Expertise, Customer Driven, Service - in Good Hands with NIEHOFF - Visit us at wire 2018 1/2018 - Niehoff Endex
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+ NIEHOFF Original : the plus over the complete life cycle of your machine. Only NIEHOFF, the global partner for the wire and cable When it comes to real understanding just trust our industry, offers a comprehensive aftersales portfolio. NIEHOFF Original+ experts. We offer you NIEHOFF A portfolio that gives you a decisive plus over the Original+ Wear Parts, NIEHOFF Original+ Spare Parts, complete life cycle of your machine investment. That is NIEHOFF Original+ Service, and NIEHOFF Original+ why we call it NIEHOFF Original+. Modernization. Our plus stands for fair cost-benefit ratio, top quality, Just contact us to learn more about NIEHOFF Original+ customized solutions, latest technology trends, utilizing or visit our home page. resources optimally, possibility to upgrade your machine, competent service engineers, and a contact person near to you who speaks your language. Expertise, Customer Driven, Service – in Good Hands with NIEHOFF
28-49 Good perspectives Contents 50 51 The NIEHOFF 4-5 digitization concept Dear Friends of NIEHOFF, The outstanding event for the wire of their high quality, existing NIEHOFF NIEHOFF Digital Assistant+ 4.0 and cable industry in the first half-year machines are worth the efforts for of 2018 will be the wire 2018 trade reconditioning and upgrade (p. 18 – 19). fair in Düsseldorf, Germany (16 – 20 Such measures can even increase their April 2018). On pages 6–9 you will productivity and efficiency levels. Cutting edge multiwire 6 get information of our exhibits along Among the upgrading components drawing technology Multiwire drawing line type MMH 121 + RM 161 with technical data. On the upper floor there is also a retrofittable cleaning of the booth our After-Sales-Service device for the contact tubes of certain The wire bunching standard 7 will be showcasing NIEHOFF Original+ D 632 type double twist bunching machine RM in-line annealers (p. 20). A worldwide unique cable 8 components and explain the benefits handling system of NIEHOFF’s new digitization concept In order to keep the manufacturing NPS double spooler type SV 402 D (p. 4-5). The data are accessible via facilities up to the latest standard, our The best way of braiding 9 the new application NIEHOFF Digital group constantly invests: At the head- Rotary braiding machine BMV 16 A ssistant+ 4.0. quarters in Schwabach a new horizon- Refurbished and ready for use 10 tal machining center is currently being Lead extrusion equipment made by HFSAB At the NIEHOFF booth our partner put into operation (p. 21), while our Ground breaking 11 c ompany HFSAB will demonstrate Indian subsidiary NIEHOFF of India exe- The NIEHOFF MMH 112 multiwire drawing machine its capability of overhauling used machi- cuted a second extension of their facili- Good perspectives for the cable industry 12-13 nery by means of a reconditioned lead ties (p. 22 – 23). The global market situation extruder screw (p. 10). Set off for new dimensions 14-15 Our company profile features C oroplast The new double twist stranding machines In our market report titled “Good Fritz Müller GmbH & Co. KG, one of Doing things differently 16-17 Coroplast Fritz Müller, Wuppertal, Gemany perspectives for the cable industry” on the leading manufacturers of adhe- pages 12 – 13 we tell you why the order sive tapes, cables and wire harnesses As good as new again – or even better 18-19 Upgrading used NIEHOFF machinery With effect from January 1, 2018 our books of cable makers should continue (p. 16 – 17). Management Team was completed by to be filled. It’s a clean thing 20 Retrofit cleaning device for RM type annealers Mr. Ralf Kappertz, who joined N IEHOFF We look forward to welcoming you at Flexibility and high precision 21 as Chief Executive Officer and Chair- The new MMH 112 type multiwire the wire trade fair and hope that you New machining center at the Schwabach plant man of the Managing Directors. He drawing machine represents a com- enjoy reading this issue of NIEHOFF Well established in India 22-23 took over the field Production and Engi- pletely new generation of multiwire Magazine. NoI has again extended its production facilities neering. The executive management drawing machines (p. 11). NIEHOFF is News / Events 24-25 consists now of Mr. Ralf Kappertz, also developing three additional double Mrs. Elena Graf, Chief Financial Officer, twist stranding machines for the manu- and Mr. Bernd Lohmüller, Chief Sales facture of compacted conductors for Ralf Kappertz Elena Graf Bernd Lohmüller Officer. energy cables (pages 14 – 15). Because CEO CFOSchwabach,CSO April 2015 Schwabach, April 2018 In the future, the NIEHOFF Magazine will be delivered also by email. We assume that you don’t object to this mode of dispatch. If you don’t wish to receive the NIEHOFF Magazine by email, please inform us explicitly by phone (+49 9122 9770), by mail or by email (info@niehoff.de). In case we don’t receive your refusal, we will act on the assumption that you agree to receive the NIEHOFF Magazine electronically (by email).
