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WHAT WE BEST AT ... WITELS-ALBERT GmbH - BESTSELLER AND NEW PRODUCTS - 2020

... is to shape the future with our brains, hearts and mouth.

As a Berlin-based company, WITELS-ALBERT GmbH has focused for decades on applications in the wire, tube, strip, cable and rope industry. Customers worldwide use our products for guiding, straightening and feeding process materials. The technical solutions we design stand for simple handling, high productivity and stable value. Services support the daily routine, the planning of processes and the development of products. Take advantage of this offer, which we will be presenting at WIRE 2020 in Düsseldorf, Germany, with many new products.

Variety for different process materials and objectives!

Long-goods such as wire, tube, strip, rope and cable require components for guiding, straightening and transport for production and processing. The respective design of the components is specific, since the type of long-goods and the objectives in production and processing are different. This results in a high variety of designs, which are also required in different sizes, as the long-goods cross-sections and the main dimensions of the cross-sections are numerous.

Keeping an overview and finding the right solution from the product range is a challenge that we are happy to support you with. Expect our expertise based on your data and boundary conditions.

We need the geometric parameters of the cross-sections and information on the mechanical parameters of the process material. Information on the packaging, the spool or coil orientation, the direction of the long-good passage and the process speed.

ROLLER BOXES WITH 2 INSTEAD OF 4 ROLLERS

For the trivial guidance of process materials with an overall geometry of less than 10 mm, the new RC 10 roller boxes are recommended, each of which represents a window for the guidance of the process material with only 2 instead of 4 guide rollers. The fully hardened guide rollers equipped with roller bearings have a specific profile which also makes it possible to significantly reduce the number of remaining individual parts. The torsion-resistant version can be mounted with 2 or 4 screws.

New design reduces sales price by 60%!

The uncompromising simplification of the design results in a selling price that is 60% lower than the selling price of comparable roller boxes, e.g. RK 10 and RK 10 VE. This saves the budget for the purchase and there are also advantages in terms of reducing the number of wear parts required during operation. If necessary, the roller axles and rollers can be replaced in no time at all.

ROLLER BOX RC 10

Your advantages:

Minimalistic design.
60% better in price.
Reduced number of wear parts.

Roller crosses RC 10 offer added value through an uncompromisingly simple design.

ROLLER BOXES RK VE SH

Roller boxes RK VE SH series allow radial and axial displacement and securing of the guide rollers. This allows the wear point of each roller to be individually adjusted.

Roller box RK 10 VE SH with radial and axial adjustable rollers.

The radial adjustment and securing of the roller axels with the rollers is achieved by means of slotted holes in the basic body of a roller box and associated hexagon nuts. This is known from the RK VE series.

Due to the special design of the roller axels, axial displacement of the roller axels with the rollers is also possible. The multi-part and externally threaded roller axels protrude more or less laterally from the basic body of a roller box section after axial displacement. This may take some getting used to, but it gives users the advantage of setting the contact or wear point correctly and achieving a 4 times longer roller life.

Roller boxes of the RK VE SH series are available in two sizes for process material diameters up to 5.0 mm and 10.0 mm.

Your advantages:

Simple by clever design.
Flexible by adjustability.
Fair by durability.

Guide round and flat wires, tubing, strands and ropes up to 5 mm and up to 10 mm with our new roller boxes RK 5 VE SH and RK 10 VE SH!

Get your added value through adjustability and longer service life at the price of the standard roller boxes RK 5, RK 5 VE, RK 10 or RK 10 VE.

ROLLER BOXES RK HM

In addition to the radial and axial adjustment of roller axels and rollers, the selection of the roller material has a decisive impact on the service life of the tools of roller guides.

The WITELS-ALBERT GmbH models RK 20 and RK 30 are made of the wear-resistant material 1.2436. Each roller is also fully hardened to a nominal hardness of 63 HRC. Rough environmental conditions and wire surfaces as well as ever higher process material speeds cause wear, which must be avoided as far as possible from the point of view of the efforts to permanently reduce costs. The use of alternative materials is recommended, which can be hardened up to 68 HRC. However, the disadvantage of these materials is that they are costly, which makes it possible to reduce costs only to a limited extent. Of course, ceramics and tungsten carbide can also be considered, but the prices of these materials are much higher. From our point of view, these materials do not represent a solution for the economical production of solid roller bodies for roller guides.

Nevertheless, how can the service life be increased?

This is achieved by a design that uses a high-quality material such as tungsten carbide in a special geometry, which can be produced inexpensively and is available at a reasonable price.

The roller designs of the newly developed roller guides RK HM series use tungsten carbide bars placed over the roll circumference. The bars are supported by a rotation-symmetrical design element, which also houses the bearings of a guide roller and the axel studs.

ROLLER BOX RK 20 HM INTRODUCING A REVOLUTIONARY NEW ROLLER DESIGN.

