the secure values, material usage during production can be minimized, which allows a very quick return on investment. Overconsumption calculations delivered by VisioCablePro for many well-known international cable manufacturer’s show, that a VCPX5 system along with a cutting device, both reduce costs immensely, so that the investment pays for itself well within the first year of usage.
Specialists in Slitting, Edging, Cutting-to-Length of Brass, Copper, Aluminum, Stainless Steel and Zinc. Distributor, processor, and fabricator specializing in Copper and Aluminum Products for the Cable, Wire, and Electrical Industries. We precision slit, deburr and edge condition copper & aluminum tape – any thickness, any width (conditions apply). Thank you for visiting us at Interwire 2017. If we missed you, contact us to see how you can receive the highest quality tape at the best possible prices!
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Please visit our homepage to view demonstration videos of the VisioCablePro systems and gain further information. Thank you to all visitors, organizers and participants for a very interesting and successful exhibition. For more details, contact iiM AG Sales Manager Edward Wark at edward.wark@iimag.de, www.cable-measurement.com.
LaserLinc U.S. LaserLinc designed the Profile Vu product line for inspecting products that do not have a constant diameter. The Profile Vu-L (for linear) system pictured will inspect and report diameter, maximum or minimum diameter, pitch, taper, taper length, and other measurements, such as straightness, on any product sample. Automation reduces inspection cycle time and operator error while increasing accuracy and eliminating paper records. The Profile Vu-R system is designed to measure minimum or maximum diameters of non-round profiles, in-process, such as for sector cables and rectangular/ flat wire. These systems operate with LaserLinc’s powerful Total Vu software, which LaserLinc focused on the company’s provides operators ™ ™ Profile Vu linear actuated Triton access to exactly gauging system. what they need in a concise user interface. Engineers get the data they want, reliably, and managers get the reports they need and know that others have the tools to satisfy business objectives. LaserLinc has been providing innovative diameter, ovality, wall thickness, eccentricity/concentricity measurement and control systems for the wire and cable industry for over 20 years. LaserLinc is a privately held, U.S. owned and operated company and its products are manufactured in the U.S. by American workers. Gauging systems are covered by an industry leading four-year warranty and lifetime software support. For more details, contact LaserLinc, info@laserlinc.com.
OEG GmbH Germany OEG GmbH specializes in the supply of optical metrology systems for different industries, displayed one of its measuring systems at the Weber & Scher booth at Interwire: the DGMS (Die Geometry Measuring System), 74 | WIRE JOURNAL INTERNATIONAL
a universal and highly accurate measuring system for wire drawing dies and wires. The measuring functions of the DGMS are diameter, roundness, reduction angle and bearing length of wire drawing dies, diameter and roundness of wires, parameters of shaped dies and diameter and roundness of enameling dies. The DGMS is characterized by a compact and modular design. The basic system proOEG GmbH’s DGMS system was displayed at vides the Weber & Scher booth. the measuring functions for diameter and roundness of wire drawing dies and can be upgraded with the additional measuring functions for reduction angle and bearing length. Additional software modules are offered for the measurement of shaped dies. The DGMS covers a diameter measuring range from 0.02 mm up to 12 mm (0.000787 in. to 0.472 in.). Larger diameters can be measured with special optics on request. The DGMS is characterized by high measuring accuracy and by a fast measurement rate. Depending on diameter to be measured, the reproducibility is between 0.1 micron and 0.75 micron. This results in an accuracy of 0.4 micron to 1 micron. The measuring speed is about five seconds for diameter and roundness, and 15 seconds for bearing length and reduction angle per die. By help of a special holder, which can be placed easily under the measuring optics, the DGMS can be used for fast and high accurate measurement of either the wire diameter or the diameter and roundness of the wires. For more details, contact Dr. Stephan Rothe, managing partner, OEG GmbH, tel. 49-335-521-38-94, s.rothe@oeggmbh.com, www.oeggmbh.com.
Proton Products International U.K. At Interwire 2017, Proton products displayed its range of technology, including the company’s InteliSENS® SL mini Series. Proton had several new products. The SL mini series of non-contact speed and length gauges—packed with features, and small enough to hold in the palm of your hand—comes at a price point where it doesn’t make sense to continue with troublesome wheels, belts and encoders which slip, wear out and cost you tons of money in lost
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FEATURE Proton Products’ Grant Latimer at the Weber & Scher booth with Greg Scher. materials. When you think about saving material and increasing profits, accurate length measurement is the proven way to do it. InteliTHERMTM HTG400. This new hand-held temperature gauge was a huge success, a product missing for so long. Simply touch the wire on exit from your preheater to get an accurate reading of wire temperature. Technology doesn’t get simpler and easier to use than this.
www.witels-albert-usa.com
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InteliSENS® ST-HF Series Spark Tester. This new stainless steel high frequency spark tester was a favorite, built to last the rigors of extrusion lines, with all the features and functions of the previous generation, such as pin-hole or bare-patch detection, report print and fault location functions. TCP IP as standard and Indus-trial Protocol, Profibus, Profinet and Devicenet options are all available. The stainless steel spark tester is not a throw-away item after only a couple of years in service. Proton Products have been serving the global wire and cable industry for more than a decade, and the people behind Proton have been serving the industry all their working careers, first as manufacturing and process engineers and then as technology suppliers. We look forward to working with and supporting our current and new customers with the best technologies we can design, manufacture and support. For more details, contact Grant Latimer, Proton Products International, grantlatimer@protonproducts.us, www.protonproducts.com
Sikora AG Germany At Interwire, Sikora’s testing and measuring spotlight was on pure insulation material for HV- and EHV-cables, for which its portfolio includes sophisticated systems for inspection, sorting and analysis.
FEATURE Harry Prunk, executive board, Sikora AG, by the company’s online PURITY SCANNER system. One displayed system, the PURITY SCANNER for online inspection and sorting of plastic materials, was designed to provide process optimization, quality assurance and cost savings during the production of wires, cables and optical fibers. Harry Prunk, a member of Sikora AG’s executive board, said that the PURITY SCANNER epitomizes the company’s approach in providing manufacturers the tools they need. The model is especially practical for manufacturers of high and extra high-voltage cables, which commonly use either cross-linkable PE for the insulation or another material gaining ground, which is HPTE (High Performance Thermoplastic Elastomer). “Regardless of which material is used for the insulation, plastics have to comply with the highest purity standards. Therefore, cable manufacturers use the PURITY SCANNER for the inspection and sorting of the material between the pellet octabin, the glove box and the hopper of the extruder.” The system includes X-ray technology and a dual-axis optical system that can detect metallic and organic impurities of 50 μm inside the pellet and on the pellet surface. Contaminated pellets are automatically sorted out. The PURITY SCANNER is combined with an intelligent processor system that displays the number of detected contaminants. It also provides statistical evaluations of detected contamination as well as an image gallery of the pellets that had been detected by the cameras. All data are automatically saved and are available in excel format and image file together with data such as time and batch number. “What we see is that not only the inspection, but also that monitoring and data logging have become more important to cable manufacturers as the generated information leads to process optimization and highest quality of the final product,” Prunk concluded. An offline model is also offered. For more details, go to www.sikora.net.
Starrett-Bytewise Measurement Systems U.S. At Interwire 2017, Starrett-Bytewise presented advances in process measuring technology that it said offers more than traditional methods. In process laser-based dimensional measurement is nothing new to the wire and cable industries. For decades, several manufacturers have been offering simple systems for measuring round parts in line by measuring a product’s shadow. But what if you wanted to capture critical dimensions like angles, corner radii, gaps, minimum thickness, minimum width, and
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area? This shadow-based measurement principal simply could not show you these values. For manufacturers that want to monitor these critical features, Starrett-Bytewise proudly introduces the next generation of in line profile measurement…the 10 mm and 30 mm Profile360. The benefits of in line measurement remain the same. By checking your wire and cable continuously, you gather more frequent measurements, remove the operator variability, immediately react to a process change, quickly gather SPC and quality data, and utilize a tool that will help you with Continuous Improvement and Industry 4.0 initiatives.
Sakina Hasanova, technical sales engineer, Taymer International, by a PLM model displayed at Interwire.
Jim Williams, sales director, Starrett-Bytewise Measurement Systems, does not believe in shadows... at least when it comes to process measuring. With the introduction of the Profile360, you are no longer confined to only taking basic diameter, maximum width, and maximum height dimensions. Instead, you will view your product in real time while it overlays to its CAD model. Your operator will immediately see how the part compares to this drawing. The operator will also see how the critical dimensions compare to their nominal values. If any of these dimensions go out of specification, the system will alert the operator and even send a signal to the line for further action. If your wire or cable is anything more complex than round, the Profile360 will provide you with more information and help you make better decisions. For more details, contact Jim Williams, sales director, Starrett-Bytewise Measurement Systems, tel. 404-915-7516, jwilliams@starrett.com, www.starrett.com/bytewise.
Taymer International, Inc. Canada At Interwire, Taymer International, Inc., displayed various vision inspection systems including Print Length Verification (PLV) system that precisely measures the distance between subsequent footage or meter markings printed on cable jackets or similar products. The PLV can communicate with different types of cable printers to
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automatically recalibrate the print interval as needed to ensure the cable is accurately printed within ±0.08mm per meter (0.008% accuracy). The printers use encoder measurements to determine the print interval with no automated process to verify the printed length. Cable printed with incorrect printing intervals can lead to customer complaints and the manufacturer giving away excess cable. Over long cable lengths, having accurately printed cable can lead to significant cost savings. The PLV uses a pair of cameras that are calibrated at a separation of 1 m or 2 ft apart allowing the PLV software to know the precise distance between parts of the image. In operation the PLV automatically takes simultaneous images of the cable at a frequency linked to the line speed to capture subsequent sequential markings. The image processing software identifies the distance between the repeating marks and compares it to the distance between the cameras, to find the true printing interval. The PLV software saves all the measurement data recorded during the run, and this data is available for quality reporting after the run. Taymer International is a world leading manufacturer of equipment for wire, cable, pipe, tube, and medical industry. Taymer offers an extensive range of solutions designated to provide value for the global wire and cable industry. For more details, call Sakina Hasanova, technical sales engineer, Taymer International, Inc., tel. 905-479-2614, info@taymer.com, www.taymer.com,
Vision Engineering U.S. At Interwire, Vision Engineering, Inc., showcased the company’s Wire Series systems dedicated to measuring wire insulation with a simple click. Users can easily obtain maximum, minimum, average and concentricity dimensions and export results in excel for reporting and/
FEATURE Vision Engineering, Inc.’s Steve Cranford had a vision to share with attendees. or cataloging. The Wire Series produces consistent measurements across users insuring safety codes are met and reduces production costs by regulating insulation quantity. The ‘click and measure’ technology is simple and operators are up and running very quickly with minimal training. Thousands of points are recognized on the inside and outside of a wire sample, then the minimum and maximum wall thickness, average wall thickness and concentricity as a percentage is calculated. Using our wire series takes the guess work out of
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where the operator thinks the minimum wall thickness is. Vision Engineering’s Swift or Swift Duo are ideal for wire up to 12 mm in diameter. The Swift Duo system offers both optical and video edge detection, giving users the tools needed to find difficult edges. The optical head uses crosshairs, while the video edge detection offers instant edge recognition and super-fast results. The Xpress system is ideal for wire samples over 12 mm and up to 65 mm in diameter. Many wire manufacturers use optical technology and caliper gauges to inspect wire samples taken from the production line, observes Simon Cosham, national metrology manager, Vision Engineering. “However, optical inspection is subjective and results tend to vary across operators. The main benefits of our Wire Series are that it provides accurate and repeatable results across users and the elimination of any guess work.” For more information or to schedule an on‐site demonstration contact Simon Cosham, metrology manager, North America, tel. 860-355‐3776, scosham@visioneng.com. www.visioneng.us.