The NIEHOFF digitization concept NIEHOFF Digital Assistant+ 4.0 Industrial companies cannot bypass the topic of “digitization”, as revealed by surveys and a glance at the markets. Digitization and Industrie 4.0 are key issues at the large trade fairs such as the Hanover Fair 2018 and the SPS in Nuremberg. These issues stand for the close interaction of machines and processes with information and communication technologies, on the one hand. On the other hand, these issues are in connection with the high speed transmission and processing of large amounts of data. 4 NIEHOFF Magazine 18/01
Numerous NIEHOFF machines The NIEHOFF immediately to NIEHOFF. This is eas- booth offer the possibility of con- have already been networked Digital Assistant+ 4.0 ier and saves time. tinuously recording and processing a A survey carried out by NIEHOFF The new NIEHOFF Digital Assistant+ number of quantities (s. pages 6-9). shows that in the wire and cable 4.0 works both as a web applica- Troubleshooting NIEHOFF thus shows the way into industry, NIEHOFF machines have tion and simultaneously for iOS and The NIEHOFF Digital Assistant+ 4.0 the future. already been digitally networked Android. Thus, a wide variety of offers customers various possibilities to a high extent. This is in harmony functionalities can be experienced. to deal with a problem and elimi- We look forward to showing you at with the widespread trend because, Many functions can be used via a nate it. We support you with help the wire how the NIEHOFF Digital according to the German Federal protected user account, depending for self-help, for example via quick Assistant+ 4.0 will help you to make Ministry of Economics and Energy on the customer’s wishes. access to the “Troubleshooting” your production safer and more (BMWi), more than 20 billion item in the documentation. You will economical. And we look forward devices and machines are already Machine monitoring find it in the NIEHOFF Digital Assis- especially to an exciting exchange of connected via the Internet today – and process monitoring tant+ 4.0 for each selected machine experiences with you. by 2030 it should be around half a Data which are recorded during as well as a collection of FAQs on Just come and visit us! trillion [1]. production reveal a lot about the the respective topic. technical condition of production If necessary, you can also con- New digitization standards systems. With the NIEHOFF Digi- tact NIEHOFF immediately using NIEHOFF interprets the topic of digi- tal Assistant+ 4.0, we help you to the ticket. Just send pictures and tization for its customers and will manufacture your products more a description of the fault at your present the result to the special- safely and economically. machine, we will take care of it. ist audience at the wire 2018 trade All processes are transparently and fair. The focus is on the application Identification of spare parts / clearly displayed, enabling you to of the NIEHOFF Digital Assistant+ enquiry concentrate on the essentials – to 4.0 developed by NIEHOFF special- With the NIEHOFF Digital Assis- eliminate the malfunction and make ists – ingeniously simple and the tant+ 4.0, spare parts can sim- the machine quickly available again. perfect tool to support our custom- ply and quickly be identified and ers in view of a safe and economical enquired. After selecting the respec- NIEHOFF Digital Assistant+ 4.0 [1] http://www.bmwi.de/Redaktion/ production. tive machine and the assembly, the at the wire DE/Dossier/digitalisierung.html required parts and their quantities Due to their additional sensors, the are selected and the enquiry is sent machines presented on the NIEHOFF NIEHOFF Magazine 18/01 5
Cutting edge multiwire drawing technology Multiwire drawing line type MMH 121 + RM 161 The multiwire drawing machine type MMH 121 is designed to draw up to 16 copper wires (Cu hard) simultaneously at one level. Here the machine is combined with an inline annealer type RM 161. The machine is simple and intui- tive to operate by means of the standardized NMI (NIEHOFF Machine Interface), a network- compatible color touchscreen which features a clear task and user-oriented navigation structure and enables an easy intuitive opera- tion. The NMI displays the produc- tion parameters, gives maintenance instructions and offers diagnostic With the NDI (NIEHOFF Data Inter- value of the drawing emulsion, out- and very narrow tolerances. The functions. Data can be recorded and face) process related data and put quantity. wire properties surpass the most archived, a recipe data management machine data can be imported or demanding specifications and pro- completes the range of functions. exported via Ethernet and OPC The MMH machines are particularly cessing requirements in view of server to an MES/ERP system. designed for copper and alumi- electrical conductivity, surface qual- num wires and of modular design. ity and mechanical properties. These Technical data MMH 121 * The intelligent technology of the Therefore, these machines can wires can be processed to multiwire max. production speed 40 m/s machine makes it possible to use be readily adapted to the specific bundles with outstanding character- 7870 fpm machine, production and process requirements of the users. istics and are ideally suited for final number of wires 16 data according to Industry 4.0. It applications or downstream pro- max. inlet diameter 2.05 mm is possible to measure motor and The wires drawn on MMH lines – cesses such as high-quality strand- AWG 12 drive data, speed, temperature and which are designed for copper and ing or braiding. max. finished diameter 0.15 mm ... 1.40 mm flow rate of the gear box oil, lubri- aluminium wires – show highly AWG 34 ½ ... AWG 15 cation properties, oil moisture, pH homogeneous characteristics * Cu hard 6 NIEHOFF Magazine 18/01
The wire bunching standard D 632 type double twist bunching machine The D 632 type double twist bunching machine is ideally suited for the manufacture of strands of copper alloy wires (e.g. CuMg alloys) for automotive wires. The machine is characterized by several features which ensure considerable energy savings compared to conventional bunching machines. Also noise emission is significantly reduced. The drive concept expresses itself in a robust operation, free of dancer or spooler vibrations. The “Stretch Forming and straight- The adjustment and control of the ening” technology realized in the winding tension throughout the D 632 ensures that the crowning entire spool filling operation makes effect is eliminated and the bunched it possible to keep the tightest pro- strand is straight. duction tolerances. The patented opto-electronic NBAT system (NIEHOFF Bunching Auto- Easy and efficient operation is matic Traverse) allows spools to be enabled via a 10”-touch-screen dis- Technical data D 632 spooled with a perfect winding play with the colour user interface max. production speed 300 m/min pattern. Spooled wire can then be NMI (NIEHOFF Machine Interface) 984 fpm payed-off tangle-free at extremely having a clear navigation structure. production range high speeds with no damage. This enables a simplified and intui- strand cross-section (soft Cu) 0.09 mm² … 6.00 mm² tive handling making operation easy. AWG 27 ½ ... 9 ½ The service proven energy-saving lay length 6 mm … 100 mm single bow (ECO-Bow) design, The sensor technology was imple- (steplessly variable) the non-contact transmission of mented in the machine with par- max. number of twists 7,000 twists/min machine data within the machine, ticular regard to the requirements of The D series machines: spool sizes a sophisticated energy-class IE3 Industry 4.0 capability and enables Successful since their launch flange diameter 630 mm energy-saving drive concept and an diameter measurement of the fin- The D 632 is part of a series of spool width 475 mm adjustable fan drive in the sound ished bunched strand, the preset lay seven differently sized models. Fur- proof cabin ensure considerable length, motor and drive data, speed, ther information about this series energy savings compared to conven- lay length, meter lengths. and current further development tional bunching machines. projects is offered on page 14–15. NIEHOFF Magazine 18/01 7