Due to the gaps between the individual bars, the effect of the automatic proportional descaling of the process material results when guiding wire rod.

Nevertheless, if the tungsten carbide rods installed in the contact area with the wire are worn out after some time, they do not have to be replaced. A simple turn around the longitudinal axis by 90° increases the service life significantly. The disassembly and assembly required for this purpose can be carried out quickly and easily within the scope of maintenance.

Your advantages:

A solution for the toughest conditions in the wire industry.
Longer service life due to material selection and adjustability.

Get your added value through adjustability and longer service life at an unbeatable price compared to known roller boxes.

TRANSPORT OF SENSITIVE PROCESS MATERIALS

To an increasing extent, feed belts are being designed into feeding units which handle tube, cable and profiled shapes. Compared to feed rolls, they have better friction coefficients and exert less surface pressure on the work piece.

At given contact pressure and torque, belts generate higher feed force than rolls. The NAK 60 Z and NAK 160 Z feeding units use transport belts as tools which clamp the process material gently and centric, i.e. each of the two transport belts of a feeding unit is arranged on a movable grooved piece which can be adjusted in the direction of the material to clamp the material via a pneumatic cylinder. The setting of the grooved pieces is done manually in the open state via a wedge, which enables a reproducible setting of the transport gap by means of a spindle mechanism and an assigned mechanical position indicator. Different process material diameters or symmetrical cross-sections with thickness dimensions between 0.6 mm and 15.0 mm or 0.6 mm and 40.0 mm can thus be clamped and transported with a defined and identical zero line in relation to upstream and downstream equipment.

Partly completed machinery feeding unit NAK 60 Z for the gently feeding of process materials.

Depending on the model and the specific transport task, transport belts with alternative back coatings can be offered. Parameters such as the hardness and thickness of the back coating and the coefficient of friction to the process material may have to be specified.

For the intermittent feed with high dynamics, an external measuring wheel is recommended to ensure tight length tolerances.

Rear tooth belt drive of the of the partly completed machinery feeding unit NAK 160 Z.

The centric feeding units are supplied ex works without actuator (motor and gearbox). If required, an actuator flange and an actuator can be mounted after consultation. In addition to the tooth discs mounted on the drive shafts, driven by the actuator, the tooth belt drive of a feeding unit NAK Z series consists of a drive belt toothed on both sides. The belt tension can be precisely adjusted via a tooth disc and an associated pneumatic cylinder. The feeding units have holes for horizontal and vertical installation. As partly completed machineries in accordance with Directive 2006/42/EC, the feeding units are supplied without a safety guards and without controls. Declaration of incorporation and assembly instructions are binding components of the contract for the procurement of a partly completed machinery feeding unit NAK Z.

Your advantages:

Gentle transport of the process material due to reduced pressure.
Stepless adjustment of the transport gap.
No process material deformation.
Centric process material transport in a large thickness range with high transport force.
Transport belts with alternative back coatings available.

Regardless of whether the transport of tubes, enamelled copper wires, cables or multiple wires is involved, the centric feeding units of the NAK Z series make the transport of process materials advantageous and inexpensive.

CENTRIC ROLLER GUIDES RZ PN

Matching our centric opening and closing feeding units NAK Z series, the centric roller guides RZ PN series can be used to reliably ensure a desired process material path. All four rollers of a roller guide RZ PN series can be centric adjusted after unlocking via a double-acting pneumatic cylinder. The roller guides are factory fitted with CROMAX rollers and are available in six sizes. The use of alternative roller materials such as through-hardened tool steel or plastics is possible. The maximum opening of the largest model RZ 500 PN is 500 mm.

Partly completed machinery roller guide RZ 70 PN.

CENTRIC ROLLER GUIDES ZR 6

For precise centric guidance of thin round and flat wires, the ZR series has been supplemented by the ZR 6 model, which is available in the familiar A, B, C, D and E designs.

Centric roller guide ZR 6 A C

Hardened and grinded rollers are used ex works for guiding process materials, which are positioned with fine-thread spindles. If desired, each threaded spindle can be locked in position by a clamping screw after the associated guide rollers have been adjusted.

ACCESSORIES FOR STRAIGHTENERS ER SERIES

The best-selling accessories from WITELS-ALBERT GmbH for straighteners are mechanical position indicators PO for the defined and reproducible adjustment of straightening rollers. The PO position indicators are available in various sizes and can be mounted on almost all series of straighteners. New in the range are the straighteners ER 5-0.8 PO, ER 7-0.8 PO, ER 9-0.8 PO, ER 11-0.8 PO and ER 13-0.8 PO, which are suitable for processing wires with diameters ranging from 0.5 mm to 0.8 mm.

