{"id":478,"date":"2018-04-19T07:31:24","date_gmt":"2018-04-19T07:31:24","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=478"},"modified":"2026-10-26T15:06:18","modified_gmt":"2026-10-26T15:06:18","slug":"copper-sheet-and-bronze-bar-wrapping-machine","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/copper-sheet-and-bronze-bar-wrapping-machine\/","title":{"rendered":"Copper sheet and bronze bar wrapping machine"},"content":{"rendered":"<blockquote>\n<p><strong>Executive summary<\/strong><\/p>\n<p>An industrial copper sheet and bronze bar wrapping machine transfers elongated, non-ferrous profiles along a precision roller conveyor through a high-speed horizontal orbital ring, applying a continuous spiral helical wrap from tip to tail. This protective packaging process preserves critical mirror\/mill surface finishes, shields against atmospheric oxidation, and eliminates mechanical abrasion caused by metal-to-metal rubbing within storage or transit bundles. Engineered for versatility, the semi-automatic S200 system processes non-ferrous profiles longer than 300 mm, with cross-sectional envelope dimensions up to 200 mm and payload weights spanning 10\u2013100 kg, supported by an inverter-controlled ring speed of 20\u2013120 r\/min.<\/p>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/vPQMjd8xVK0\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<\/blockquote>\n<hr \/>\n<p>This specialized horizontal orbital packaging system is engineered specifically for narrow copper strips, busbars, and drawn bronze bars. A blue heavy-duty powered roller conveyor transports each profile directly through a compact rotary ring housed within an OSHA\/CE-compliant yellow perimeter safety cage. Overhead pneumatic vertical hold-down assemblies with non-marking polyurethane rollers clamp the elongated workpieces continuously, suppressing vertical vibration, transverse shifting, and edge flutter during high-tension spiral wrapping cycles.<\/p>\n<h2 id=\"table-of-contents\">Table of Contents<\/h2>\n<ul>\n<li><a href=\"#why-wrap\">Why copper sheet and bronze bar are wrapped<\/a><\/li>\n<li><a href=\"#how\">How the orbital wrapper works<\/a><\/li>\n<li><a href=\"#flat-vs-round\">Flat strip vs round bar<\/a><\/li>\n<li><a href=\"#specs\">S200 technical specifications<\/a><\/li>\n<li><a href=\"#example\">Worked engineering example: copper busbar<\/a><\/li>\n<li><a href=\"#selection-checklist\">Engineering selection checklist<\/a><\/li>\n<li><a href=\"#safety\">Machine safety standards: EN 415-10 and ISO 12100<\/a><\/li>\n<li><a href=\"#engineering-faq\">Engineering FAQ<\/a><\/li>\n<li><a href=\"#next-step\">Next step: engineering review &amp; quotation<\/a><\/li>\n<li><a href=\"#related-reading\">Related technical reading<\/a><\/li>\n<li><a href=\"#sources\">Reference standards &amp; sources<\/a><\/li>\n<\/ul>\n<h2 id=\"why-wrap\">Why copper sheet and bronze bar are wrapped<\/h2>\n<p>High-purity copper and architectural bronze profiles command premium pricing based entirely on pristine surface finish, exact geometric flatness, and metallurgical integrity. Even microscopic surface defects can cause commercial rejections:<\/p>\n<ul>\n<li><strong>Atmospheric &amp; galvanic oxidation<\/strong>: Residual moisture, airborne sulfates, and acidic fingerprint oils initiate rapid chemical tarnishing, discolouration, and copper patina, rendering bare stock unacceptable for electrical switchgear or architectural installations.<\/li>\n<li><strong>Fretting abrasion &amp; micro-scratching<\/strong>: Copper is a relatively ductile non-ferrous metal (Mohs hardness ~3). Unwrapped bars packed into bundles vibrate dynamically during road or ocean transport, causing aggressive inter-pass friction, gouging, and surface scuffing.<\/li>\n<li><strong>Burr snagging &amp; edge deformation<\/strong>: Sheared strip edges often possess micro-burrs that hook into adjacent components unless sealed under stable tension.