Zumbach Electronics Corp. U.S. Zumbach Electronic AG Switzerland Zumbach Electronics Corp. was honored to celebrate our 60th anniversary at Interwire 2017, and in keeping with our well known reputation as a technological
Zumbach Electronics Corp.’s Tim Moore by an ODAC model at the company’s booth. leader we were pleased to introduce the following innovative product solutions: A complete line of ODAC® Laser Diameter scanners certified to conform to Ethernet/IP specifications by ODVA, the governing body for Ethernet/IP. This native implementation of Ethernet IP not only supports higher data rates than gateway based solutions, but also supplies the Rockwell Automation licensed, EDS AOP
Toroidal® Steel Reel
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to enable convenient integration into the Allen Bradley families of PLCs. All ODAC scanners support Calibrated Single Scan (CSS) processing for the highest measurement accuracy and increased repeatability with up to 9000 scans per second. All the measuring heads of the ODAC series use the company’s patented scan technology to maintain accuracy with very low temperature drift. OPC UA is now integrated into the next generation USYS IPC series processors. These processors are powerful, modular and very flexible systems, suitable for any manufacturing process in the wire and cable, plastics, rubber, cold steel, and metals industries. Fully configurable for process monitoring, automatic line control, SPC and SQC data acquisition, and data archiving they represent a leap forward in process control technology. One of the keys in enabling faster intelligence and efficiency in the deployment of these new technologies and manufacturing management systems is to partner with and utilize leading edge technologies from companies that have the structure and dedication to work with end users in different ways. Zumbach Electronics believes in its ability to enable horizontal and vertical integration across various levels of the automation pyramid, from the sensor to the ERP system. For more details, call tel. 914-241-7080, or go to sales@zumbach.com, www.zumbach.com.
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Contents lists available at ScienceDirect
Contents lists available at ScienceDirect
Fusion Engineering and Design Fusion Engineering and Design
journal homepage: www.elsevier.com/locate/fusengdes journal homepage: www.elsevier.com/locate/fusengdes
Cyclic load effect on round strands made by twisted stacks of HTS tapes Cyclic load effect on round strands made by twisted stacks of HTS tapes N. Bykovsky ∗ , D. Uglietti, R. Wesche, P. Bruzzone N. Bykovsky , D. Uglietti, R. Wesche, P. Bruzzone
∗ EPFL-SPC, Superconductivity Group, PSI, CH-5232 Villigen, Switzerland
EPFL-SPC, Superconductivity Group, PSI, CH-5232 Villigen, Switzerland
h i g h l i g h t s i g h l i gof h s load degradation in the HTS cable prototype is performed. •hInvestigation thetcyclic • Results of transverse load fatigue tests on the HTS strands at 77 K are presented. • Design Investigation of the cyclic load degradation in the HTSCS cable is performed. of the new HTS cable prototype for the DEMO coilsprototype is discussed. • Results of transverse load fatigue tests on the HTS strands at 77 K are presented. • Design of the new HTS cable prototype for the DEMO CS coils is discussed. a r t i c l e
i n f o
a r thistory: i c l e i n f o Article Received 30 September 2016 Received in revised form 28 March 2017 Article history: Accepted 12 September April 2017 2016 Received 30 Available online xxxform 28 March 2017 Received in revised Accepted 12 April 2017 Available online xxx Keywords: HTS high current cables Coated conductors Keywords: Cyclic loadcurrent cables HTS high Coated conductors Cyclic load
1. Introduction
a b s t r a c t
a b s DC t rtests a cperformed t Various recently with full-size 60 kA HTS cable prototypes in the EDIPO test facility demonstrated that proposed design of HTS strand at Swiss Plasma Center (SPC) – stack of HTS tapes Various and DC tests performed recently with full-size HTS cable prototypes in the fusion EDIPO test facility twisted soldered between two copper profiles60– kA is applicable for high-current cables, but demonstrated of that design of HTS strand against at Swissthe Plasma (SPC) – stack of HTS tapes improvement theproposed strand mechanical properties cyclicCenter loading is still needed. Based on twisted and soldered between two between copper profiles – is applicable forprototypes high-current fusion cables, but experimentally obtained correlation the performances of cable at different operating improvement of the strand mechanical is still was needed. Based on conditions, further investigation of cyclicproperties transverseagainst load onthe thecyclic strandloading performance performed at experimentally between thewithstand performances of cable prototypes at operation different operating 77 K. Aiming to obtained obtain a correlation strand design able to a continuous cyclic load of some conditions, further investigation of cyclic transverse onmanufacturer the strand performance was performed at thousand cycles, influence of the strand geometry andload tape’s has been studied. Cyclic load 77 K.been Aiming to obtain a strand design able to withstand a continuous load operation has applied up to 1000 cycles for straight and bent samples at the cyclic load amplitudes up toof4 some MPa. thousand cycles, influence the design strand geometry andprototype tape’s manufacturer has been studied. Cyclic load Based on the obtained data,ofnext of HTS cable will be discussed. has been applied upThe to 1000 cyclesPublished for straight and bentB.V. samples load amplitudes up to the 4 MPa. © 2017 Author(s). by Elsevier This isat anthe open access article under CC Based on the obtained data, next design oflicense HTS cable prototype will be discussed. BY-NC-ND (http://creativecommons.org/licenses/by-nc-nd/4.0/). © 2017 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/).
1. Two Introduction test campaigns have been performed recently with the 60 kA HTS cable prototypes at SPC. Initial measurements of the Two test campaigns have demonstrated been performed with the current-sharing temperature anrecently excellent agree60 kA with HTS cable prototypes at SPC. Initial measurements of the ment the expected cable performance for the operating current-sharing temperature demonstrated an excellent agreecurrent from 20 kA to 70 kA and in the background magnetic field ment with expected cabletest, performance for was the set operating up to 12 T [9].the During the cycling where the field at 12 T current from 20was kA to 70 kAin and in themanner background field and the current applied a cyclic from 0magnetic kA to 50 kA, a up to 12decrease T [9]. During the cycling test, with where the field was set at 12 gradual of the performance the number of cycles hasT and the current[1]. was applied a cyclic manner 0 kA to 50 kA,ina been observed After 2000incycles this fatiguefrom behavior results gradual decrease of the performance the numberand of cycles has ≈10% and ≈20% performance drop forwith the SuperPower SuperOx been observed [1]. After 2000 cycles this fatigue behavior results in prototypes respectively. Further inspection of the SuperOx proto≈10%revealed and ≈20% performance drop for the SuperPower and SuperOx type that the Lorentz force acting on the strands in the prototypes respectively. Further inspection ofthe theHTS SuperOx protocable is the key factor of the degradation. Thus, cable layout type revealed that the Lorentz force actingbut ondesign the strands in the is feasible for application in fusion magnets, of the strand cable is the key factor of the degradation. Thus, the HTS cable layout is feasible for application in fusion magnets, but design of the strand
∗ Corresponding author. E-mail address: nikolay.bykovsky@psi.ch (N. Bykovsky). ∗ Corresponding author.
still requires alterations in order to withstand the electromagnetic cyclic load during the cable operation. still requires alterations in order to withstand the electromagnetic cyclic load during the cable operation. 2. FEM analysis
2. In FEM analysis order to formulate a scope of the work, let first see results of the corresponding mechanical analysis. Mechanical stresses for a In order formulate a scope have of thebeen work, let first see of geometry ofto the cable prototypes calculated in aresults 2D ‘plain the corresponding mechanical Mechanical for a strain’ FEM model similar to theanalysis. one in [3]. The model stresses also includes geometry ofdomain the cable prototypes havemodulus been calculated inEach a 2D ‘plain steel jacket with the Young’s 207 GPa. stack strain’ similar to the The modelfield also directed includes of the FEM cablemodel carries I = 3 kA at Bone = 12inT[3]. background steel jacket domain with the Young’s modulus 207 GPa.byEach stack along the wide side of the cable. The self-field produced the cable ofalso the taken cable into carries I = 3 kA at B = 12 Tthe background field directed is account. Considering Lorentz body forces actalong side of the and cable. The self-field produced by the cable ing onthe thewide stack domain assuming zero-displacement for the is also taken into account. forces bottom side of the jacket, Considering distributionsthe of Lorentz the vonbody Mises stressactin ing cable on thespace stackare domain assuming zero-displacement for the the shownand in Fig. 1 for the different orientations of bottom side of the jacket, distributions of the von Mises stress in the stacks in the cable. theAverage cable space shown in in Fig.the 1 for thedomains differentis orientations of von are Mises stress stack presented in the 2. stacks in theof cable. Fig. The labels curves and strand numbers correspond to those Average von estimation Mises stress stack domains is presented in in Fig. 1. A rough of in thethe transverse load as 2IB/D is close to Fig. average 2. The labels of obtained curves and numbers correspond those the stress forstrand the bottom layer of stacks to (strand in Fig. 1. A rough estimation of the transverse load as 2IB/D is close to the average stress obtained for the bottom layer of stacks (strand
http://dx.doi.org/10.1016/j.fusengdes.2017.04.050 E-mail address: nikolay.bykovsky@psi.ch (N. Bykovsky). 0920-3796/© 2017 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/ 4.0/). http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
0920-3796/© 2017 The Author(s). Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/ 4.0/).
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050 Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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Fig. 1. Distribution of the von Mises stress in the cable operating at 60 kA in 12 T background field for the different stacks orientations.
Fig. 3. Experimental setup for the cyclic transverse load test at 77 K.