STRAIGHTENING SYSTEM CONSISTING OF TWO STRAIGHTENERS ER 9-0.8 PO AND ONE CONNECTING BRACKET VW.

The designs of these straighteners use a new PO top bar and a new design for the spindles, which serve the defined and reproducible adjustment of the grooved pieces respectively of the straightening rollers. The new design principle offers many advantages. Fewer individual parts are required for each unit, the adjustment spindles are not affected by pin bores and time is saved when mounting the straightening units. For the daily routine of the defined adjustment of straightening rollers, this means time savings and a completely new level of robustness of the straightening units, especially with regard to the incorrect operation of the adjustment spindles.

New PO top bar, new spindle design and mechanical position indicators PO for the defined and reproducible adjustment of the straightening rollers.

Good to know:

Existing straighteners of the ER series can be retrofitted on the customers end without great effort. We offer PO conversion kits for all ER models from a diameter range >0.5, each of which contains all required individual and standard parts.

Your advantages:

Defined adjustment of the straightening rollers during the processing of thin wires.
Stable process results and a low reject rate.
Mechanical position indicators PO can be retrofitted.

ACCESSORIES FOR STRAIGHTENERS RT AND RTS SERIES

Assemblies with base plates for the design of straightening systems are available for the series ERS, KV, LR, PR, PS, RA and RB.

Usually two straighteners are mounted in different planes. Assemblies with base plates are now also available for RT and RTS series straighteners.

BASE PLATE FOR A STRAIGHTENING SYSTEM OFFERING FOUR STRAIGHTENING PLANES.

Up to six RT/RTS straighteners of the same size can be connected to form a straightening system or straightening chain. At least two straighteners of a straightening system or straightening chain must have an identical number of rollers. Connecting brackets VW are always part of a design.

Discover our smart and ready-to-install assemblies, making it possible to straighten round wires in up to six straightening planes and achieving a convincing straightening quality.

Connecting brackets VW connect at least two straighteners of the RT and/or RTS series to a straightening system. They are also an important element in the design of ready-to-install assemblies that use base plates and specific supports on which the VW connecting brackets are placed.

Your advantages:

Reduced effort for the integration of straightening systems.
High straightening quality and stable process results.

STRAIGHTENING MODULES SM SERIES

"Let’s make it simple. Really simple." Steve Jobs

The handling, productivity and value retention of components for straightening process materials are of essential importance. The saving of resources and aspects of the sustainability and flexibility of products influence the economic efficiency during the life phase and will decide in the future on the use of the products.

With this in background, the technical design of straighteners and straightening systems, their manufacture in well-adjusted quantities and the exploitation of the technical possibilities of the straightening process are important influencing factors which offer scope for creative reflection and further improvement of the understanding of the process.

As a manufacturer of components, WITELS-ALBERT GmbH is committed to this environment and presents a revolutionary new concept for the design, manufacture and use of straighteners and straightening systems with the introduction of the SM series of straightening modules.

STRAIGHTENING MODULES SM SERIES

Inspired by the very popular toy bricks from our northern neighbour Denmark, which have been part of a cleverly designed modular system for generations, WITELS-ALBERT GmbH transfers the basic idea of discretization to the design, manufacture and use of straighteners and straightening systems.

The knowledge of the essence of the product straightener leads to the straightening module.

The bricks of the straighteners and straightening systems of the future are the new straightening modules of the SM series, which are optimized in every detail. The optimization is accompanied by the project planning, the design and concerns in particular the production of the module bodies by modern CNC machines without personnel employment as well as the assembly of the straightening modules, straighteners and straightening systems in short time. The calculation results of the project planning result in binding specifications for designs that focus on simplicity and minimization of the number of individual parts. SM series straightening modules represent the essence of the product straightener. They are reduced to the absolute minimum, just like the world-famous toy bricks from Denmark.

“Simple can be harder than complex: You have to work hard to get your thinking clean to make it simple. But it’s worth it in the end because once you get there, you can move mountains.” Steve Jobs

The employees of WITELS-ALBERT GmbH understand very well the content of the above citation from Steve Jobs, the charismatic co-founder and CEO of Apple Inc. for many years, as these experiences, expressed well in words, could be experienced during the design of the modules. The results of our efforts over the months are simple at first glance, but the variety and possibilities resulting from the simplicity are impressive.

  1. Manless and fast mass production of straightening modules ensure a very good availability and a very good price for customers.
  2. Just one type of module per size is used for a straightener or a straightening system.
  3. Simple and fast assembly of straightening modules and straightening modules to straighteners and straightening systems.
  4. Enlarged straightening ranges (min. and max. process material diameter) with smallest possible roller spacing.
  5. Optimization/extension of straightening ranges (min. and max. process material diameter) by means of easily adjustable roller spacing or ex works adjustable roller spacing, e.g. for processing specific profiles or tubes.
  6. High flexibility with regard to the number of rollers per plane.
  7. Sale of straightening modules with or without basic and cover bars.
  8. Client-side design of specific base and cover bars for specific applications.
  9. Scalable design for straighteners and straightening systems in terms of roller spacing and number of rollers.
  10. Compatible accessories for straightening modules for ensuring straightening processes in up to 4 straightening planes per straightening system including inlet and outlet guide blocks.
"LESS IS MORE."

