| BWE Conform� continuous extrusion machines are recognised as the industry standard for the production of small copper strips for electrical applications such as magnet wire, transformer windings, commutators etc. The process has become well-known for low capital and production costs, short lead times, quick changeovers and excellent product quality, in a single stage, from feed stock to finished product. The company has recently launched its third generation Conform process, the Reflex� machine, which incorporates three new (patented) features to make set-up easier, adjust tooling clearances, adjust the coining-roll position, reduce pre-heat time, reduce running costs and improve overall efficiency.
The Reflex adjustment system uses two unique mechanisms, the Resolver and the Twin Eccentric, that position machine components. These mechanisms are designed to convert shaft rotation, provided by a high-torque motor and gearbox, into linear movement without sacrificing machine rigidity. Two adjusters are used to set and control tooling clearances while a third is used to position the coining roll. The control system provides a variety of functions for initial set-up and dynamic adjustment while the machine is running.
Tooling is pre-heated and maintained at optimum operating temperature by an induction heating system that is engineered into the Conform shoe to provide direct, high-efficiency heat where it is most needed. A water-cooled induction coil surrounding the die chamber is used to directly heat the body of the chamber. The magnetic flux generated is routed through low reluctance paths around the chamber to complete the magnetic circuit and prevent heating of the surrounding shoe. Water-cooled flexible cables carry power from a self-contained control unit that incorporates the power supply, semi-sealed cooling system, chamber detection and fault protection. Fully automatic wheel cooling is provided through a network of internal cooling channels. Coolant flow is controlled by a variable speed pump which is supervised by the control system using wheel temperature and a pre-programmed pump speed/flow/temperature characteristic map.
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