Table 1 Parameters of strands used for the sample manufacturing. Tape’s manufacturer
SuperOx
SuperPower
4 110 16 6.2 4.3/2 ≈1600
3 93 26 6 3.3/3 ≈1000
Cross-section
Width of tape w, mm Thickness of tape dt , m Number of tapes n Diameter D, mm Slot width/height, mm Strand Ic at 77 K/sf, A
Fig. 2. Average von Mises stress in the stacks. See Fig. 1 for definition of the curve labels and strand numbers.
numbers from 11 to 20) of the (c) case, where D = 6.2 mm is the strand diameter. Significantly higher stress is obtained for the (a) case, but the values stay below 20 MPa. Comparing the calculated stress with the performance of the single strands under the transverse load [3], significant degradation is not expected during the cable operation. This leads to an assumption that the obtained performance degradation of the prototypes is not related to the stress magnitude, but could be linked with the fatigue properties of strands. Though a very stable performance at 77 K of the single ReBCO tapes was reported in the tensile [5,8,6] and transverse load fatigue tests [4,7], the more sophisticated stress distribution in a multi-tape strand may result in a peel stress in the superconducting layer, what reduces drastically the fatigue properties of the strand. Study of the fatigue phenomena on the strands was performed on the experimental assembly that described in the following section. Obtained results on a set of SuperOx and SuperPower strands for different magnitudes and directions of the transverse load will be presented and discussed in Section 4.
3. Experimental details The original press assembly that was used in the preliminary transverse load tests of the strands [3] was upgraded for an automatic control, see Fig. 3. Signal from the piezo sensor is used as a feedback for control of the DC motor. Worm gear installed on the top plate of fiberglass support serves as a reduction drive (20:1) for the motor and also prevents release of the applied force at a system idle. During the system operation the strand in the press is immersed in a liquid nitrogen bath. In order to reduce heat transfer from the cooling region of the system, the steel shaft is composed of three pieces with a hollow part in the center. External force is applied in a cyclic manner from 0 to the maximum value F corresponding to the pressure pmax = F/(lD), where l = 15 mm is the length of the anvil. Note that actual body force acting on strands in the cable is simulated by the contact force between the strand and anvil. Two types of strands that have been selected for the cyclic load tests are presented in Table 1. The SuperOx strands correspond to those used in the 60 kA cable prototype and aimed to reproduce the fatigue properties obtained during the cable measurements [1]. The SuperPower strands composed of 3 mm wide tapes have demonstrated promising results in the bending and transverse load tests
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion JUNE 2017 | 83 Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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3
Fig. 4. Photo of one strand used in the measurements.
[3] and were selected for the measurements to further validate as a possible candidate for the next cable prototype. In total 6 strands have been manufactured: 3 SuperOx and 3 SuperPower. One of the SuperPower strands has non-annealed copper profiles, while the other samples were manufactured with the ones preliminary annealed at 300 ◦ C, what strongly reduces the yield strength of copper. Aiming to better reproduce the mechanical state in the cable, two samples were also bent before the cyclic loading at radius ≈36 mm, what corresponds to strand bending around the cable edge in the prototypes [2]. Each sample is about 30 cm long and contains 4 regions with the voltage taps at a distance 2 cm to be tested in the press, see Fig. 4. The transverse load was applied on the region from 0 to pmax up to 1000 cycles, with intermediate measurements of the strand Ic as a function of number of cycles nc at zero and maximum load pmax . Tolerance for the applied load pmax has been set conservatively to ±1 MPa in order to increase the frequency of operation. After the tuning of PID control, the system can operate up to 6 cycles per minute, what allows to perform a full cycling test on the strand region within one day. The maximum force that can be transmitted in the assembly is ≈10 kN, what corresponds to pmax ≈ 110 MPa. 4. Results and discussion Obtained test results are normalized to the critical current of the strand measured after the first load cycle Ic (1) (see typical values in Table 1). The data are summarized in Fig. 5 (estimated error bar is ≈0.5%). Degradation of the strand performance during the cyclic loading has been observed. For the different load directions studied on the straight SuperOx strands (0◦ vs 90◦ ) similar results have been obtained. Applied bending at 360 mm radius on the SuperOx strand does not cause weakening of the fatigue properties for the cyclic load at 20 MPa and 30 MPa, but at 40 MPa the strand performance degraded by 5% already at 800 cycles. Nevertheless the Ic evolution of the SuperOx cable prototype during the cycling test [1] was not reproduced in the performed measurements of the SuperOx strands. On top of that, there is no data correlation for the different pressure amplitudes: the loading at 20 MPa results typically in the higher degradation than at 30 MPa. Possible reasons of these issues will be addressed below in this section. The SuperPower strands with the annealed copper profiles perform weaker in the measurements than the SuperOx ones. Higher degradation has been obtained on both the straight and bent samples, with a higher impact of the bending on the fatigue properties. Similar to the SuperOx strands, no data correlation for the different pmax has been also observed: for the bent SuperPower sample better fatigue properties were obtained at 30 MPa than at 20 MPa. On the other hand, the sample with the non-annealed copper profiles has demonstrated a very stable performance for the load amplitudes up to 40 MPa: strand Ic was almost not affected after 1000 load cycles. As a preliminary conclusion, annealing of the copper profiles could be responsible for the strand performance degradation in the cyclic load measurements.
Fig. 5. Evolution of Ic (at 77 K/sf) against the number of cycles nc for SuperOx (top plot) and SuperPower strands (bottom plot) for different amplitudes of cyclic load pmax . Each individual color corresponds to one sample tested at selected bending and direction of the transverse load.
Fig. 6. Cross-section of the straight strands after 1000 load cycles (90◦ load, pmax = 20 MPa): left – SuperOx, center – SuperPower, right – SuperPower (nonannealed copper). Dashed circles are drawn from the strand centers; diameter of the left circle is 6.2 mm, other two – 6 mm.
Comparing Ic (1) to the value measured before the loading, a noticeable irreversible degradation for some of the tested regions has been obtained (up to 5%). This may indicate a presence of voids in the cross-section of the strand. In order to validate this assumption the strands were cut after the measurements at the locations of the test regions. The corresponding cross-sections that were subjected to 90◦ load at pmax = 20 MPa of the straight SuperOx and SuperPower (with annealed and non-annealed copper profiles) strands are presented in Fig. 6. All the pictures show an issue with the strand manufacturing: the slot space is not completely filled with solder. This leads to a higher stress concentration at the location of voids during the transverse loading. Comparing the cross-sections of the SuperPower strands, one can see effect of the annealing: the annealed pro-
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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Table 2 Geometry parameters of the cable designs presented in Fig. 7. Cable
Round
Flat
Width of tape, mm Strand diameter, mm Annealing of copper profiles Number of strands Thickness of core, mm
4.8 10.0 No 6 10
3.3 7.0 Yes 12 5
Cable space, mm2
710
750
Fig. 7. Cross-section of the HTS cables for CS coil: left (‘round’) – 4.8 mm width tapes, non-annealed copper profiles; right (‘flat’) – 3.3 mm width tapes, annealed copper profiles.
files, being a ‘softer’ material, have a highly deformed shape, while the non-annealed ones are not deformed. It agrees with a distinction in the test results between the two SuperPower samples (see Fig. 5). Nevertheless by improving the strand manufacturing process, effect of the copper annealing on the fatigue properties could be significantly reduced if voids will not be presented in the strand volume. A local non-homogeneity of the mechanical properties of the annealed profiles could be present, because the temperature distribution along the profiles during the annealing process was not precisely controlled. This would explain the cases when better fatigue properties were obtained at higher pmax on the SuperOx and SuperPower strands. Since the performance evolution of the SuperOx cable prototype was not reproduced in the cyclic load measurements, further study of the cyclic transverse load for the annealed and non-annealed copper profiles will be performed with new HTS cable prototypes. Preliminary details over the possible cable designs will be discussed in the next section. 5. HTS cable prototypes Next HTS cable prototypes at SPC are meant to demonstrate their applicability for the central solenoid (CS) coils of fusion magnets. In a layer winding design of the CS coil with a superconductor grading (HTS is envisaged in high field section, Nb3 Sn – intermediate fields, NbTi – lowest fields), use of HTS conductors in the innermost layers at 1.9 m radius allows to reduce external radius of the CS module to 2.8 m (see details of the SPC coil design for EUROfusion in [10]). For the conductors operating at 53.6 kA the estimated peak magnetic field in the CS midplane is ≈18 T. Hence, for the cable test in SULTAN at 10.8 T (peak field of the facility) the cables should be designed for the critical current ≈88 kA, assuming 13% current margin and 1.43 scaling factor from 18 T to 10.8 T. Preliminary design study of the cable prototypes composed of the annealed and non-annealed copper profiles was carried out for the HTS tapes produced by Shanghai Superconductor Technology (SST) company (width of the tapes: 3.3 mm or 4.8 mm, thickness: 60–100 rmmum, current density at 4.2 K/12 T: 55–90 A/mm). Obtained parameters for the two cable designs are summarized in Table 2; also see corresponding illustrations in Fig. 7. Several cable aspects have been addressed in the presented designs:
• The cable space has been balanced for the two prototypes. • While a flat geometry provides better bending properties for the cable, applying the same twist-pitches for the cables leads to a round geometry for the cable with non-annealed profiles in order to increase bending radius of the strand in the cable. • In order to obtain similar current capacity for the two cables, total width of HTS tapes in the cross-section (i.e. if all the tapes were arranged side by side) should be adjusted. Depending on the SST tape current density, required total tapes’ width for a 88 kA cable is from 0.9 m to 1.5 m. In the ‘round’ cable with 4.8 mm width tapes it can be achieved by using from 33 to 49 tapes per strand, in the ‘flat’ cable with 3.3 mm width tapes – from 25 to 37 tapes per strand. As a result, the two cable designs have a similar geometry and represent a different arrangement of the superconductor. Thus, effect of the copper annealing on the cable performance can be revealed directly from the measurements in SULTAN. Six additional copper rods of 3.4 mm diameter might be used in the ‘round’ cable between the strands and steel jacket to increase the copper cross-section in the cable and to better redistribute the mechanical stresses (i.e. lower the stress in the stacks). 6. Summary Influence of the cyclic transverse load on the round HTS strands has been studied at 77 K. While the Ic degradation during the cycling has been observed, performance evolution of the SuperOx cable prototype was not reproduced in the measurements. Cross-section analysis of the samples after the mechanical tests revealed the issue with the manufacturing process, which should be improved especially for the strands composed of copper profiles with a spit-line along the c-axis of the stack. Performance of the strand with nonannealed copper profiles was not affected during the cyclic loading. Effect of the profile annealing on the cable properties will be further investigated during the test of HTS cable prototypes in the SULTAN test facility at SPC. Acknowledgments The authors thank the Paul Scherrer Institute (PSI) for the technical support. This work has been carried out within the framework of the EUROfusion Consortium and has received funding from the Euratom Research and Training Programme 2014–2018 under grant agreement No 633053. The views and opinions expressed herein do not necessarily reflect those of the European Commission. References [1] D. Uglietti, N. Bykovsky, K. Sedlak, B. Stepanov, R. Wesche, P. Bruzzone, Supercond. Sci. Technol. 28 (2015) 124005. [2] N. Bykovsky, D. Uglietti, K. Sedlak, B. Stepanov, R. Wesche, P. Bruzzone, Supercond. Sci. Technol. 29 (2016) 084002. [3] N. Bykovsky, D. Uglietti, R. Wesche, P. Bruzzone, IEEE Trans. Appl. Supercond. 26 (2016) 4201207. [4] A. Mbaruku, J. Schwartz, IEEE Trans. Appl. Supercond. 18 (2008) 1743–1752. [5] M. Sugano, Y. Yoshida, M. Hojo, K. Shikimachi, N. Hirano, S. Nagaya, Supercond. Sci. Technol. 21 (2008) 054006. [6] H.-S. Shin, M.J. Dedicatoria, Cryogenics 51 (2011) 237–240. [7] J.W. Ekin, S.L. Bray, N. Cheggour, C.C. Clickner, S.R. Foltyn, P.N. Arendt, A.A. Polyanskii, et al., IEEE Trans. Appl. Supercond. 11 (2001) 3389–3392. [8] H.-S. Shin, A. Gorospe, Z. Bautista, M.J. Dedicatoria, Supercond. Sci. Technol. 29 (2016) 014001. [9] N. Bykovsky, D. Uglietti, R. Wesche, P. Bruzzone, IEEE Trans. Appl. Supercond. 25 (2015) 4800304. [10] R. Wesche, N. Bykovsky, X. Sarasola, K. Sedlak, B. Stepanov, D. Uglietti, P. Bruzzone, Fusion Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes. 2017.04.052 (in press).