<\/li>\n<\/ul>\n<p>Encapsulating each workpiece or consolidated mini-bundle in an unbroken spiral envelope of LLDPE stretch film, paper, or multi-layer VCI (Volatile Corrosion Inhibitor) material preserves factory-fresh mill surfaces completely from final cut-off to end-user unboxing.<\/p>\n<h2 id=\"how\">How the orbital wrapper works<\/h2>\n<p>The semi-automatic orbital packaging process coordinates two synchronized kinematic axes:<\/p>\n<ol>\n<li><strong>Longitudinal feed axis<\/strong>: The profile rests on a motor-driven infeed roller conveyor lined with non-marking synthetic sleeves. Photoelectric sensors detect the leading edge of the workpiece, triggering the automatic conveyor drive and sequence interlocks.<\/li>\n<li><strong>Rotary wrapping axis<\/strong>: The profile advances through the rotating orbital ring. An integrated roll carriage spins orbitally around the moving profile, dispensing tensioned wrapping material in a uniform spiral helix along its entire length.<\/li>\n<\/ol>\n<p>Ring rotation speed is modulated through an AC variable frequency drive (VFD), while web tension is maintained mechanically via a micro-adjustable friction core brake. Both infeed and outfeed conveyors utilize programmable soft-start\/soft-stop acceleration ramps to prevent workpiece slippage.<\/p>\n<h3>Overlap Kinematics<\/h3>\n<p>Film overlap percentage is strictly governed by the ratio between conveyor linear speed and ring rotational velocity:<\/p>\n<p><code>Advance per ring revolution (mm) = Conveyor speed (m\/min) &times; 1,000 &divide; Ring rotational speed (r\/min)<\/code><\/p>\n<p><code>Effective overlap width (mm) = Film web width (mm) - Advance per ring revolution (mm)<\/code><\/p>\n<p><code>Overlap percentage (%) = [1 - (Advance per ring revolution &divide; Film web width)] &times; 100%<\/code><\/p>\n<p>Increasing conveyor linear advance or decreasing ring rotational speed lowers overlap density, whereas elevating ring speed creates a tighter, multi-layered protective barrier.<\/p>\n<h2 id=\"flat-vs-round\">Flat strip vs round bar<\/h2>\n<p>Non-ferrous profiles exhibit distinct mechanical dynamics inside an orbital wrapper:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Comparative Engineering Parameter<\/th>\n<th style=\"text-align: left\">Flat Copper Strip \/ Sheet Bar<\/th>\n<th style=\"text-align: left\">Round Bronze Bar \/ Rod<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Ring Envelope Clearance Rule<\/strong><\/td>\n<td style=\"text-align: left\">Profile cross-section diagonal <code>&radic;(W&sup2; + T&sup2;)<\/code> must not exceed 200 mm<\/td>\n<td style=\"text-align: left\">External diameter <code>OD<\/code> must not exceed 200 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Dynamic Workpiece Restraint<\/strong><\/td>\n<td style=\"text-align: left\">Pneumatic vertical hold-down rollers prevent upward lift, edge flutter, and torsional twisting<\/td>\n<td style=\"text-align: left\">V-groove guide rollers maintain axial centering; minimal vertical downforce required<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Film Dispensing Length per Turn<\/strong><\/td>\n<td style=\"text-align: left\">Theoretical perimeter: <code>2 &times; (Width + Thickness)<\/code><\/td>\n<td style=\"text-align: left\">Theoretical perimeter: <code>&pi; &times; External Diameter<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Primary Process Vulnerabilities<\/strong><\/td>\n<td style=\"text-align: left\">Knife-edge film shearing; transverse profile bowing under excessive web tension<\/td>\n<td style=\"text-align: left\">Rotational rolling drift; impact damage to precision bar ends<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Contact Surface Protection<\/strong><\/td>\n<td style=\"text-align: left\">Polyurethane (PU) coated rollers prevent indentation marks on broad copper faces<\/td>\n<td style=\"text-align: left\">High-density polyethylene (HDPE) rollers eliminate metallic transfer marks<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<h2 id=\"specs\">S200 technical