A worldwide unique cable handling system NPS double spooler type SV 402 D The NPS double spooler type SV 402 D is part of the NIEHOFF Package System (NPS), a highly efficient, safe and economic handling system for automotive wires. The spooler is designed to operate in-line with extrusion lines. Spool change from full to empty spool is carried out automatically. The sensor technology of the machine makes it possible to use machine, production and process data according to Industry 4.0 It is possible to measure motor and drive data, rotational speed, speed, vibrations, main drive temperature. The protected conical wire laying PP series also offer the same pro spools and require therefore much technology offers a secure, stable duction safety and the same less return shipping space than Technical data SV 402 D * and tangle-free package on the NPS application potential like all 3 million traditional spools. Upon return to max. production speed 1800 m/min spools both when full or partially NPS spools made of ABS plastic and the cable manufacturer NPS spools 5900 fpm empty. Thus, NPS spools enable are fully compatible with them. can be easily and quickly re-assem- production range highest cable pay-off speeds into bled and then re-used for dozens of insulated wires, cross section 0.13 mm² downstream processes. A worldwide unique system cycles. (Cu alloys) AWG 26 The NIEHOFF Package System NPS Cu wire strands, cross section 0.22 mm² … 6.00 mm² The most recent highlight of the consists of the specially developed The NPS is the world’s only packag- (soft Cu) AWG 23 ½ ... 9 ½ NPS is the completely new devel- SV type spoolers and the collapsible ing system for automotive wires cable outer diameter 1.0 mm … 5.0 mm oped NPS PP spool series. These NPS plastic multiway spools. Empty which allows trouble-free and (including insulation) collapsible multiway plastic spools NPS spools can be fully dismantled tangle-free paying-off at highest spool sizes NPS Multiway System are offered in the same dimensions and nested into each other. In this speeds. The NPS has almost totally flange diameter 400 mm as all NPS ABS spools at very cost way they take up only a third of the replaced conventional package winding width 400 / 250 / 150 / 100 mm efficient price. The spools of the NPS space of comparable conventional systems in the automotive industry. * flexible Cu conductors 8 NIEHOFF Magazine 18/01
The best way of braiding Rotary braiding machine BMV 16 The 16-carrier lever arm rotary The interior of a BMV type rotary braiding machine BMV 16 is ide- braiding machine resembles a Swiss ally suited for the production of data precision watch and is equipped with cables, control cables and coaxial several sensors. cables. Furthermore, for the pro- duction of automobile hybrid cables By means of further monitoring Also for the BMV braiding machines into which a film must be inserted systems, some optionally available, new functionalities have been devel- before and after braiding as well as BMV braiders can operate unat- oped according to the requirements for the production of braids for bat- tended for extended periods and of Industry 4.0. It is possible to tery cables and strand braids. Addi- without frequent operator interven- measure motor and drive data, rota- tionally, the machine can be used tion. One example is the tempera- tional speed, speed, braiding pitch, for the production of the mechani- ture control of the slide ways. This temperature of the slide ways. cal reinforcement of pressure hoses. option is very important at the high processing speed. The BMV braiding machines can be Among the features of NIEHOFF’s and braiding pitch as well as an an equipped with an integrated cen- BMV machines, which include four automatic central lubrication system. The machine demonstrated at the tral taping device enabling braid- vertical models with 12, 16 or 24 booth is equipped with the WTM ing and the subsequent taping to be bobbins, there is the infinitely vari- From the pay-off of the cable to (WTM – wire tension monitor- completed in one step. It is possible able electronical control of line speed be braided via the individual wires ing) system: The tension at each to manufacture, if required, also and bundles of wires up to the final spool carrier is measured by means products with tapes which must Technical data BMV 16 take-up of the braided cable: A of integrated measurement elec- be applied both before and after quality assurance system controls tronics at the dancer and transmit- braiding in S or Z direction. These Processing of bare or plated round or flat wire made from all process steps in the machine. ted to the control panel of the BMV. central taping devices can also be copper, aluminum or stainless An empty bobbin detection sys- There, a visualization of the tension individually activated. The advan- steel as well as artificial yarn tem, available as an option, stops is carried out for each spool carrier. tages: Space savings, elimination of and fibers with single-wire 0.05 mm ... 0.3 mm the machine automatically before Mean values and extreme values are rewinding processes and an increase diameters 40 AWG … 28 1/2 AWG a braiding bobbin is completely displayed to the operator who can in product quality. max. braiding pitch 3 mm … 120 mm empty. In this way, waste and the quickly react to possible changes central passage 50 mm amount of residual wire left on the and impact positively on the quality haul-off capstan diameter 500/650 mm (optional) bobbin are kept at a minimum. of the braiding product. NIEHOFF Magazine 18/01 9