Please cite this article in press as: N. Bykovsky, et al., Cyclic load effect on round strands made by twisted stacks of HTS tapes, Fusion JUNE 2017 | 85 Eng. Des. (2017), http://dx.doi.org/10.1016/j.fusengdes.2017.04.050
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ExperimentalProcedia research of the life time of the cable vibration Engineering 176 (2017) 423 – 428 dampers а *b Igor K. Dynamics Mikhalkinand , Yury K. Ponomarev , Oleg .B.Simakovc Vibroacoustics of Machines Samara State Aerospaceresearch University (National Moskovskoe shosse 34, Samara 443086, Russian Federation Experimental ofResearch the University), life time of the cable vibration INFOTRANS, Polevaya Str. 47, Samara 443001, Russian Federation dampers b
a,c
Abstract
Igor K. Mikhalkinа, Yury K. Ponomarev*b, Oleg .B.Simakovc
b This paperState is dedicated life time(National researchResearch regarding the cableMoskovskoe units, which are intended for443086, vibration protection of the tools and Samara AerospacetoUniversity University), shosse 34, Samara Russian Federation equipment of the computerized labor coaches (KVL). These protection units are the serial product of INFOTRANS and they are a,c INFOTRANS, Polevaya Str. 47, Samara 443001, Russian Federation used on the Russian Railways, in CIS countries and some countries of the West Europe. The object, purpose and tasks of this research is clarifying of possible ways for using of the cable vibration dampers in order to protect the automated hardware units, computers and hard discs for data storage against vibration and shock. These units run under hard conditions of heavy vibration and short-time shocks. Abstract
Keywords: Vibrationtoprotection; vibration damper; control of parameters; railroad This paper is dedicated life timecable research regarding thelife-time; cable units, which are intended for vibration protection of the tools and equipment of the computerized labor coaches (KVL). These protection units are the serial product of INFOTRANS and they are used on the Russian Railways, in CIS countries and some countries of the West Europe. The object, purpose and tasks of this 1. Introduction research is clarifying of possible ways for using of the cable vibration dampers in order to protect the automated hardware units, computers and hard discs for data storage against vibration and shock. These units run under hard conditions of heavy vibration and short-time shocks. Actually the cable units for protection against vibration are serial products of such famous foreign companies like
StopCock, Enidine, Hutchinson. These units are also produced serially by the Russian companies like Astron, companies have patents for their developments. However there are a few of published theoretical and experimental research papers of authors, which deal with engineering and selling of the cable vibration dampers. Particular importance in this area has Samara 1. Introduction University and RPC INFOTRANS. They deal not only with engineering and licensing of products, but they study Keywords: Vibration protection; cable vibration controletc. of parameters; railroad INFOTRANS (Samara), INMORdamper; (St. life-time; Petersburg) All above-mentioned
Actually the cable units for protection against vibration are serial products of such famous foreign companies like StopCock, Enidine, Hutchinson. These units are also produced serially by the Russian companies like Astron, * INFOTRANS (Samara), INMOR (St. Petersburg) etc. All above-mentioned companies have patents for their Corresponding author. Tel.: +7-987-9294770; developments. However there are a few of published theoretical and experimental research papers of authors, which E-mail address: ponomarev-ssau@yandex.ru deal with engineering and selling of the cable vibration dampers. Particular importance in this area has Samara University and RPC INFOTRANS. They deal not only with engineering and licensing of products, but they study
* Corresponding author. Tel.: +7-987-9294770; E-mail address: ponomarev-ssau@yandex.ru
1877-7058 © 2017 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of the international conference on Dynamics and Vibroacoustics of Machines
doi:10.1016/j.proeng.2017.02.341
86 | SAMARA AEROSPACE RUSSIA 1877-7058 © 2017STATE The Authors. Published by UNIVERSITY, Elsevier Ltd. ThisINFOTRANS is an open access/ article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the organizing committee of the international conference on Dynamics and Vibroacoustics of Machines
Igor K. Mikhalkin et al. / Procedia Engineering 176 (2017) 423 – 428
the characteristics of vibration dampers, their reliability by operation; they develop the methods for calculation of stiffness and damping characteristics [1 - 5]. The published materials show that there are many issues to be studied regarding the characteristics of the cable vibration dampers. There are no simple ways to take in account the geometric nonlinearity of the cables as the elastic bars, especially by the spatial axle lines. The methods for producing of contact pressure between cables wires are not definitely clear and there are no descriptions of them. There are no adequate models for hysteresis description and models for running effect by contacts. There are no instructions regarding changing of contact pressure between cables wires during long-term storage of the produced cable coils bevor production of the vibration dampers. Finally, there is little information about life-time of the cable vibration dampers, which are used under condition of heavy vibration. The only papers which are really close to solving of problems regarding geometric nonlinearity of the characteristics in multilayer elastic systems are the papers of P.P. Balandin [6], S.D. Ponomarev with co-authors and without [7 - 11], N.А. Chernishev [12], Е.А. Popov [13] and V.А. Svetlitskii [14, 15]. The papers [7 - 15] are carried out for the cylinder multicore compression springs, which was used in the 60th of the previous century for the first time. They was used as dampers acting against pushes and shocks, as energy storage devices in basic weapons, pull-back springs with substantial stroke and the flat characteristic in explosive engines, anti-resonating springs with big internal rubber. P.P. Balandin[6] and S.D. Ponomarev [7 – 11] have calculated the stiffness and strength of the multicore springs and detailed analyzed the operation of cables. They have described their geometry, characteristics of productions and springs lays with two, three, four, five and six cores without taking in account the rubber effect by wire contact. Using the Mor integrals they have got the simplified expressions for calculating of spring compression under compression force (without taking in account the effect of lateral force Q). The lateral force Q is used for multicore compression springs in paper of S.D. Ponomarev and V.А. Olenev [11]. S.D. Ponomarev and L.Е. Andreeva [14] show, that there is a huge difference between characteristics of the multicore compression springs because of technological factor. That’s why the offered calculation method should be considered as an approximate one. The mentioned papers don’t include the issue about theoretical generation of hysteresis. But we should note, that the authors of research [7 - 11] have done a huge work regarding mathematical description of the geometry of the screw wires, which build the compositions of multicore screw spring. This research can be used as a base for mathematical description of more complicated cable constructions with 37, 49, 133 and more wires, which are used for production of the cable vibration dampers and further for forecasting of the life cycle of the cable elements. Big complexity of the geometric description of the components of the cable dampers and difficulties by description of the rubbing friction (the amount and line/contact point distribution of compression forces are not clear, it’s difficult to define frictional factor) lead to the situation, that the characteristics of the vibration dampers are still defined by experiment in the whole world. So V.S. Iliinskii [15] have mathematically processed the experimental data and he has got dependencies for resonance frequency of the cable vibration G-form and tube type dampers. This paper doesn’t include the data about nonlinearity of the characteristics, true form of hysteresis of the cable vibration dampers in use [15]. But the monography of V.S. Iliinskii includes one basically wrong idea. The author says, that according to this idea «the harmonic load complies with an elliptical hysteresis loop » (page. 16 [15]). In this case V.S. Iliinskii references to the famous paper of E.S. Sorokin[16], in which the prof. Е.S. Sorokin offers to use the ellipse form of hysteresis by building constructions as the most simply one concerning mathematical description. E.S. Sorokin offers in his articles [16 - 19] to use this offer as hypothesis. Further the offer of E.S. Sorokin was called as «hypothesis of Sorokin» in many articles and books about construction damping. Based on this wrong fact V.S. Iliinskii develops a damping index formula for the cable vibration dampers. This index for G-form vibration damper seems to be depending on the range, and for the cylinder damper it is a ca. permanent value. We note, that in spite of simplicity of this formula the paper of V.S. Iliinskii is an important paper nowadays and was important in that time. This paper is used by students and post-graduate students, which study the basic principles for engineering of the vibrational systems. Based on the papers of V.S. Iliinskii the Bulgarian research workers B. Belnikolovskii, G. Dunchev and S. Banov have got an idea to research the cylinder cable vibration dampers. They have controlled the conformity of in [15] offered formulas and they have carried out the comparison in according with a corresponding experiment [20]. It
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was confirmed, that the stiffness of the vibration dampers is quite well ( 7 %), but it was mentioned, that the damping index for all kinds of the vibration dampers is a variable value, which can be changed in ten times depending on the range. It complies with the experimental data, which was published by another research workers [21 - 24]. In [20] you can see the data about nonlinear load characteristic of the cylinder vibration damper. However the form of hysteresis isn’t mentioned. Two unique monographies should especially be noted, which are dedicated to the strength and stiffness calculation of the elastic pins. It is a monography of E.P. Popov [25] and V.А. Svetlitskii [12, 13]. Calculation of the elastic pins which help to define the elastic displacement components of the elastic damping elements of the vibration damper are calculated in papers [25, 12 ] taking in account following tolerances: standard cross sections of the pin, flat and non-deformed cross sections safe their characteristics even after deforming (hypothesis of Bernulli), that means that the displacements aren’t taken in account; dimensions of the cross section are considered to be compact in comparison with the length and radius of pin axle curve; axle line of the pin is considered as inextensional; the Sen-Venan principle is correct. Acc. to this principle the different, but static equivalent and local loads lead to the same stress condition of the pin (without taking in account of the local stresses close to the load application point). In this case the considered tasks are linear not geometrically, but physically. The principles of independence of forces effects (superposition principle) and principle of invariability of the initial values, which are used for defining of mast reaction and inside power factors, aren’t here in effect: mast reaction and inside power factors are changed during deforming. So Е.P. Popov [25] and V.А. Svetlitskii [12, 13] say, that every elastic pin can’t be statically defined in itself. There are differences by approaches too. By developing of the balance equations Е.P. Popov [25] uses the system of criteria coordinates for the first time. These coordinates include geometrical parameters of non-load (initial) pin, its power and moment load, applied to the pin ends. As a result there is a coordinate space, there the load pin is a part of periodically changed curve, which is described mathematically in the unique way. Reversed conversion of this curve from nondimensional coordinate to dimensional ones provides an exact profile of the elastic pin line with predefined limiting conditions regarding ends fastening and load conditions. The lack of this theory is, that the pin should be plain and it shouldn’t include any concentrated or distributed load inside of the pin section from the beginning to the end. According to this it’s impossible to use the theory of E.P. Popov in order to calculate the load elastic damping elements with distributed rubber forces. But it’s possible to calculate the elastic component of load characteristic of any cable-, band- or plain pin element if the loads are situated in a plane of the element. It’s possible to calculate the tension of the element without taking in account of the effects of distributed rubber forces. V.S. Svetlitskii [12] developes his balance equations in vector differential form for special load of random situated pin. The distributed power- and moment loads can cause the effect on the pin too. Concentrated loads can be both «dead» and guiding ones. The «dead» is a load, which keeps its direction by system deforming. The system of equations refers to non-dimensional version. In this case the calculation results are general ones. The system of vector differential equations is done using the methods of sequential approximations. The method is elegant, efficient, but extremely difficult. The adoption of approach takes much time for understanding of the ideas and programming of task. Otherwise this solution is not possible. The solution of Е.P. Popov regarding solving of the tasks about curve of the elastic pins can’t be considered as a simply one, but his appendixes include the set of Fortran calculation software units incl. detailed instructions regarding initial data and test examples. We should note, that V.S. Svetlitskii and Е.P. Popov don’t take in account the rubber effect by pin calculation. It means, that the adoption of the methods [25, 12] for tasks of construction damping is a question of the future. There is another way to solve the problems referring to calculation of load characteristic of the vibration dampers with regular form of elastic damping components and to further calculation of life time of cables by curving and winding of them. That’s the method of the end elements. Moreover in these days there are many end-elementpackages for computers: «Ansys», «Nastran», «LS DINA» etc. After the authors had studied the methods in the
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sphere of these packages, they chose the method of end elements in order to create a method for calculating of elastic components of the load characteristics. The authors added the experimental methods for defining of nonelastic characteristic of the multicore elements using general characteristics of hysteresis systems from the paper [23 ] and proper researches. It follows from the above, that developing of units for vibration protection using elastic elements in form of cables is a challenging task for providing of reliability and durability of machine, devices and equipment. However the main task is to define the cable resource during an experiment by curving and winding of them. They are the main arts of load and damping states of the vibration dampers [3, 4]. The resource rope vibration isolators are important issues to the stability of their characteristics, stability under conditions of multi-component spatial cyclic loading, technology of the ensemble of tethered elements, recording forms, calculation of strength, especially production of small structures, creation of structures vibration isolators from non-magnetic materials, the minimization of the dispersion characteristics in mass production. These questions were partly addressed in [20, 27 - 43], but their complete solution is far from complete. 2. Description of the test method Within this research the resource of the cable vibration dampers was studied using a special device. Thanks to the device structure it’s possible to change the eccentricity value and to define the required deformation of the vibration damper during the resource test (Fig. 1).
