In the wire manufacturing industry, efficiency and precision are paramount. The process of using standalone drawing machines followed by separate coiling operations, while flexible, often requires space and handling, leading to high labor cost  and potential for inconsistencies.

Combining a bullblock with a bending coiler has therefore emerged as a powerful solution to meet today’s market demands. The advantages of this process include:

• Increased efficiency: The double wire take-up on carousel minimizes downtime and increases throughput depending on the final coil weight
• Improved precision: The integration ensures that the wire maintains consistent quality throughout the drawing and coiling processes.
• Wire surface control system: possibility to add a wire surface control system between bull block and bending coiler

This solution finds extensive applications across various industries, including key sectors such as Automotive, Construction and Mechanical engineering. Components like springs, fasteners, rolling bearings and cold heading parts can be manufactured with ease.

 

Technical integration & challenges

From a technical standpoint, integrating a bullblock with a bending coiler involves several key considerations:

• Synchronization: Ensuring that both machines operate at compatible speeds to maintain consistent tension and avoid wire breakage.
• Control Systems: Advanced control systems are required to manage the operations of both machines seamlessly.
• Space and Layout: Proper planning of the machine layout to optimize space and workflow efficiency.

There are also challenges to consider:

• Wire Range limitations: The integrated system may have restrictions on the range of wire diameters it can handle effectively.
• Setup complexity: Initial setup and synchronization of the machines can be complex and may require skilled technicians.

 

 Why choose a bull block in combination with bending coiler?

Despite the initial challenges, combining a bull block with a bending coiler represents a significant advancement in wire manufacturing, offering enhanced efficiency, precision, and cost-effectiveness.

Additional advantages include:

• Horizontal double payoff type KAM to reduce downtimes
• Pre-driving and straightening unit on the bull block for easy handling of wire feeding to the bending coiler
• After drawing on the bullblock, the wire is fed to the bending coiler. This process is very smooth on the wire surface to avoid damages
• Double wire take-up on carousel increases productivity by 20-30% depending on finished wire weight
• The line can be easily supplemented with a wire surface control system between the bull block and the bending coiler
• To further increase efficiency, the line can be supplemented with a welding machine between the wire pay-off and the bull block
• An automatic coil discharge followed by compacting and automatic strapping station can be provided to further increase efficiency and relieve workers

MFL Group’s bull block and bending coiler system are designed to deliver superior performance:

• Robust Construction: Built to handle heavy-duty operations with minimal downtime.
• Advanced Control Systems: Featuring state-of-the-art control systems for precise synchronization and operation.
• Customizable Solutions: Our machines can be tailored to handle a wide range of wire diameters and materials, providing flexibility to meet diverse industry needs.
• Ease of Maintenance: Designed with maintenance in mind, our system allows for easy access to critical components, reducing maintenance time and costs.

The KHZ series, a horizontal bull block machine, is designed by the Koch brand for heavy industry.

Our close connections with wire manufacturers in Altena, Germany, and the surrounding areas enable us to continually develop this machine technology in line with industrial practice.

Our horizontal drawing systems together with the bending coiler can handle wire with an inlet diameter of 12.0 mm up to 28.0 mm to finish diameter of 10.0 mm up to 24,0 mm. KHZ series have demonstrated exceptional effectiveness, particularly for large wire diameters exceeding 20.0 mm. Wire diameters of up to 50.0 mm can be handled from coil to coil.

An automatic pull-in dog enables these machines to be operated ergonomically and efficiently, mainly for coil production with connected take-up carrier.

The AVP series is an MFL Group bending coiler which is very versatile in terms of final applications. Normally used in diameter range from Ø 3 to 15 mm, it can reach larger diameters up to Ø 24 mm depending on the material. This machine is designed to offer maximum versatility in terms of wire diameters and finish coil sizes. 

For more information on how our integrated systems can benefit your operations, contact us today.

 

CONCLUSION

Combining a bull block with a bending coiler represents a significant advancement in wire manufacturing, offering enhanced efficiency, precision, and cost-effectiveness. For more information on how our integrated systems can benefit your operations, contact us today.

Authors: Oliver Funke and Andrea Froio, Area Managers (Wire and Rope Division)