Our movie shows the basic idea of the module system and a selection of the possibilities our customers benefit from when using SM series straightening modules.

ALTERNATING MOUNTING OF STRAIGHTENING MODULES ON BASE PLATES IN TWO PLANES, STABILITY DUE TO IDENTICAL COVER BARS, INLET AND OUTLET GUIDE BLOCKS AND CONNECTION BRACKETS FOR ENSURING ANY ANGLE BETWEEN THE STRAIGHTENING PLANES, MARKINGS FOR PREFERRED ANGLES (0°, 45°, 90°, 135°)

LESS IS MORE, BUT THERE'S ONE MORE THING ...

Less is more, but there is another news for those who adjust the straightening rollers of our straighteners.

How to straighten straight quality?

Many employees in the wire manufacturing and processing industry ask themselves this question on a daily basis, regardless of the technical solution used. No matter whether conventional straightening technology with manually adjustable straightening rollers or semi-automated straightening technology with actuators is used for the positioning of the straightening rollers, no straight quality can be straightened without the knowledge of the adjustemnt values of the straightening rollers.

A virtual image of the real straightening process of WITELS-ALBERT GmbH provides valuable support and enables the worldwide availability of an answer to the question of how to save time, material, work and energy when adjusting straighteners and straightening systems.

The answer is provided by the web-based service How2Straight.com. The offer uses implemented result files of variation calculations for straighteners of the WITELS-ALBERT GmbH and makes them available to the operating personnel in practice. After registration and login, the setting data of the straightening rollers for straightening units are made available as part of a temporary subscription. This enables experienced and inexperienced operators to determine the nominal values of the roller positions of straighteners in order to achieve the desired straight finished product quality. Experienced operators can also compare existing knowledge with the recommendations of WITELS-ALBERT GmbH or check the current setting practice.

DETERMINATION OF ADJUSTMENT DATA

In addition to the selection of a straightening unit or a straightening machine, each calculation requires further specifications by the user which correspond to the variation parameters of the variation calculations, i.e. the wire diameter, the technical yield point and the modulus of elasticity must be specified. It should be possible to determine or research these properties without great effort. After a calculation, the results are clearly displayed and a diagram schematically informs about the assignment of the visualized roller adjustment values to the straightening rollers of the respective straightener, taking into account the wire entering in a bent state. On request, the data including the graphic can be printed out or saved in PDF format in a file.

The process of using the web-based service How2Straight.com is clearly structured in three simple steps. In no time at all, the right straightener or straightening machine is selected, the process material parameters are entered and the adjustment data are available.

Whether desktop or mobile device, the service How2Straight.com is available worldwide.

For WITELS-ALBERT GmbH, the availability of roller adjustment values for straighteners closes the circle of services around the straightening of process materials. Basic adjustments for roller straighteners for the production of straight round steel wire can be determined objectively with the support of the web-based service How2Straight.com and are available worldwide. They support users of straighteners from WITELS-ALBERT GmbH in producing sustainably and efficiently. Time, material, work and energy can be saved and the profit can be improved.

Experience the practice of Willy Wire on movie and follow his example. Discover the potential of your straightening units with help of How2Straight.com.

Discover the potential of your straightening units with help of How2Straight.com services.

IDENTIFICATION OF PRODUCTS

Keeping track of hundreds of WITELS-ALBERT GmbH products is a real challenge. Our resellers and our customers also take up this challenge. For the identification of our products we introduce a product identification, which consists of the job number and the article number. This enables the identification of delivered products for customer replacement and supports the determination of details of required spare parts.

Depending on the size of the product, a character string consisting of Arabic numbers or a Data Matrix Code is used for product identification. The following example identifies a product that was delivered under job number 108570 and has article number 7429.

RTS 7-5.0 3/4 Straightener with data matrix code for product identification (DMC 108724/4205)

For decoding the Data Matrix Code we recommend the free app CortexScan. Alternatively, the Data Matrix Code of the product can be photographed and the photo sent to WITELS-ALBERT GmbH by eMail for decoding. We would also be pleased to receive the engraved character string on the product to prepare an offer for the replacement of the product or to cover the need for spare parts.

WITELS-ALBERT GmbH, Malteserstraße 151-159, 12277 Berlin, Deutschland/Germany

Tel.: +49 30 723 988 0, FAX: +49 30 723 988 88, info@witels-albert.com

Created By
Marcus Paech
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