disc
gear
pusher leaf spring power sensor
essentric vibration damper
Fig. 1. The principle diagram Device for resource test of the cable vibration damper
Fig. 2. Photo of a fragment of device for resource test of the vibration dampers
The test was carried out using the cable vibration damper of a spherical type. You can see the diagram of this vibration damper on the Fig. 3 [2, 3]. The test results allowed finding out of an empirical dependence between the turn index D D / d (D = 2R – diameter of the curvature of the element axle line, R – curvature radius, d – cable diameter) and amount of cycles bevor destruction of Ni for transport load as follows (indexes mean the tension (i = 1) and compression (i = 2) of the vibration damper):
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N1 0,03 D 6,07 ;
(1)
N 2 0,03 D 6,5 .
(2)
Fig. 3. Photo of the vibration dampers, used for the experiment
Fig. 4. Diagram for control of meanperodical stiffness during tests of the vibration dampers using suspension or bearing loading diagram
3.Conclusion Testing of the cable vibration damper resource is an intensive procedure because of a huge amount of parameters, which often cannot be defined as the quantitative values. For instance, these parameters include the technological parameters of the cable lay, cable holding time before producing of the vibration dampers, production technics for vibration dampers, presence/absence of temperature stabilization of the vibration damper form after production procedure, presence/absence of the core or the central steel wire as a component of the cable, storage time for end vibration dampers in the warehouse after the production procedure, cable type. Moreover there is a group of parameters, which can be measured and fixed during the test, but these parameters are undefined in the real operation. That’s why the test results provided by the authors of this paper can be considered as a qualitative control of functionality and reliability of this type of vibration protection. In this case two research results can be considered as proved: according to the suspension diagram the cable vibration dampers with radius profile of components have longtime resource in relation to main diagram; the relative diameter of the axle line curvature of the elastic elements effects the resource of the vibration dampers. Personal experience of the authors by operation of the system for vibration protection of on-board automated systems installed on dampers of mentioned type shows that their real resource is at least 10 years by their practically day-and-night operation as a part of the computerized labor-coaches from JSC PRC INFOTRANS [26]. References [1] Mikhalkin I.К., Simakov О.B., Ponomarev Y.K. Development of means of vibration protection apparatus and equipment in track-measuring test cars of the «INFOTRANS» system. - Collection. Science and education of transport: materials from III All-Russian research-to-practice conference (2010; Samara-Penza). Samara: Samara State Transport University, 2010.- P. 210 – 212. [2] V.I.Kalakutskii, Ponomaryov Y.K. Details of construction and calculation of characteristics of all-metal vibration dampers with cable elastic damping elements for space loading. Collection. «Nonuniform constructions». Research papers of XXX Ural seminar on nonuniform constructions, Ekaterinburg, 2000 y., p 152 – 157. [3] Patent 2082039 RU, Int.Cl. F16F 7/14. The method of forming of elasting adhesive elements of cable vibration dampers /Ponomaryov Yu.К., Kalugin P.А., Kraynov V.I. and etc. Bul № 17, - 1977.
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Igor K. Mikhalkin et al. / Procedia Engineering 176 (2017) 423 – 428 [4] Patent RF on useful unit № 67663. Int.Cl. F16F 7/14. Vibration damper/ Author.: Ponomaryov Y.К., Mikhalkin I.К., Kotov А.С., Ermakov А.I. and etc. Publicated. 27.10.07, Bul. № 26. [5] Ponomarev Y.К., Posokhov P.V. Development of mathematical model of cable vibration damper with assembly of radius-linear constructed elements. In collection of research papers «New materials and technologies in machine industry», version 18, Bryansk, publication БГИТА, Bryansk, 2013, p. 105 – 110. [6] P. P. Balandin. Calculation of the springs made of coiled wire. Reporter of engineers and technicians, 1940, Nr. 10, p. 577 582. [7] S.D. Ponomarev. Calculation of the coiled springs. Part Calculations for stiffness in machine building sphere, Nr/ 1, general editing S. D. Ponomarev, Mashgis, 1957. [8] S. D. Ponomarev. Stiffness and strength of multicore compression springs. Part Dynamic and strength of the springs, М., publisher АN USSR, 1950, pp. 79 128. [9] S. D. Ponomarev, V. А. Olenev. Curvature of the multicore springs. Part. Strength calculations. М.: Machine building, 1976, Ver. 17, pp. 56 75. [10] S.D. Ponomarev. Optimized engineering of the multicore torsion springs, made from cables with center core. Part. Strength calculations. М.: Machine building, 1977, Ver. 18, pp. 239 245. [11] S. D. Ponomarev, V. А. Olenev. Research of cross power effect on strength and stiffness of the multicore compression springs. Part. Dynamic, strength and durability of machine components. Izhevsk. Izhevsk high school for mechanics, 1977, Ver. II, p. 5 17. [12] V.А. Svetlitskii. Mechanics of the pins. In two parts. Part 1 – Statics. М.: high school, 1987, 320 p. [13] V.А. Svetlitskii. Mechanics of the pins. In two parts. Part 2 – Dynamic. М., High school.,1987, 304 p. [14] S. D. Ponomarev, L.Е. Andreev. Calculation of the elastic elements of the machines and devices. 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Theoretical and experimental research of cylindrical movements of vibration dampers (All-Russian Exhibition Centre). – Magazine «Machine building», 39, Nr. 6, Sofia, pp. 257 259. [21] I.D. Eskin, Y.K. Ponomarev. Regarding question about similarity of structural damping systems according to elastic and friction characteristics // Vibration damping of equipment and devices; Report of interregional workshop. Ulianovsk. B.i., 1974, pp. 97 106. [22] I.D. Eskin, Y.К. Ponomarev. Properties of separate classes of the structural damping systems, specified by criteria of classification // Vibration damping of equipment and devices. Report of interregional workshop. Ulianovsk. B.i., 1974, pp. 77 87. [23] I.D. Eskin, Y.К. Ponomarev. Description of general elastic and friction characteristic pf dampers and shock-absorbers with constructional damping // Vibration strength and reliability of motors and systems of flying vehicles. Kuibyshev, KuAI, 1975, pp. 35 43. [24] Y.N. Lapshov. General statistic and dynamic characteristics of the cable vibration dampers. – Reports «Vibration strength abd reliability of motors and systems of flying vehicles». Kuibyshev, KuAI, 1980, Ver. 7, pp. 98 –103. [25] Е.P. Popov. Theory and calculation of the elastic pins. М., Science. Main publisher of physical and mathematical literature, 1986, 286 p. [26] www.infotrans-logistic.ru [27] Allen et al. Patent USA № 6.299.150, - 2001. [28] С. Сamossi. Vibrationen und Strosse elastisch aufnemendes Dampfungsglied. Deushen Patentes № 110751, - 1966. [29] Jean-Yves Hay. Dispositio antivibratio. Patent ES № 2.093.491, - 1994. [30] Jean-Yves Hay. Shock and Vibration Damping Mount. Patent USA № 5.690.322, - 1997. [31] B.F. Augustine. Flexible Shaft-Coupling. Patent USA № 1.010.717, - 1911. [32] A.J. Briggs. Attachment for Wire Rope and Process of Producing The Same. Patent USA № 1.643.110, - 1927. [33] E.F. Curtis. Flexible Shaft. Patent USA № 906.113, - 1908. [34] E.R. Parson. Metod of Making Brushes. Patent USA № 2.317.110, - 1943. [35] J.C. Lockwood. Mechanical Coshioning Device. Patent USA № 2.594.665, - 1950. [36] A.H. Leipert. Universal Joint. Patent USA № 1.602.912, - 1926. [37] V.A. Pershin, E.I.Shpadi, G.V. Lasutkin, A.D.Pichugin, V.N.Trubin. Shock-Absorbing Article and A Method for Producing Same. Patent USA № 3.844.545, - 1974. [38] E.T. Chamberlain. Cable Grip. Patent USA № 2.615.402, - 1951. [39] W.A.Larned. Elastic Metal Stringing and Method of Making the Same. Patent USA № 1.695.595, - 1928. [40] E. Schmoll. Die folgenden Angaben sind den vom Anmeider eingereichten Unterlagen entnommen. Deutschen Patent № 10327318, - 2005. [41] A.S.Hallidie. Wire Rope or Cable. Patent USA № 339.646, - 1886. [42] A. Linn. Electrode Supporting Structure. Patent USA № 2.154.275, - 1939. [43] M.A. West. Transmission Saft for Vehicles. Patent USA № 1.897.542, - 1929.