Refurbished and ready for use Lead extrusion equipment made by HFSAB H. Folke Sandelin AB (HFSAB) will also exhibit at the NIEHOFF booth. The company established in Sweden is the global market leader in the area of lead extruders and cable stripping machines. and maintain. They are fully auto- matic and extremely reliable with their state of the art control system, enabling continuous operation for weeks with little or no variation in resulting in a higher line speed and NIEHOFF and HFSAB temperatures, wall thickness or con- a higher output. As the outer cable HFSAB, formerly known as H. Folke centricity. sheath over the lead is smaller, the Sandelin AB, celebrates its 60th cable transportation weight is lower, anniversary this year following its Modernizing used lead extruders and as smaller quantities of lead founding in 1958. Nowadays HFSAB HFSAB is also capable of overhaul- are required, less electrical power is is a world leader in the production ing used machines so that they are needed for melting and processing. of lead extrusion and cable strip- as good as new again. This capa- In this way, cable manufacturing ping, repair and recovery equip- bility will be demonstrated with a costs can be considerably reduced, ment. reconditioned screw of a horizontal potentially resulting in savings of lead extruder. hundreds of thousands of USD each year. User benefits Horizontal lead extruders By using advanced lead sheathing Cable stripping machinery A lead alloy sheath is one of the extrusion equipment, cable manu- Also available from HFSAB are most important parts of a sub- facturing costs can be reduced as cable stripping machines which are marine cable because it provides the lead wall thickness can be kept capable of removing individual lay- H. Folke Sandelin AB a 100% moisture barrier.The lead within +/- 0.05 mm along the entire ers without causing any damage to Dynamovägen 7, Box 4086 extruders built by HFSAB are ideally length of a cable with correspond- the subsequent layer below. As a SE-591 04 Motala, Sweden Phone +46 141 203630 suited for the application of such ing savings in lead. Compared with result enabling the outer jacket, lead Fax +46 141 203639 barriers. The extruders are horizon- conventional extrusion systems, sheath or triple layer XLPE to be re- E-mail: hfsab@hfsab.com tal, floor standing, easy to install less quantities of lead are needed applied and the cable repaired. Web: www.hfsab.com 10 NIEHOFF Magazine 18/01
Ground breaking The NIEHOFF MMH 112 multiwire drawing machine NIEHOFF is one of the pioneers of the multiwire drawing technology. Even after its introduction to the Industrially proven wire and cable industry, NIEHOFF has been able to provide groundbreaking impulses again and again. All variants of the MMH 112 are Now, the multiwire drawing machine type MMH 112 is on the market. This machine represents a completely on the market and been used by new generation of multiwire drawing machines. renowned wire and cable manufac- turers for a year. maximum of 21, 25 or 31 drafts. No special foundation is required for Video sequences at the wire setting up the machine. At the wire trade fair, NIEHOFF will demonstrate the function of the Efficiency and user-friendliness MMH 112 in the video sequences The MMH 112 achieves a high level recorded during the industrial test- of production quality, and this with ing by different customers. reduced energy and other operating costs. The machine is characterized Interested? as an ergonomic, user-friendly sys- Just come and visit us in Düssel- tem with longer maintenance inter- dorf, the NIEHOFF team is looking vals that is easier to maintain than forward to informing you about our More than 1,500 MMH lines manufacturers. In the combination conventional wire drawing lines. new multiwire drawing machine In 1985, NIEHOFF put the first multi- MMH 112 + RM 202 + 2 x S 632, MMH 112. wire drawing machine of the MMH the new machine was presented Sensorics and Industry 4.0 series with integrated continuous to the specialist world for the first The MMH 112 is equipped with Technical data MMH 112 annealer on the market. Meanwhile, time in spring 2016. The 21-draft more sensors than previous MMH max. production speed 40 m/s more than 1,500 MMH multiwire machine can draw 16 wires at one machines so that the new NIEHOFF wires in one level 16 drawing lines are in operation all level and is usable for copper and digitization concept can be used to Numbers of drafts: 21 / 25 / 31 over the world. aluminum. its full extent (see pages 4–5). There max. inlet diameter 2.6 mm Like all MMH machines, the MMH are recorded, among others, the (Cu hard) AWG 10 MMH 112: The new generation 112 has a modular design and can motor and drive data, the produc- max. finished depending on the of multiwire drawing machines therefore be ideally adapted to the tion speed, the temperature, humid- diameter number of drafts and the inlet NIEHOFF has continued to further individual requirements of the users. ity and flow rate of the gear oil as diameter develop the MMH technology in It can be built with one or two levels well as various properties of the cooperation with wire and cable and in three different lengths for a drawing emulsion. NIEHOFF Magazine 18/01 11
Good perspectives for the cable industry The global market situation of the wire and cable industry Wires and cables are indispensable for the transmission of electric power and ing funtions need more extensive mies: China and India account for and electronic data and therefore vital for all technical projects which have cablings than cars with combustion half of the growth in global energy to do with mobility and the activities on the automotive sector, with energy engine. In this regard, Dieter Bellé, demand. Energy from renew- generation and distribution, and with urbanisation, to name just a few. until recently chairman of the man- able sources is the fastest growing The developments in these fields justify the expection that the order books agement board of the wire, cable energy source, accounting for 40% of cable makers will continue to be filled. and harness manufacturer Leoni of the increase in primary energy. AG, told a journalist that he expects These are essential findings of the The global wire and cable demand is which gathered this information, for Leoni 10 % higher turnover for “BP Energy Outlook. 2018 edi- estimated at USD 200 billion in 2018 expects that 2018 will be another cables for electric engines compared tion. BP energy economics” [5]. This (Fig.1) [1]. This finding is supported record-setting year with global light with cables for combustion engines analysis assumes that the world GDP by the fact that the global purchas- vehicle sales estimated to reach [4]. will more than double by 2040, ing managers’ Index (PMI) gained 95.9 million units, up 1.5% from momentum in the second half year 2017 [2]. This might be an inter- 2017 and OECD statistics indicate esting figure for automotive wire Market driver: Global wire and cable demand a real GDP year-on-year change in and wiring harness manufactur- Energy supply 250 many economically relevant areas ers as an essential part of the cars’ The world continues to elec- Africa & the Middle East Asia-Pacific & South Asia Americas Europe & CIS such as G20 (3.8 %), Germany electrical/electronic equipment are trify, with almost 70% of the (2.1%), Eurozone (1.9%), Russia the bunched wires and cables con- increase in primary energy 200 (2.1%), USA (2.4%), China (6.6%), nected into a wiring harness which going to the power sector. and India (7.2%.) spreads through the cars. A top The share of vehicle kilo- 150 range car now has more than 1000 metres powered by electric- Market driver: Automotive individual cables with a total length ity increases, as the number industry of more than 3 km. For weight and of electric cars grows. The 100 In the year 2017 record car sales on space reasons there has been a interaction of fully auton- a global level were achieved, for the trend towards the use of aluminium omous cars with shared 8th year in a row. Total light vehicle and thin copper alloys wires with mobility boosts the intensity 50 sales are expected to post around thin wall jacketing or materials that with which electric cars are 94.5 million units, a new record – can be used at higher temperatures driven. All of the growth in up 2.4% compared with 2016. The [3]. Cars with hybrid or electric drive energy consumption is in fast 0 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017 2018 information company IHS Markit, and cars with autonomous driv- growing developing econo- Fig. 1. Values in USD million, 2017/18 data estimated [1] 12 NIEHOFF Magazine 18/01