specifications<\/h2>\n<p>The S200 model represents an optimal footprint for standalone packaging cells or extrusion line discharge tables:<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Engineering Parameter<\/th>\n<th style=\"text-align: left\">S200 Standard Machine Rating<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>Workpiece Length Range<\/strong><\/td>\n<td style=\"text-align: left\">Minimum 300 mm to unrestricted maximum<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Cross-Sectional Envelope (OD \/ Diagonal)<\/strong><\/td>\n<td style=\"text-align: left\">10 mm minimum to 200 mm maximum<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Payload Weight Range<\/strong><\/td>\n<td style=\"text-align: left\">10 kg to 100 kg (balanced line load)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Infeed \/ Outfeed Roller Conveyors<\/strong><\/td>\n<td style=\"text-align: left\">2,000 mm length each, motor-driven with PU sleeve protection<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Conveyor Linear Speed Range<\/strong><\/td>\n<td style=\"text-align: left\">4.0\u201312.0 m\/min (inverter variable speed control)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Orbital Ring Rotational Speed<\/strong><\/td>\n<td style=\"text-align: left\">20\u2013120 r\/min (inverter variable speed control)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Installed Power Supply<\/strong><\/td>\n<td style=\"text-align: left\">Approx. 2.1 kW, AC 380 V, 3-Phase, 50\/60 Hz (customizable)<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Wrapping Consumable Specs<\/strong><\/td>\n<td style=\"text-align: left\">LLDPE stretch film (25\u201350 \u00b5m), roll width 120\u2013200 mm, roll OD 150\u2013200 mm, core ID 50 mm<\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>Alternative Consumable Compatibility<\/strong><\/td>\n<td style=\"text-align: left\">Crepe kraft paper, woven PE strip, VCI corrosion-inhibiting film<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><em>Note: Heavy-gauge sheared copper with aggressive burrs requires 35\u201350 \u00b5m film to prevent puncture failures. Profile-matched pneumatic hold-down assemblies and automated pneumatic clamp\/cut systems are customized and confirmed at quote.<\/em><\/p>\n<h2 id=\"example\">Worked engineering example: copper busbar<\/h2>\n<p>Evaluate the wrapping parameters for an extruded pure copper busbar measuring <strong>100 mm (width) \u00d7 10 mm (thickness)<\/strong> with a total cut length of <strong>3,000 mm<\/strong>, wrapped using <strong>120 mm wide film<\/strong> targeted at a <strong>50% overlap<\/strong>. Pure copper density is taken as <strong>8,960 kg\/m\u00b3<\/strong>.<\/p>\n<table>\n<thead>\n<tr>\n<th style=\"text-align: left\">Calculation Step<\/th>\n<th style=\"text-align: left\">Engineering Formula &amp; Input Data<\/th>\n<th style=\"text-align: left\">Validated Output<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td style=\"text-align: left\"><strong>1. Total Profile Volume<\/strong><\/td>\n<td style=\"text-align: left\"><code>V = 0.100 m &times; 0.010 m &times; 3.000 m<\/code><\/td>\n<td style=\"text-align: left\"><code>0.003 m&sup3;<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>2. Total Workpiece Mass<\/strong><\/td>\n<td style=\"text-align: left\"><code>M = 0.003 m&sup3; &times; 8,960 kg\/m&sup3;<\/code><\/td>\n<td style=\"text-align: left\"><code>26.88 kg (about 27 kg)<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>3. Sectional Diagonal<\/strong><\/td>\n<td style=\"text-align: left\"><code>D = &radic;(100&sup2; + 10&sup2;) = &radic;(10,000 + 100) = &radic;10,100<\/code><\/td>\n<td style=\"text-align: left\"><code>100.5 mm<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>4. S200 Dimensional Envelope Check<\/strong><\/td>\n<td style=\"text-align: left\">Length \u2265 300 mm (actual 3,000 mm); <code>D &le; 200 mm<\/code> (actual 100.5 mm); Mass 10\u2013100 kg (actual 26.9 kg)<\/td>\n<td style=\"text-align: left\"><strong>Fully compliant (Pass)<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>5. Advance per Ring Revolution<\/strong><\/td>\n<td style=\"text-align: left\"><code>Advance = Film Width &times; (1 - Overlap Ratio) = 120 mm &times; (1 - 0.50)<\/code><\/td>\n<td style=\"text-align: left\"><code>60.0 mm<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>6. Total Helical Ring Turns<\/strong><\/td>\n<td style=\"text-align: left\"><code>Turns = Profile Length &divide; Advance = 3,000 mm &divide; 60 mm<\/code><\/td>\n<td style=\"text-align: left\"><code>50 revolutions<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>7. Operating Speed Kinematics<\/strong><\/td>\n<td style=\"text-align: left\">Ring set at <code>80 r\/min<\/code>; <code>Conveyor Speed = 80 r\/min &times; 0.060 m = 4.8 m\/min<\/code><\/td>\n<td style=\"text-align: left\"><strong>4.8 m\/min (within 4\u201312 m\/min range)<\/strong><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>8. Cycle Wrap Time<\/strong><\/td>\n<td style=\"text-align: left\"><code>T = 3.0 m &divide; 4.8 m\/min = 0.625 min<\/code><\/td>\n<td style=\"text-align: left\"><code>37.5 seconds<\/code><\/td>\n<\/tr>\n<tr>\n<td style=\"text-align: left\"><strong>9. Theoretical Film Consumption<\/strong><\/td>\n<td style=\"text-align: left\"><code>50 turns &times; 2 &times; (0.10 m + 0.01 m) = 50 &times; 0.22 m<\/code> (excluding prestretch &amp; tail wraps)<\/td>\n<td style=\"text-align: left\"><code>11.0 linear meters<\/code><\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p><strong>Engineering Validation:<\/strong>\nThe 100.5 mm diagonal leaves approximately 49.7 mm of radial working clearance inside the 200 mm ring cavity, ensuring no web snagging. Operating the ring at 80 r\/min matches a conveyor speed of 4.8 m\/min, operating smoothly within the S200 mechanical thresholds (4.0\u201312.0 m\/min). If the ring were run at only 60 r\/min, a 60 mm advance would demand 3.6 m\/min conveyor speed\u2014falling below the motor VFD minimum continuous cooling threshold (4.0 m\/min).<\/p>\n<h2 id=\"selection-checklist\">Engineering selection checklist<\/h2>\n<p>To configure an optimal packaging machine specification, confirm the following application parameters:<\/p>\n<ol>\n<li><strong>Alloy Grade &amp; Finish<\/strong>: Electrolytic copper (ETP\/OFHC), architectural bronze, brass, or mirror-buffed profiles.<\/li>\n<li><strong>Cross-Sectional Bounds<\/strong>: Minimum and maximum section dimensions (Width \u00d7 Thickness for flats; OD for rounds).<\/li>\n<li><strong>Length &amp; Mass Bounds<\/strong>: Minimum cut length (must exceed 300 mm for continuous conveyor transfer) and maximum bundle weight.<\/li>\n<li><strong>Bundle Consolidation<\/strong>: Single-profile packaging versus nested multi-piece master bundles.<\/li>\n<li><strong>Consumable Selection<\/strong>: Cast LLDPE film, VCI anti-corrosion barrier film, or neutral-pH kraft paper.<\/li>\n<li><strong>Automation Level<\/strong>: Manual film tail tethering\/severing versus pneumatic automatic clamp-and-cut integration with downstream sorting.<\/li>\n<\/ol>\n<h2 id=\"safety\">Machine safety standards: EN 415-10 and ISO 12100<\/h2>\n<p>The S200 horizontal wrapping machine is engineered in strict compliance with harmonized European packaging machinery standards:<\/p>\n<ul>\n<li><strong>EN 415-10 Compliance<\/strong>: Governs safety requirements for horizontal orbital wrappers, ensuring physical interlocking perimeter guarding around rotating parts, nip-point shielding on infeed\/outfeed rollers, and captive key safety interlocks.<\/li>\n<li><strong>ISO 12100 Risk Assessment<\/strong>: Comprehensive risk mitigation protocols reduce residual mechanical risks (pinching, trapping, cutting) to tolerable industry limits.<\/li>\n<li><strong>Operator Safeguards<\/strong>: Features an ergonomic industrial control panel with prominent emergency-stop (E-stop) pushbuttons, low-voltage control circuits (24 V DC), and comprehensive operational fault annunciation.