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Procedia CIRP 59 (2017) 252 – 256
The 5th International Conference on Through-life Engineering Services (TESConf 2016)
Experiment Results Failure Progression from Low Power Wires Availableof online at www.sciencedirect.com
ScienceDirect Mohammad Samie*, Alireza Alghassi, Ian Jennions IVHM Centre, Cranfield dUniversity, Bedford, MK43 0AL, UK * Corresponding author. m.samie@cranfield.ac.uk Procedia CIRP 59 (2017) 252 – 256
Abstract
The 5th International Conference on Through-life Engineering Services (TESConf 2016)
Experiment Results of Failure Progression from Low Power Wires
Despite various studies that have been conducted so far on the failure of high power cables, failure progression in low power cables, wires and interconnections have not been well understood yet. In general, it is hypothesised that failures of wires are progressed from random intermittent failures that are gradually developed as hard faults. This paper aims to present a test rig and possible test techniques that can be used for testing Mohammad Samie*, Jennions the failure progression of wires and interconnections. ResearchAlireza presentedAlghassi, in this paperIan is based on tools, equipment and techniques that facilitate various ageing mechanisms needed to capture proper and right failure patterns from low power cables, wires and interconnections. IVHM Centre, Cranfield dUniversity, Bedford, MK43 0AL, UK ©2016 2016The The Authors. Published by Elsevier B.V. © Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license under responsibility of the Programme Committee of the 5th International Conference on Through-life Engineering Services *Peer-review Corresponding author. m.samie@cranfield.ac.uk (http://creativecommons.org/licenses/by-nc-nd/4.0/). (TESConfunder 2016). Peer-review responsibility of the scientific committee of the The 5th International Conference on Through-life Engineering Services (TESConf 2016) Keywords: No-Fault-Found, Intermittent Fault, Reliability, Accelerated Aging Mechanisms.
Abstract Despite various studies that have been conducted so far on the failure of high power cables, failure progression in low power cables, wires and interconnections that failures of wires are progressed from random intermittent 1. Introductionhave not been well understood yet. In general, it is hypothesised processors, microcontrollers, and memories causing random failures that are gradually developed as hard faults. This paper aims to present a test rig and possible testVarious techniquesstrategies that can beand used efforts for testing intermittent failures [5]. in the Industrial failure progression of wires andasinterconnections. Research presented in this and paperisolating is based intermittent on tools, equipment andbeen techniques that applications such aviation systems widely detecting fault have presented facilitate various ageing mechanisms needed to capture proper and by right failure patterns from low cables, wires interconnections. suffer from a specific type of fault that can’t be duplicated can be in [6-8]. Wakil [9] power also discuss thatand intermittency ©2016 2016The The Authors. Published by Elsevier B.V. © Authors. Published by to Elsevier This isnature. an open access article the CC BY-NC-ND licensea fixed frequency sinusoidal signal into evaluating technicians due theirB.V. random Hence, theunderdetected by injecting Conference on Through-life Engineering Services Peer-review under responsibility of the Programme Committee of the 5th International (http://creativecommons.org/licenses/by-nc-nd/4.0/). potential failure can’t be fixed using conventional techniques. electronics interconnection system. (TESConfunder 2016). Peer-review responsibility of the scientific committee of the The 5th International Conference on Through-life Engineering Services (TESConf 2016)
They highly add to the maintenance cost because they remain It can be hypothesised that the property of a failure sign of faultsAging are Mechanisms. hidden during the troubleshooting. types such as amplitude, duration and repetition of failure signal is Keywords: No-Fault-Found, Intermittent Fault,These Reliability, Accelerated known as No-fault-fault (NFF) [1-3]. In the literature, they increased as the system is gradually aged. At an earlier stage have been also called as Fault-No-Found (FNF), No-Faultof fault progression (stage 1 in Fig. 1), random low-level Apparent (NFA), Fault-Cleared-During-Investigation (FCDI), noises are seen in the failure signal; however, the system 1. Introduction processors, microcontrollers, and memories random and etc. would be subject to intermittency and NFF causing if duration and intermittent [5]. toVarious and 2). efforts in spikes get certain strategies levels (stage System The cause of NFF is attributed to various mechanical, amplitude offailures Industrialenvironmental applications such aviationissues systemsincluding widely detecting andmechanisms isolating intermittent fault have been faults presented degradation further develop semi-hard and chemical, and ashuman suffer from mechanical a specific type of fault(vibration) that can’t be duplicated by in [6-8]. Wakil alsostage discuss stresses electromagnetic permanent hard [9] faults, 3 inthat Fig.intermittency 1. Testing can such bea oxidation, evaluating technicians due to their random nature. Hence, the detected by injecting a fixed frequency sinusoidal signal fields, poor design and bad/wrong operation. They cause hypothesis requires the development of proper test rigs into that conventional techniques. potential failure can’t be fixedin;using electronicsvarious interconnection system. various intermittency issues for instance, chassis, PCBs, facilitate accelerated gaining mechanisms conducted They highlycables add toand thewires maintenance cost because they aged. remain can be hypothesised that the property failure sign regards, connectors, as the system is gradually on Itwires, cables, interconnections, and etc. ofIn athis of or faults are hidden during the These amplitude, duration and repetition of failure signal such as of number challenges that should be taking into account are: is Intermittent faulttroubleshooting. [4] is a malfunction of types a device system known as No-fault-fault (NFF)irregular, [1-3]. Ininthe literature, they increased as the system is gradually aged. At an earlier stage that occurs at intervals, usually a device or system have been alsonormally called asatFault-No-Found in Fig. 1), random from low-level of fault of progression that functions other times. In(FNF), many No-Faultindustrial x Lack knowledge:(stage Fault1detection technology low Apparent (NFA), Fault-Cleared-During-Investigation (FCDI), noises arewires seenisin signal; however, the system applications such as in-line replaceable unit (LRU) of aviation power notthe wellfailure understood. and etc. intermittent faults found in the power chain of a would be subject andofNFF if duration and systems, x Sampling speed:toAtintermittency an earlier stage degradation, spikeof spikes getfailure to certain (stage System The cause of cascaded NFF is attributed to electronic various mechanical, amplitude circuitry, look like as 2). noises that system can be into other like variations in the signallevels degradation mechanisms further develop semi-hard faults and chemical, environmental and human issues including permanent hard faults, stage 3 in Fig. 1. Testing such a oxidation, mechanical stresses (vibration) electromagnetic fields, poor design and bad/wrong operation. They cause hypothesis requires the development of proper test rigs that various intermittency issues in; for instance, chassis, PCBs, facilitate various accelerated gaining mechanisms conducted connectors, cables and wires as the system is gradually aged. on wires, cables, interconnections, and etc. In this regards, number of challenges that should be taking into account are: Intermittent fault [4] is a malfunction of a device or system that occurs at intervals, usually irregular, in a device or system that functions normally at other times. In many industrial x Lack of knowledge: Fault detection technology from low applications such as in-line replaceable unit (LRU) of aviation power wires is not well understood. systems, intermittent faults found in the power chain of a x Sampling speed: At an earlier stage of degradation, spikesystem can be cascaded into other electronic circuitry, like variations in the failure signal look like as noises that
2212-8271 © 2016 The Authors. Published by Elsevier B.V. This is an open access article under the CC BY-NC-ND license (http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of the scientific committee of the The 5th International Conference on Through-life Engineering Services (TESConf 2016) doi:10.1016/j.procir.2016.10.005
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contain higher frequency contents. Hence, a high-speed sampling is required for capturing tools to avoid missing important intermittency signs. x Resolution: As the system develops degradation gradually, a high resolution capturing tools would be needed to record changes at higher possible accuracy. x The size of degradation profile: Sampling at higher speed and resolution causes recording a huge degradation data be created even just from a single thin wire as it may take hours or days to fail the wire gradually. x Development of test rig: Development of the test rig to age low power wires needs additional care to avoid noise while providing better-capturing facilities.
repeated under four different scenarios. Two scenarios for each test are operated using a switch (SW in Fig. 3, 4 and 5) to manage either a dead or live circuit. Live circuit is fed up using a DC power supply (PS) that powers load of the test circuit (LD) up. The other two testing scenarios vary as: x First test: cutting strands of wire one by one, or cutting the wire under test, gradually, while its strands remain together. x Second Test: twisting a wire under test in one continues direction, or in two frequent directions. x Third test: applying pressure/force on twisted contact of a wire while either pressure is just increased, or increasedreleased repeatedly in a sequence of present and absence of force.
Fig. 1. Three-stage fault progression [4].
In order to contribute to knowledge for providing a better understanding of failure progression mechanisms in low power wires and connections, this paper presents a simple capturing technique that supports reasoning needs where small changes in the failure patterns are almost missed out due to spike like changes at an earlier stage. In this regard, a test rig that assists us to age single and multi-strand thin wires is developed, too. Then results are presented; however, testing the earlier mentioned hypothesis in regards to fault progression is left for future work along with signal analysis steps needed for interpreting failure patterns and characterising property of intermittency. The rest of the paper will be as follow; section 2 will consist of the test platform, where it shall be further explained the created test rig, its mechanisms and limitations in accelerating ageing mechanisms of single/multi-strand wires including concepts and principles of possible test techniques that can be conducted using the developed test rig. Section 3 shall cover a model for the test rig describing changes in the resistance of the wires under tests. Results are presented in section 4. Lastly, section 5 shall cover the conclusion.
Fig. 2. Created test rig used to age wires and connections at Through Life Engineering Centre, Cranfield University.
2. Test Rig A test rig that facilitates three different ageing mechanisms on low power multi-strand wires has been created, Fig. 2. Concepts of tests are summarised in the Fig. 3, 4, and 5. First test facilities cutting strands of wire one by one, gradually, Fig. 3. Next test ages wire by twisting them using a motor, Fig. 4. Finally, ends of a broken wire are twisted to one another to regenerate their contact again; and then, recreated contact is stressed under pressure in test 3, Fig. 5. Each test is
Fig. 3. Test 1, cutting strands of wire one by one. Digital multi-meter presents step changes in the resistance of wire as strands are broken by the cutter.