driven by increasing prosperity in competitiveness. For ENTSO, adapt- tural functions, mobility solutions, fast growing emerging economies, ing the power system for the future communication and life style and as more than 2.5 billion people are means augmenting and digitizing environmental factors which all lifted from low incomes. This ris- the network. Hardware is as impor- require cables for the transmission [1] William Plunkett: Latest market develop- ing prosperity drives an increase in tant as software. Regarding hard- of electric power and and electronic ments. Conference contribution, CabWire Industry Forum 2017, Düsseldorf, Germany, global energy demand (Fig. 2). ware, cables account for over half of data [7]. November 2017. Concerning Europa, ENTSO-E, the the infrastructure. If around 75% of the world popu- http://www.grin.uk.com/wp-content/ uploads/2017/11/Latest-market-develop- European Network of Transmission lation are inhabitants of cities and ments-Integer.pdf System Operators, and Europacable, Market driver: Urbanisation megacities, they will live on less [2] Global Auto Sales Growth to Slow in 2018. the association of Europe’s wire and Half of the world’s population now than 2.8% of the world surface. In IHS Markit, January 2018. http://news.ihsmarkit.com/press-release/ cable manufacturers, calculated that lives in cities. The trend researching such highly condensed metropoli- automotive/global-auto-sales-growth-slow- by 2030 some 46,000 km of land company Trendone forecasts that tan areas only a maximum of 15% 2018-yet-remain-record-levels-959-million- lig and submarine cables are needed this figure will rise up to 75% by of the electricity requirement can [3] Philip Radbourne: Global Auto Industry Re- – 42,000 km of HVDC (High Volt- 2050 with the largest movements be generated itself. Such regions mains Strong and in Rude Health. October 2017. age Direct Current) and 4,000 km towards urban centers taking place can be supplied with electricity from www.integer-research.com/integer-alert/ of HVAC (High Voltage Alternating in Asia, Africa and Latin America. solar thermal power plants (CSP) global-auto-industry-remains-strong-and- Current) lines [6]. For Europacable, Urbanisation is connected with sev- with storage and possible fossil in-rude-health/ [4] Elektromobilität wird bei Kfz-Zulieferern delays would put at risk Europe’s eral macro-trends such as infrastruc- backups which are built in desert- Opfer fordern. Regionale Firmen formieren like landscapes with a high solar ihre Kräfte für die Zukunft. in: Online- Dienst nordbayern.de, 30.01.2017. radiation [8]. It is obvious that for www.nordbayern.de/wirtschaft/elektro- Primary energy demand the power transmission over thou- mobilitat-wird-bei-kfz-zulieferern-opfer- fordern-1.5774201 sands of miles and the power distri- [5] BP Energy Outlook. 2018 edition. BP energy End-use sector Region Fuel bution huge quantities of cables are economics. February 2018. required. www.bp.com/content/dam/bp/en/corpo- 20 20 20 rate/pdf/energy-economics/energy-out- Transport Other Renewables look/bp-energy-outlook-2018.pdf Africa Hydro Industry Other Asia Conclusion [6] Forecast and demand and manufacturing Non-combusted Nuclear capacity for HVAC and HVDC undergrond 15 15 India 15 Coal With increasing demands, wire and and submarine cables. ENTSO-E / Europa- Buildings China OECD Gas cable manufacturers face unique cable, January 2018. www.europacable.eu/wp-content/up- Oil challenges, and despite cost and loads/2018/02/ENTSO-E-Europacable-Joint- 10 10 10 competitive pressure there are con- Paper-SIGNED-Jan-2018.pdf [7] Macro-trends of the Urbanisation tinuing market possibilities to ben- www.trendone.com/en/trend-universe/ efit from the market development. mega-trends/mega-trend-detail/urbanisa- 5 5 5 NIEHOFF supports wire and cable tion.html [8] Bernhard Hoffschmidt: Energy in the future. manufacturers with cutting-edge Conference contribution, CabWire 0 0 0 manufacturing technology and a Industry Forum 2017, Düsseldorf, Germany, November 2017. comprehensive portfolio of services 20 20 20 20 20 20 19 19 19 19 19 19 20 20 20 20 20 20 19 19 19 20 20 20 http://elib.dlr.de/117805/1/171107_ 00 00 00 80 90 80 90 80 90 40 40 40 30 30 30 70 20 70 20 70 20 10 10 10 provided by NIEHOFF specialists. Energy_in_the_future.pdf Fig. 2. Values in billion tonnes of oil equivalent (toe), 2020/40 data estimated [5] NIEHOFF Magazine 18/01 13
Set off for new dimensions The new double twist stranding machines D 1252 / D 1602 / D 2002 NIEHOFF has been designing and building bunchers and stranders since the 1960s. The most recent result of the continuing development in this area are three new double twist stranding machines for energy cables. Until now the biggest model of this series is the D 1251 type version which works with a pulling force of 12 kN. With this machine the D series comprises seven differently sized models built in right-hand or left-hand version which cover strand established at the end of 2016, is Three new models by NST will be the D 1252 model. cross sections from 0.013 mm² to 95 developing three additional double The NST team consists of special- It will be built in 2018 and adapted mm² (Cu wire strands) or 120 mm² twist stranding machines. They bear ists with extensive experience in the to more respective areas of appli- (Al wire strands). NIEHOFF now goes the designations D 1252, D 1602, design of rotating machines for the cation than the existing D 1251 a step further towards even higher and D 2002 and are mainly foreseen cable production (NIEHOFF Maga- model. Both machines are fore- pulling forces: NST (NIEHOFF Strand- for the manufacture of compacted zine 2/2017, page 22). The first seen for conductors with a 7 wire ing Technology S.L.), which was conductors for energy cables. machine which has been designed design, for example 7 x 3.05 mm, 14 NIEHOFF Magazine 18/01
but the D 1252 is designed for up to ture of the rotor bearings and the Technical data D 1252 D 1602 D 2002 19 wires too. The next larger model vibration of the rotor. As an option, max. line speed 300 200 150 m/min (D 1602) will be intended for con- a dancer tension control can be 984 fpm ductors with a 19 wire design, and installed too. The wireless telemetry max rotating speed 2000 1200 1000 twists/min (tpm) the D 2002 for all designs beyond. for all signals including encoders production range In parallel to this development, the and the absence of brushes increase wire diameter 1.0 – 3.2 1.5 – 4.8 1.5 – 4.8 mm peripheral machinery is going to be the production reliability and sim- strand cross-section developed. plify maintenance. conductors, Al + Cu, Class 5 6 – 120 16 – 240 16 – 400 mm² Due to the design, there is a straight 9 – 250 5 – 450 5 – 800 AWG - KCMIL Characteristics of the cable path from the second twist conductors Class 2 Cu 6 – 95 16 – 150 16 – 400 mm² 9 – 2/0 5 – 300 5 – 800 AWG - KCMIL new D machines pulley to the capstan enhancing the Like all machines of the D series, quality of the cables which can be conductors Class 2 Al 6 – 120 16 – 150 16 – 500 mm² 9 – 250 5 – 300 5 – 1000 AWG - KCMIL the new D type machines feature compacted via a motorized closing/ compacting Cu 70 150 300 mm² the service proven energy-saving compacting die with cable lubri Al 120 150 400 mm² single bow design and are equipped cation. lay length, steplessly variable 25 – 750 40 – 400 50 – 500 mm with an energy-class IE3 energy- Also ergonomic criteria have been max. cable diameter 25 30 30 mm saving rotor drive and an adjustable considered and simplify the work fan drive in the sound proof cabin. of the operator: For all range of max. spool size A smooth conductor treatment is machines the working height is flange diameter 1250 1600 2000 mm ensured by the fact that all pulleys 1300 mm. Also the new D type spool width 950 1180 1500 mm and capstans have big diameters. machines are operated using a net- max spool weight 4000 8000 12000 kg The automatic traverse is equipped work-compatible Human Machine with a flange detection allowing Interface (HMI) color touchscreen spools to be perfectly spooled. Even monitor called NMI (NIEHOFF at high speeds, spooled cables can Machine Interface) which displays be payed-off tangle-free and with any information, instructions, pre- NIEHOFF Stranding Technology S.L. Xarol 8, 2-C no damage. Several sensors moni- stored receipts and system status Pol. Ind. Les Guixeres tor the quality of the production messages in the language of the 08915 Badalona process, for example the tempera- operator. Barcelona – Spain NIEHOFF Magazine 18/01 15
Doing things differently Coroplast Fritz Müller GmbH & Co. KG, Wuppertal Wuppertal, an industrial and university town with almost 350,000 inhabitants, is located near Düsseldorf and well known for its suspension monorail and the attractive surroundings of the “Bergisches Land” (Berg Country). There where the wire and cable industry can look back on a long history, Coroplast Fritz Müller GmbH & Co. KG, or Coroplast in short, has its headquarters. The company manufactures adhesive tapes, cables and wire harnesses and is one of the world’s technology leaders. The company history as laminated papers, oil flax and ing systems and telephone systems. 6,000 employees, about 800 of The second half of the 19th century oiled silk. At the end of 1928, the Soon after the end of the Second them based at the parent company was marked in many parts of Ger- entrepreneur, who then was only 25 World War, still in the 1940s, cable in Wuppertal. Coroplast runs eleven many by the industrialisation process years old, began to set up his own manufacture was started. At that production sites in Germany, Poland, and the increased use of electric- production facility and in the sub- time, in 1948, the catchy brand China, Tunisia, the USA, Mexico and ity. This development went hand sequent year he produced with five name Coroplast came into being Moldova and generated total sales in hand with the growth of a cable employees varnish-impregnated tex- and quickly became a synonym for of € 470 million in 2016. industry. Fritz Müller, son of a family tile hoses and varnished cables for the company name “Fritz Müller”. that processed varnishes, discovered cars (braided copper wires). Auto- In the mid-1980s, Coroplast started Products for many areas promising market opportunities in motive manufacturers and machine manufacturing complete cable of application the cable industry. In February 1928 factories such as AEG were supplied. assemblies (harnesses) using cables The production of Coroplast is sub- he established the company “Fritz In the 1930s, when the synthetic and adhesive tape manufactured in- divided into the segments “Adhe- Müller Elektroisoliermaterial” in the plastic polymer PVC was ready for house and transformed this produc- sive Tapes”, “Wires & Cables” and town of Barmen which is today part the market, the company was one tion into a separate division. “Cable Assemblies”. The range of of Wuppertal. The sales programme of the first to use and process this Today, Coroplast is a family-owned vehicle wiring in the Wires & Cables consisted of textile insulation hoses material and began to manufacture company in the third-generation division has expanded strongly over and other insulating materials such insulated copper cables for light- and globally active with around the past few years, with advanced 16 NIEHOFF Magazine 18/01
insulation and cable jacket materi- Top Employers Germany Award NIEHOFF and Coroplast als playing an important role. In col- Natalie Mekelburger, grandniece of Maschinenfabrik NIEHOFF and laboration with automotive manu- the company’s founder and CEO Coroplast maintain a good, mutu- facturers and OEM companies, since 2006, sums up Coroplast’s ally beneficial partnership and share Coroplast has developed high-volt- principle of success as follows: “We similar goals and values. NIEHOFF age and charging cables designed are not simply satisfied with the is delighted to assist Coroplast in for continuous use at temperatures existing status quo, but differenti- its successful development which is up to 180 °C and especially suitable ate ourselves in each of our fields of currently reflected amongst others for the wiring of vehicles with alter- business by creating processes and in the global expansion of the sili- native drive systems. Also new are products that are better than those cone production. the sensor and control systems with of our competitors. Our motto is the brand name Coroflex® which “Doing things differently” – always are designed for use in automation, with the best interests of our cus- cleanroom and medical technology tomers in mind”. Great attention is as well as in the food and bever- also paid to the well-being of the age industry. With the innovative employees. By means of the com- Coroflex® product family, Coroplast pany’s own CoroAcademy, Coro- has been nominated for the German plast offers them a wide range of Innovation Award 2018. Besides advanced training courses and has the cable production, the “Cable set up a special continuing educa- Assemblies” division is a full-service tion programme for trainees. In provider offering all types of wir- 2018, Coroplast received the “Top ing harnesses used in the car. In this Employer Germany” award for its context, in-house testing and valida- exemplary personnel management tion procedures based on current and employee orientation for the standards play a central role. tenth time. Volkswagen, Daimler and Tesla Society and junior employees Coroplast products can be found In view of its responsibility towards in almost all well-known players of the general public, Coroplast pro- the automotive industry, for exam- motes cultural and sporting proj- Coroplast Fritz Müller ple Volkswagen, Daimler or Tesla, ects. At the same time, Coroplast GmbH & Co. KG as well as in mechanical and plant cooperates with schools and the Tapes – Cables – Cable Assemblies engineering or automation technol- University of Wuppertal to support Wittener Straße 271, 42279 Wuppertal Telefon +49 202 2681 0 ogy. The products are also used in young people in their professional Telefax +49 202 2681 375 building installations and for electri- orientation and thus ensure their E-Mail coroplast@coroplast.de cal and household appliances. own future viability. Web www.coroplast.de/ NIEHOFF Magazine 18/01 17