<\/li>\n<\/ul>\n<h2 id=\"engineering-faq\">Engineering FAQ<\/h2>\n<p><strong>Q: Can the S200 wrap brass profiles and aluminum extrusions without mechanical modification?<\/strong>\nA: Yes. The orbital ring wrapping principle relies strictly on workpiece exterior geometric dimensions and total mass, completely independent of the non-ferrous alloy composition.<\/p>\n<p><strong>Q: How is exact wrapping overlap adjusted during production changeovers?<\/strong>\nA: Overlap is controlled digitally by modifying the ratio between the conveyor VFD linear speed and the orbital ring VFD rotational speed. A higher ring speed relative to conveyor advance increases the overlap percentage.<\/p>\n<p><strong>Q: Can multiple flat copper strips be wrapped together as a consolidated bundle?<\/strong>\nA: Yes. Multiple pieces can be strapped or direct-wrapped as a unified bundle, provided the outer bounding diagonal of the bundle cross-section does not exceed 200 mm and total bundle mass remains within the 100 kg system capacity.<\/p>\n<p><strong>Q: What electrical utility connection is required for the S200?<\/strong>\nA: The baseline system requires approximately 2.1 kW connected load on a 3-phase AC 380 V 50\/60 Hz supply. Custom drive packages for 220 V, 415 V, or 480 V industrial grids are available upon request.<\/p>\n<h2 id=\"next-step\">Next step: engineering review &amp; quotation<\/h2>\n<ol>\n<li><strong>Submit Product Data<\/strong>: Send your cross-section drawings (W \u00d7 T or OD), profile lengths, and target production rates to <strong>info@fhopepack.com<\/strong>.<\/li>\n<li><strong>Engineering Layout Review<\/strong>: Our packaging engineers will model your profile envelope, calculate ring clearances, and determine the optimal roller PU compound and hold-down geometry.<\/li>\n<li><strong>Comprehensive Proposal<\/strong>: Receive a detailed technical specification sheet, formal quotation, and cycle time analysis within <strong>24 business hours<\/strong>.<\/li>\n<\/ol>\n<h2 id=\"related-reading\">Related technical reading<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Semiauto-horizontal-wrapper\/Semiauto-horizontal-orbital-wrapper-S200.html\">Semi-automatic horizontal orbital wrapper S200 (product)<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Customize-orbital-wrapper\/Profile-wrapping-machine.html\">Profile horizontal orbital wrapping machine (product)<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/rod-wrapping-machinestretch-wrapper-packing-machine\/\">Rod wrapping machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/videos\/manual-horizontal-wrapping-machine\/\">Manual horizontal wrapping machine<\/a><\/li>\n<\/ul>\n<h2 id=\"sources\">Reference standards &amp; sources<\/h2>\n<ul>\n<li>FHOPEPACK Engineering Documentation: S200 Semi-Automatic Horizontal Orbital Wrapping Systems<\/li>\n<li>EN 415-10: Safety of Packaging Machines \u2013 Part 10: General Requirements<\/li>\n<li>ISO 12100:2010: Safety of Machinery \u2013 General Principles for Design \u2013 Risk Assessment and Risk Reduction<\/li>\n<li>Copper Development Association (CDA): Surface Preservation and Packaging of Wrought Non-Ferrous Alloys<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-10-19<\/p>","protected":false},"excerpt":{"rendered":"<p>Executive summary An industrial copper sheet and bronze bar wrapping machine transfers elongated, non-ferrous profiles along a precision roller conveyor through a high-speed horizontal orbital ring, applying a continuous spiral helical wrap from tip to [&hellip;]<\/p>","protected":false},"author":1,"featured_media":3067,"comment_status":"closed","ping_status":"closed","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Copper Sheet and Bronze Bar Wrapping Machine | FHOPE","_seopress_titles_desc":"How our orbital wrapper packs copper sheet strips and bronze bars on a roller conveyor: S200 range, speed matching for overlap and a copper bar 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