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3. Model of Test Scenarios Regardless of what ageing mechanism is employed to degrade the wire, the proposed test rig can be modelled by a circuit shown in Fig. 6 from the capturing point of view. In this figure, VDMM and IDMM are voltage was seen and currently produced by DMM, respectively. VPS is a voltage of power supply. RLeads are the resistance of probes that connect 4-wired DMM to the wire under test. Rwire is the resistance of the wire under test that is changed due to degradation; and finally, RSW and RL are resistances of the switch and the load. RSW can be ignored when the switch is on as its value is too small in comparison with the resistance of the load, RL. The same, as internal resistance of multi-meter VDMM is too high; hence Isense is ignored so that digital multi-meter senses voltage across the wire under test, VRwire:
VDMM
VRwire
(1)
Fig. 4. Test 2, twisting a multi-strand wire. The wire is gradually aged as motor twists wire under test forward and backward.
Fig. 6. Model of test rig from the capturing point of view for both the live and dead circuit. Rwire is the wire under test.
Fig. 5. Test 3, to examine changes in the resistance of wire as the connection is stressed by pressure (P).
All the various testing scenarios are listed in Table 1. In any case, a Digital Multi-Meter (DMM) [10] is used to capture changes in the resistance of wire. The power supply has a 12 volt DC with a maximum current of 1 A. It is not intended to test wires under the condition of AC power supply.
For a dead circuit, when the switch is off, the circuit of Fig. 6 can be simplified as the circuit in Fig. 7-a. Fig. 7-b is a simplified circuit for when the switch is on considering Norton theorem applied to the power supply and load while ignoring resistance of the switch.
Table 1. List of testing scenarios. Test type
Mechanical Action
Dead Circuit
Live Circuit
Test 1
Cutting a wire gradually
S1,1
S1,3
Cutting the strands one by one
S1,2
S1,4
Twisting (one direction)
S2,1
S2,3
Twisting (two directions)
S2,2
S2,4
Pressure is increased, gradually
S3,1
S3,3
Pressure is increased and released frequently
S3,2
S3,4
Test 2
Test 3
Electrical Action
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Fig. 7. A simplified model of test rig: a) dead circuit, b) live circuit.
The resistance of wire under test for a dead circuit, Rwireis obviously calculated from equation 2, Fig. 7-a:
dead,
Rwire dead
Rwire
VRwire dead I DMM
(2)
In the case of a live circuit, Rwire-live is amplified in compare with a dead circuit because DMM assumes that wire under test is derived only by IDMM; however, external power supply PS also contributes in the voltage across the Rwire. Using KCL of Kirchhoff's law, the voltage across the wire under test is obtained from equation 3 for a live circuit.
VRwire live Rwire || RL
I DMM
VPS RL
R
U
l A
(8)
where U is resistivity, l is length, and A is cross-sectional area of the wire that is almost equal to the summation of strands’ cross-sectional areas, ai where n is a number of strands.
A
ÂŚ
n
i 1
ai
(9)
(3)
In this experiment, resistance of the wire under test is over 100 times smaller than RL, hence equation 3 can be rewritten as equation 4:
VRwire live Rwire
I DMM
VPS RL
(4)
Equation 4 can be also rewritten as equation 5 and 6:
VRwire live Rwire
§ 1 VPS ¡ ¸¸ I DMM ¨¨1 Š I DMM RL š
(5)
VRwire live I DMM
§ 1 VPS ¡ ¸¸ Rwire ¨¨1 Š I DMM RL š
(6)
Fig. 8. Results for a wire under test 1 when a dead circuit is utilised, a) test scenario S1,2, b) test scenario S1,1.
VPS/RL is the current of external power supply, IPS; and from equation 2 it is known that Rwire-dead is equal to Rwire. Hence, by substituting them in the equation 6:
Rwire live
Rwire dead 1 AI
(7)
where AI is amplification gain for the resistance of the wire under test in a live circuit accounted for IPS/IDMM. This amplification helps us to capture changes in the resistance of the wire under test accurately in compare with a dead circuit. 4. Test Results Results for different test scenarios listed in Table 1 are shown in Fig. 7 to 11. Regardless, when a test is conducted using a dead circuit, captured values of resistance looks so noisy that hardly any clear meaning can be distinguished. In contrast, tests using live circuit provide us much better degradation profile with distinct steps in the pattern of resistance. Steps obviously refer to the moments that strands of a wire are broken, Fig. 9. In fact, each strand is broken in a form of sudden failure. Hence, steps are created in the failure pattern of the wire as strands are broken one by one over time. Whenever a strand of wire is broken, effective crosssectional area of whole wire that contribute to the resistance of the wire is reduced, equation 8 [11]:
Fig. 9. Results for a wire under test 1 when a live circuit is utilised, a) test scenario S1,4, b) test scenario S1,3.
Degrading a wire using the twisting mechanism shown in Fig. 3 causes strands to gradually stress and ultimately break. However resistance is increased whenever a strand is broken, but twisting process causes some of the broken strands to get in touch and move across one another for a short period of time. This generates many noises in the pattern of resistance as shown in Fig. 10 and 11. Still steps in the patterns captured from a live circuit, Fig. 11, can be distinguished in contrast with patterns from a dead circuit, Fig. 10. An example of aged wire through twisting test process is shown in Fig. 12. Similarly, it can be seen in the Fig. 13 that resistance is reduced when the ends of a broken wire are simply twisted and connected under pressure; however, resistance is reduced when pressure is released. In fact, twisting ends of a broken wire to one another provides connection nevertheless the twisted contact of the wire is under pressure or not. Pressure/force just increases contact area; and so, provides a higher cross-sectional area that reduces the contact resistance, equation 9.
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Fig. 10. Twisting the wire under test in a dead circuit, S2,2. Meaningful changes in the resistance hardly can be detected.
provides us with a better capturing facility to track small changes in the resistance as the wire is gradually degraded. In fact, a live circuit amplifies resistance of the wire so that minimal capturing noise won’t affect the result. Such a technique satisfies reasoning needs to get distinct meaning while interpreting degradation profile. It is a technique to improve even 4-wire resistance measurement facility of conventional DMMs. Authors of this paper aim to continue their experiments and research toward investigating fault progression mechanism in low power wires and interconnections in their future research while utilising the created test rig and capturing techniques. Acknowledgements The authors would like to sincerely thank the “Engineering and Physical Sciences Research Council (EPSRC)”, the UK's main agency for funding research in engineering and the physical sciences, for supporting and granting the Trough Life Engineering Centre center at the Cranfield University to carry research in the field of No-Fault-Found (NFF) and looking into the various issues of intermittencies in wirings, connections and etc., over the last few years.
Fig. 11. Twisting the wire under test in a live circuit, S2,4.
Fig. 12. An example of aged wire through twisting test process.
Fig. 13. Results from wire under pressure: a) test 3, S3,2, b) test 3, S3,4.
5. Conclusion A test rig that utilises various ageing mechanisms; including cutting and twisting wires as well as pressing twisted broken wires have been presented. The created test rig enabled us to measure the resistances of wires under tests within a dead and live circuit. Results show that the live test
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References [1] H. Qi, S. Ganesan and M. Pecht, "No-Fault Found and Intermittent Failures in Electronic Products," Microelectronics Reliability Elsevier, vol. 48, no. 5, 2008. pp. 663-674. [2] E. Larsson, B. Eklow, S. Davidsson, R. Aitken, A. Jutman, and C. Lotz, "No fault found: The root cause," 2015 IEEE 33rd VLSI Test Symposium (VTS), Apr. 2015. [3] M. Ilarslan; L. Y. Ungar, "Mitigating the Impact of False Alarms and No Fault Found events in military systems", 2015 IEEE AUTOTESTCON, pp. 45-46. Nov. 2015. [4] A. Correcher, E. García, F. Morant, E. Quiles and L. Rodríguez, "Intermittent Failure Dynamics Characterization," IEEE Transactions on reliability, Vol. 61, no. 3, 2012. pp. 649-658. [5] J. Gracia-Morán; J. Carlos Baraza-Calvo; Daniel Gil-Tomás; Luis J., and et. al., "Effects of Intermittent Faults on the Reliability of a Reduced Instruction Set Computing (RISC) Microprocessor", IEEE Transactions on Reliability, Vol: 63, Issue: 1, 2014. pp: 144–153. [6] W. Syed, S. K Han and P. Philips, "Intermittent fault finding strategies," in Procedia CIRP, 2nd International Through-life Engineering Services Conference, Elsevier, Vol. 11, 2013. pp. 74-79. [7] B. Cai; Y. Liu; M. Xie, "A Dynamic-Bayesian-Network-Based Fault Diagnosis Methodology Considering Transient and Intermittent Faults", IEEE Transactions on Automation Science and Engineering. Issue: 99, 2016. pp. 1 – 10. [8] S. Paul, F. Cynthia and et al, "Spread Spectrum Sensors for Critical Fault Location on Live Wires," IEEE Sensors Journal, June 2005. Vol. 5, Issue: 6, 2005. pp. 1445-1450. [9] W. A. Syed; S. Perinpanayagam; M. Samie; I. Jennions, "A Novel Intermittent Fault Detection Algorithm and Health Monitoring for Electronic Interconnections", IEEE Transactions on Components, Packaging and Manufacturing Technology, Vol. 6, Issue: 3, 2016. pp. 400–406. [10] L. Sevgi, "Digital Multi-Meters and Basic Measurements", IEEE Antennas and Propagation Magazine. Vol. 49, Issue: 4, 2007. pp. 232– 237. [11] G. Russ, "A System for Analyzing Contact Resistance", IEEE Transactions on Components, Hybrids, and Manufacturing Technology. Vol. 2, Issue: 3, 1979. pp. 317–320.
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Roller clamp for wire processing U.S. Patent No.: 9,643,234 Patent date: May 9, 2017 Filed: Aug. 5, 2014 Assignee: Automated Industrial Machinery, Inc., USA Inventor: Tony Suto A roller clamping apparatus is provided that includes a first jaw and a second jaw configured to move relative to each other between an open position and a closed position. The jaws include at least one drive roller supported by the first jaw and configured to rotate a round wire having a longitudinal axis. The apparatus further includes at least one support element supported by the second jaw. When the jaws are in a closed position, the drive roller and the support rollers tangentially contact an outside surface of the wire. The support element is positioned to make contact with the wire across the longitudinal axis of the wire when the wire is secured within the clamping apparatus. Mechanisms and methods that use the roller clamping apparatus are also disclosed.
Fluted heater wire U.S. Patent No.: 9,642,979 Patent date: May 9, 2017 Filed: Nov. 4, 2015 Assignee: CareFusion 207, Inc., USA Inventors: Neil Korneff, Christopher Varga A heater wire for removing condensation from a respiratory gas conduit is provided. The heater wire includes at least one groove disposed thereon. The heater wire is positioned in a respiratory gas conduit. The groove may wick up water from a condensation region within the respiratory gas conduit and transport the wicked up water from the condensation region to a re-evaporation region. The wicked up water may be evaporated by a hot surface of the wire.