As good as new again – or even better Upgrading used NIEHOFF machinery by NIEHOFF specialists High quality, reliability, efficiency, durability and value retention are key Decades of experience know-how and practice – and all NIEHOFF upgrade specialists are users of NIEHOFF machines benefit criteria which distinguish wire and cable machines built by Maschinenfabrik best qualified for this task because from it. NIEHOFF. For that reason, existing NIEHOFF machines – even after decades of they are fully familiar with all aspects of the underlying machine Original documents and operation – are worth the efforts for reconditioning and upgrade to the latest philosophy. As NIEHOFF service OEM quality parts technical standards. Such upgrades can return equipment to almost as good specialists have been caring for A further decisive criterion is that NIEHOFF machines around the NIEHOFF upgrading specialists have as new conditions, and with special measures, NIEHOFF upgrade specialists world for decades, they have an direct access to an excellent docu- are even able to increase the machines’ productivity and efficiency levels. incredible amount of experience, mentation with all the data which is 18 NIEHOFF Magazine 18/01
important for machine upgrading. ously develops new components reconditioned on site. With smaller single wire, could be converted to Most of the spare parts required for for upgrading existing NIEHOFF machines, it sometimes makes more a two-wire machine and a quick- each reconditioning job are pro- machines, which can significantly sense to remove the parts that need change die system as well as an duced in house on cutting-edge reduce operating costs. reconditioning, e.g. gearboxes, and upgrade for drawing shaped wire machining centers to OEM quality. send them to corporate headquar- could be installed too. Where third party components are Upgrading measures ters or a subsidiary to have the work brought in, NIEHOFF makes sure The first measure taken before a done. NIEHOFF quality that they all meet the high NIEHOFF NIEHOFF machine is reconditioned After having checked each of the quality standards. is an on-site thorough inspection Additional components assemblies, the reconditioned of the complete line by NIEHOFF Often, also new drives or even a machine can be repainted as an Specific performance specialists. Then, upgrading nor- complete new electrical system are option. In every case, the next steps improvements mally starts with a complete disman- installed on an upgraded machine. It are assembly, a test run and a pre- NIEHOFF can reliably demonstrate tling of the machine. Everything is might make sense to add also new shipment inspection by the user. the specific performance improve- cleaned, new bearings are installed components to extend the function- Then, the machine is delivered with ments which can be achieved by and worn parts are replaced by new ality of the machine. A rod break- a comprehensive set of documen- performing an upgrade in any given ones. Large machines such as rod down machine, for example, which tation to its point of use, where situation. NIEHOFF also continu- breakdown machines are normally was originally designed to handle a it is installed and recommissioned by NIEHOFF engineers. All users of NIEHOFF machines benefit from the expertise of NIEHOFF’s competent and highly motivated service special- ists and the comprehensive NIEHOFF Original+ After Sales service offer- ings. NIEHOFF contact person for reconditioning and upgrades: Thomas Guttenberger Phone: +49 9122 977 329 Email: t.guttenberger@niehoff.de Pictures: Various stages during the reconditioning of an MMH type multiwire drawing machine with approximately 60,000 hours of operation. NIEHOFF Magazine 18/01 19
It’s a clean thing Retrofit cleaning device for RM type annealers Components of the quality brand NIEHOFF Original+ help exploit the efficiency reserves of NIEHOFF systems and sustainably reduce their operating costs. Among these components there is a retrofittable cleaning device for continuous resistance annealers which are combined with MMH multiwire drawing machines. High quality wires wires; at the same time, the wire The device is foreseen for annealers and contact tube surfaces are pro- of the RM series which are already tected. The retrofittable cleaning equipped with a contact tube clean- device thus contributes to increas- ing device. Essentially, the retrofit ing the wire quality and to extend- device consists of a traversing unit ing the service life of the contact and a set of disc brushes which is tubes. The device is available from connected to it and can be replaced. the NIEHOFF Original+ after-sales- technology are constantly working know the complete range of ser- There is a selection of different service. to further improve the well-proven vices and also learn how NIEHOFF cleaning brushes. The quickly rotat- products. The users of NIEHOFF interprets the subject of “digitiza- ing disc brushes are moved over the NIEHOFF After-Sales Original+ machines can therefore be sure that tion” (s. page 4). contact tubes according to individu- With components of the quality they receive the best quality. ally adjustable cycles and displace- brand NIEHOFF Original+, NIEHOFF ment paths and clean the tube sur- guarantees its customers a reli- wire 2018 faces very thoroughly. Due to the able supply of OEM wear and spare On the upper floor of the exhibition very clean surface, a very good elec- parts. Meanwhile, more than 1.3 booth at the wire 2018 trade fair, NIEHOFF contact person for wear and spare parts as well as modernization: trical contact is achieved between million parts are delivered annually. NIEHOFF‘s after-sales-service pres- Ralf Johne the contact tube and the wires sup- NIEHOFF specialists who are famil- ents components of the NIEHOFF Phone: +49 9122 977 283 porting the annealing effect in the iar with all the subtleties of NIEHOFF Original+ brand. The visitors get to EmaiL: r.johne@niehoff.de 20 NIEHOFF Magazine 18/01
Flexibility and high precision New machining center at the Schwabach plant The quality which is typical for machine is designed for machin- more can be prepared for machin- and economic efficiency, NIEHOFF NIEHOFF machines is based, among ing gear boxes for the MMH series ing. The X travel in the machining has made good experiences with other topics, on the fact that their of multiwire drawing machines, area is 3 m. The machining center is its first machining center, on which components are manufactured on amongst others. For the installation, equipped with a Siemens Sinumerik among other things the gear boxes high quality machines. NIEHOFF a concrete foundation with dimen- 840D SL Operate control system. for rod breakdown machines are constantly invests in order to keep sions of 13 m x 16 m x 2.5 m had to Other special features include a tool processed. its machinery and tools up to the be prepared. magazine that can accomodate 300 latest standard. The latest example The machining center is equipped tools and a central suction device is a new machining center which with three automatically movable for metal chips that removes chips is currently being put into opera- pallet tables on which the work- and liquids from the pallet tables. A tion at the company’s headquar- pieces to be processed are clamped. special feature is the fully automatic ters in Schwabach and represents The largest pallet has a mount- emptying of the suction device, an investment of almost € 2 million. ing area of 2 m x 1.6 m. While one which therefore never gets full. The horizontal boring and milling workpiece is being machined, two With regard to precision, reliability NIEHOFF Magazine 18/01 21