WAI MEMBERS seeking positions are entitled to free “Position Wanted” classified ads. CLASSIFIED AD RATES: • $1.30 per word for WJI and on-line classifieds at wirenet.org (20-word minimum). • Blind box numbers, add $25. • Boldface headlines, add $6 per line (up to 18 characters per line). Specify category.
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SALES POSITION SOUGHT. Wire operations professional with over 35 years’ experience in both Round and shaped wire is seeking an Operations or territory Sales position in North Central US. Offering Broad-Based Experience and a Track Record of Success in Driving Performance Gains and Innovative Product Development for Start-up and Established Operations. Experience in engineering, manufacturing, tooling, and field operations management within start-up, turnaround, and highgrowth environments. Able to deliver breakthrough developments through strategic hands-on leadership and participative management style. Skilled manager, negotiator, communicator, and leader; bring out the best in diverse, cross-functional work teams. Expert at sizing up organizational needs and areas for improvement to implement win-win strategies and tactical action plans fulfilling production improvement and bottom-line objectives. Goal-setter and visionary leader. Contact wireinterest52@ yahoo.com
“LET OUR SUCCESS BE YOUR SUCCESS” Wire Resources is the foremost recruiting firm in the Wire & Cable Industry. Since 1967 we have partnered with industry Manufacturers to secure the services of executives, managers, and thousands of key individual contributors. Contact: Peter Carino, pcarino@ wireresources.com or online at www.linkedin.com/in/petercarino1/ Wire Resources Inc., PO Box 593, Riverside, CT 06878, tel. 203-6223000. www.wireresources.com.
CAREER OPPORTUNITIES SALES REPRESENTATIVE. U.S. manufacturer of tungsten carbide drawing dies seeks a sales individual for territories in the USA and in Canada. Interested parties please respond to classified@wirenet.org
MACHINERY USED MORGAN-KOCH 26” DEAD BLOCK TAKEUPS For sale galvanizing line take ups Twenty-four (24) V-groove take up units: • Block/capstan dia. 26 inches • Wire working Range: 0.060” to 0.250” • Wire material: Low to high-carbon steel • Maximum speed 240/FPM • Take-ups are individually driven by 3 HP AC motors • Includes pattern-lay turntables • 4 (3+3 symmetric) wire payoff positions that complete 24 positions • All motors are 230 VAC/3PH/60Hz • AC drives to regulate speed • Each capstan is fitted with a speed and meter counter indicator. • Air operated coil holding arms provided to accumulate wire while coils are removed. • Coil weight: 500-2,000 lbs. Please contact Ida Pardo at pardo@knottco.com.
WWW.URBANOASSOCIATES. COM. For New (Hakusan Heat Pressure Welders, Ferrous & NonFerrous; Marldon Rolling Ring Traverses) & Used Wire & Cable Equipment (buttwelders, coldwelders, and pointers). Tel: 727-863-4700 or by e-mail, please send to urbassoc@ verizon.net. AA ENTERPRISE. MÉXICO. Proveedores de soldadoras eléctricas y manuales; impresoras y discos; cilindros, bandas y anillos para recocedores, bobinas/ carretes de plástico y acero; carretes p/ enmalladoras; bandas para caterpillar; tapes; conos y anillos de cerámica y tungsteno p/ estiradoras; maquinaria p/ producción; cabezas de extrusión, etc.ayala1953@ gmail.com.
MEDIA FERROUS WIRE HANDBOOK. Written by WAI members and edited by Dr. Robert M. Shemenski, this 1,168 page, hard-cover, indexed publication is a definitive industry resource for ferrous wire. It is a modern-day reference tool for those working directly in the steel wire or manufacturing, engineering, or operations sectors of the industry. The publication includes 36 chapters on a broad range of topics including many of the equipment types, processes, and specialty applications of steel wire manufacturing. The book begins with a history of the steel industry and its evolution, followed by details on: continuous casting; controlled rod cooling; rod defects; pickling and coating; mechanical descaling; deformation in cold drawing;
JUNE 2017 | 101
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wiredrawing theory, machinery, and finishing equipment; lubrication; heat treatment; stress relief; annealing; oil tempering; patenting; corrosion; galvanizing; statistical process control; bridge rope and strand; nails, barbed wire, mechanical springs. The price is $235, $195 for WAI members. To purchase, go to wirenet.org and click on The WAI Store. SIX SIGMA AND OTHER IMPROVEMENT TOOLS FOR THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 135page indexed book (published in 2011) was written by industry expert Douglas B. Relyea, founder of Quality Principle Associates, a New Englandbased consulting firm specializing in the education and application of data analysis techniques to industrial problem solving. The book includes:
the benefits of statistical process control over statistical product control; real-world industrial examples and case studies showing how to use the techniques; ways for management to determine if the investment in process capability studies is providing an appropriate return; methods to correct lack of stability and capability once either condition has been identified, such as the ANOVA technique and the simple three-factor designed experiment; and a flow chart that enables machine operators to execute a process capability study without interfering with productivity. The list price is $45, $40 for WAI members, plus shipping. To purchase, go to wirenet. org and click on The WAI Store. THE PRACTICAL APPLICATION OF THE PROCESS CAPABILITY STUDY. Creating a universal language for problem solving, this 2011 135-page booth by industry expert Douglas Relyea, founder of Quality
GLOBAL ONLINE AUCTION: Complete Legendary Wire Products Manufacturing Plant Dating Back to 1927. Assets to Include Wire Forming, Wire Cutting, Metal Tooling, Rolling Stock, MRO, Facility Support, and Much More! Start: June 21, 2017 / 8am EDT Ending: June 23, 2017 / 10am EDT Location: 800 Woodward Heights Ferndale, MI 48220 Preview: June 19, 2017 / 9am - 4pm EDT • IDEAL Automatic 8 Head CNC Mesh Welder Model GA0512 with Dual Cross/Triple Line Wire Loaders • PAVE HURON 3D CNC Wire Bender • PAVE MICRO 6 DUAL HEAD CNC Wire Bender • PAVE VARIFORM DUAL HEAD CNC Wire Bender • Complete Powder Coat System – Nordson Encore 12 Gun Assembly with I-control New 2012 • Steelman Burn Off Oven • Facility Support • Rolling Stock • Storage Trailers • Machine Tools • Over 60 Press/Spot/Butt Welders to 400 KVA • Punch Presses • Straighteners • Notchers • Trucks • Tool Room Equipment • Wood Working Equipment • Much Much More! Sale In Partnership With:
FOR MORE INFORMATION, PLEASE CONTACT: ALEX DOVE / 650.759.9048 / ADOVE@HGINC.COM ED KRAUSE / 215.932.4089 / ED@FHMACHINERY.COM
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102 | WIRE JOURNAL INTERNATIONAL
Principle Associates, a consulting firm specializing in the education and application of data analysis techniques to industrial problem solving. The list price is $45, $40 for WAI members, plus shipping. To buy, go to wirenet.org and click on The WAI Store. THE SMALL SHOP. This book, 327 pages, by Gary Conner, the author of Lean Manufacturing for the Small Shop, describes Six Sigma and its use by smaller companies. Published by the Society of Manufacturing Engineers, it shows the relationship between continuous improvement, lean, and quality, and focuses on implementation for operators, managers, and owners. It includes a supplementary CD-ROM. Price, $95, $75 for WAI members, plus shipping. To purchase, go to wirenet.org and click on The WAI Store.
ADVERTISER............................. PAGE
ADVERTISER............................. PAGE
Amacoil Inc .............................................. Cover 3
Gem Gravure Co Inc ..........................................41
Anbao Wire & Mesh Co Ltd ..............................80
Guill Tool & Engineering Co .............................16
Anderson Forest Products ...............................71
Henrich GmbH ...................................................53
Beneke Wire Co .................................................75
Honta America ...................................................33
Beta LaserMike Products (An NDC Technologies Brand) .......................17
Howar Equipment Inc ........................................20
Black Sea Technology Inc ................................21
Inosym Ltd ...................................................30, 60
Carris Reels Inc ....................................... Cover 4
KEIR Manufacturing Inc ..................................102
CBC Metals Processing ....................................73
Lamnea Bruk AB ................................................27
Cemanco LC.......................................................80
Locton Limited ...................................................76
Clinton Instrument Co .......................................28
Madem SA ..........................................................23
Electric Cable Compounds Inc...................58, 97
MFL Group .........................................................57
Esteves Group USA...........................................19
Metal Link Inc .....................................................77
George Evans Corp ...........................................81
Mexichem Specialty Compounds Inc .... Cover 2
Fenn LLC ............................................................61
Morgan-Koch Corp ............................................79
FMS USA Inc ......................................................62
Oden Technologies ...........................................49
Huestis Industrial ..............................................52
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ADVERTISERS’ INDEX
ADVERTISERS’ INDEX
ADVERTISERS’ INDEX PEOPLE
ADVERTISER............................. PAGE
ADVERTISER............................. PAGE
P & R Specialty Inc ............................................65
Upcast OY ............................................................5
Paramount Die Co ...............................................4
Wire & Plastic Machinery Corp ........................13
Pressure Welding Machines Ltd ......................55
Witels Albert USA Ltd........................................76
Process Sheaves LLC .......................................56
World Wide Innovators ...................................102
Proton Products International Ltd ...................67
Wyrepak Industries .....................................26, 99
Queins Machines GmbH ...................................51
Zumbach Electronics Corp ...............................31
Rainbow Rubber & Plastics Inc..........................2 Rosendahl Nextrom GmbH ...............................15
WIRE ASSOCIATION INT’L ADS
Sanxin Wire Die Inc .............................................9
WAI HardWIRED.................................................32
SARK-USA Inc ...................................................25
Interwire 2017 Sponsors/Volunteers.......... 38-39
SIKORA AG ..........................................................7
Global Ferrous Rod & Wire Symposium Sponsors/Volunteers ........... 44-45
Sivaco Québec .....................................................1 Sonoco Reels .....................................................63 Steel Cable Reels/Tektapes ..............................59 Tensor Machinery Ltd .......................................29
WIRE JOURNAL
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U.K., France, Italy, Spain, Holland, Belgium, Denmark & Scandinavia Jennie Franks David Franks & Co. Tel/fax: 44-1223-360472 franksco @btopenworld.com
ASIA/ WAI INDIA OFFICE India Office Wire & Cable Services Pvt. Ltd. Rahatani, Pune - 411017, India Huned Contractor mobile - +91 988 1084 202 hcontractor@wirenet.org China Office Zhuang (Frank) zhilu Shanghai, China 200331 mobile - 0086-18018681117 zzs12151116@163.com
August 2017 • Asia Outlook • wire Southeast Asia preview
Germany, Austria, & Switzerland Dagmar Melcher Media Service Int. Tel: 49-8801-914682 Fax: 49-8801-914683 dmelcher@t-online.de
104 | WIRE JOURNAL INTERNATIONAL
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