Well established in India NoI has again extended its production facilities NIEHOFF of India (NoI) executed a second extension of their facilities (phase III) situated at Pashamylaram Industrial Estate close to the city of Hyderabad in India. NoI, the Indian subsidiary of NIEHOFF, operates a modern equipped factory which was opened in 2007 and was already extended in 2011/2012. Because of the good order situation a further extension became necessary. In phase III, NoI added a new assembly hall, a bigger area for the quality department, a new canteen block for employees, two modern painting booths, a roof top PV solar plant 150 kWp and a sewage treatment plant. After com- pletion of phase III, NoI’s facilities are admeasuring app. 11,000 m² for production and related activities. The increased space shall accommo- date all departments of the com- 22 NIEHOFF Magazine 18/01
NIEHOFF in India NIEHOFF has been active in India for more than 30 years. NoI, founded in 1997, has rapidly become the market leader in India for rod breakdown machines, multiwire drawing machines and bunching machines. Besides these machines, NoI builds annealers, spoolers, bunching machines and pay-offs. Machines made by NoI, all con- forming to NIEHOFF standards, are mainly destined for the Indian mar- ket. Moreover, NoI has also deliv- ered machines to Sri Lanka, Ban- gladesh, Pakistan, Sudan, Jordan, Mali, Kenya, Botswana, Nigeria, and South Africa. Service, knowledge and quality NoI is also responsible for the com- Countries where machines made by NIEHOFF of India (NoI) conforming to NIEHOFF standards plete after-sales service including are in operation. technical assistance and the reliable and fast supply of NIEHOFF custom- ers with NIEHOFF Original+ parts for all NIEHOFF machinery. In order to pany in a spacious and ergonomic Lohmüller, Managing Director of be familiar with the latest technol- working environment to cater to NIEHOFF Group, and Mr. Ashwin ogy and to meet the high NIEHOFF the increased demand for wire and Julka, Chairman of the board of quality standards, the management cable equipment foreseen from the NIEHOFF of India. The event was of NoI, Managing Director Daniel Indian wire and cable market. well attended by top customers of Thomas and the team at NOI work NoI, suppliers and employees. There in a close cooperation with the par- Ceremonial opening were about 500 people at the inau- ent company in Schwabach, and The new buildings and facili- guration event held at the premises NoI’s service engineers regularly ties were officially inaugurated of NoI. The day was concluded with train there. on 29th of November 2017 by a nice dinner which was organized Mrs. Ulla N iehoff, share holder at a leading hotel in the city of of N IEHOFF, Germany, Mr. Bernd Hyderabad. NIEHOFF Magazine 18/01 23
NIEHOFF history: Much started with the 109 E For a short while now, a particular machinery dealer, the machine Walter Niehoff transformed this wire with 4 mm inlet diameter in eye-catcher in the company res- returned to Schwabach, its place of department into a separate, legally 17 drafts to a finished diameter of taurant at the NIEHOFF headquar- origin. independent company, renamed 0.8 mm. ters is a NIEHOFF drawing machine Like the name of the restaurant it Maschinenfabrik NIEHOFF on In September 1952, NIEHOFF also for solder wire type 109 E built in (“Fifty One”), this machine also January 1, 1951, and began with a took part in the “Second Euro- 1952. As proved in the NIEHOFF recalls the early days of Mas- handful of employees to develop pean Machine Tool Exhibition” in documentation, the fully functional chinenfabrik NIEHOFF which completely new drawing machines Hanover, Germany, the predeces- machine was delivered on August emerged from the wire drawing for non-ferrous metal wires. One sor of the EMO. Among the exhibits 6, 1952 to the Bruch company machine department of the tra- of them was the multiple draw- there was also a 109 E. On the one where it then had been in operation ditional Schwabach engineering ing machine for lead wire type hand, the 109 E represents high until the company was dissolved a company “Drahtziehstein-Indust- 109 E. It was designed for lead, tin quality which should become one few years ago. Assisted by a used rie J.M. Bauer”. The entrepreneur and solder wires and could draw a of the most important success cri- teria for NIEHOFF machines, and on the other hand the machine stands for NIEHOFF’s first activities to become busy in foreign markets. Promotional poster for the “Second European Machine Tool Exhibition” (left) Source: https://www.werkstatt-betrieb.de/ fachinformationen/mediathek/artikel/willkommen- in-zeiten-des-wirtschaftswunders-3739736.html Multiple drawing machine type 109 E for lead wire (right). 24 NIEHOFF Magazine 18/01
NIEHOFF family: Events A big party Advanced Cable Middle East 2018 (Integer Research) 8 – 9 May, 2018 The summer weather was perfectly Dubai, UAE suited for taking part at skill games in the outdoor area, practicing 55th Intercable General Meeting 4 – 8 June, 2018 climbing on the walls of a boul- Portorož, Slovenia dering tower or chatting a bit in a shady seating area. The youngest Wire & Cable Guangzhou 11 – 13 June, 2018 visitors had a lot of fun on a bouncy Guangzhou, China castle and in many other interactive activities. Various food trucks took 12th CRU Wire and Cable Conference 2018 care of the physical well-being with 18 – 20 June, 2018 a rich culinary offer. Copenhagen, Denmark Of course, the visitors took the NIEHOFF-Herborn Máquinas Ltda. opportunity to take a look around (NHM) the administration and production In-house exhibition areas and gain an impression of End of August 2018 São Paulo, Brazil what a NIEHOFF employee is busy every day. In an article published in ArabCab Conference the NIEHOFF staff magazine, the (Arab Cable Manufacturers Association) daughter of an employee writes September 2018 their families were invited to this that she now understands what her special event in last September, and father is talking about when he tells wire China 2018 26 – 29 September, 2018 around 900 guests followed this the family of a “project talk about Shanghai, China invitation. an MSM 86 with WF”. They spent a particular day on the The NIEHOFF factory at the head- NIEHOFF ENDEX North America (NENA) premises of the headquarters with quarters in Schwabach was built In-house exhibition with a large marquee and top entertain- between 2008 and 2015/16. Oktoberfest celebration evening ment such as interviews and a quiz Around 450 people are employed 22–26 October, 2018 Swedesboro, NJ/USA under the motto “Who Wants to Be there, almost 50 of whom are train- Not only working in good coopera- a Millionaire?”. ees. There are families from which a wire India 2018 tion with the colleagues, but also Two bands created a joyful atmo- member of the third generation has 27 – 29 November, 2018 Mumbai, India celebrating in a fitting manner have sphere with sweeping music and already been working at NIEHOFF, always been part of NIEHOFF. The got many guests on the dance floor so that one could say that NIEHOFF 56th Intercable General Meeting NIEHOFF staff and their families as in the evening. is a family company in the truest November 2018 well as the partners together with sense of the word. NIEHOFF Magazine 18/01 25
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