{"id":69,"date":"2018-04-17T08:06:18","date_gmt":"2018-04-17T08:06:18","guid":{"rendered":"http:\/\/www.fhopepack.com\/videos\/?p=69"},"modified":"2026-11-06T09:53:48","modified_gmt":"2026-11-06T09:53:48","slug":"automatic-steel-wire-coiler-for-wire-winding-and-strapping","status":"publish","type":"post","link":"https:\/\/www.fhopepack.com\/videos\/automatic-steel-wire-coiler-for-wire-winding-and-strapping\/","title":{"rendered":"Automatic Steel Wire Coiler: Length, Coil Weight and PP Strapping"},"content":{"rendered":"<h2>Executive summary<\/h2>\n<p>Our horizontal automatic steel wire coiler links directly to continuous drawing and processing lines, converting continuous wire flow into dense, precision-wound coils and strapped packages. Using dual-wheel synchronized encoders and high-speed counter modules, the system monitors feed length to the centimetre, winds coils on a servo-driven collapsible mandrel, executes clean shear cuts at target values, and transfers packages to an automated strapping head. Securing coils radially through the eye with 10 mm \u00d7 0.8 mm polypropylene (PP) strapping joined by friction-vibration welding, the equipment eliminates operator guesswork and provides stable, transport-ready wire packages.<\/p>\n<iframe loading=\"lazy\" width=\"940\" height=\"535\" src=\"https:\/\/www.youtube.com\/embed\/UxF5uujcLuw\" frameborder=\"0\" allow=\"accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share\" allowfullscreen><\/iframe>\n<hr \/>\n<h2>How the coiler works<\/h2>\n<p>The automatic coiling and packaging sequence operates through coordinated sub-assemblies controlled by an industrial PLC and synchronized multi-axis servo drives:<\/p>\n<table>\n<thead>\n<tr>\n<th>Sub-assembly<\/th>\n<th>Mechanical function<\/th>\n<th>Tooling and motion control<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Metering Station<\/td>\n<td>Tracks linear wire feed to the centimetre; triggers shear actuation<\/td>\n<td>Hard-anodized alloy wheel with sprag clutch, rubberized counter-wheel, and optical sensor<\/td>\n<\/tr>\n<tr>\n<td>Winding Station<\/td>\n<td>Clamps wire tip and winds uniform, multi-layer coils<\/td>\n<td>Cantilevered collapsible pneumatic mandrel driven by closed-loop AC servo<\/td>\n<\/tr>\n<tr>\n<td>Transfer Manipulator<\/td>\n<td>Clamps wound coil internally and delivers it to packaging<\/td>\n<td>Heavy-duty gantry with pneumatic\/servo expanding internal diameter (ID) jaws<\/td>\n<\/tr>\n<tr>\n<td>Shearing Unit<\/td>\n<td>Delivers clean, burr-free cut at target cut-off threshold<\/td>\n<td>High-wear alloy tool steel blade powered by high-speed pneumatic cylinder<\/td>\n<\/tr>\n<tr>\n<td>Strapping Head<\/td>\n<td>Feeds, tensions, and friction-welds strap through the coil eye<\/td>\n<td>Compact indexing radial strap chute with wear-resistant guide track<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<p>Wire traversing is driven by an independent servo ballscrew electronically geared to the spindle rotational speed. This ensures exact pitch control across alternating layers without wire cross-overs or snagging. Once winding reaches target length, the winder stops or diverts into an accumulator dancer, the shear fires, and the collapsible mandrel collapses radially to allow immediate extraction by the transfer manipulator.<\/p>\n<h2>Coil length to target weight<\/h2>\n<p>Wire mills sell by weight, but continuous production lines control process cycles by linear distance. Converting target package weight into an exact cut-off length relies on wire cross-section and nominal density (carbon steel: 7.85 g\/cm\u00b3, or 0.00785 g\/mm\u00b3).<\/p>\n<p>The standard volumetric mass calculation:<\/p>\n<p><code>Weight per Metre (g\/m) = (&pi; &times; d&sup2; &divide; 4) &times; 7.85<\/code><\/p>\n<p><code>Target Length (m) = Target Coil Weight (kg) &times; 1000 &divide; Weight per Metre (g\/m)<\/code><\/p>\n<blockquote>\n<p>Illustrative calculation \u2013 2.50 mm carbon steel wire:<\/p>\n<table>\n<thead>\n<tr>\n<th>Parameter<\/th>\n<th>Engineering Value<\/th>\n<th>Unit<\/th>\n<\/tr>\n<\/thead>\n<tbody>\n<tr>\n<td>Nominal Wire Diameter (d)<\/td>\n<td>2.50<\/td>\n<td>mm<\/td>\n<\/tr>\n<tr>\n<td>Cross-Sectional Area (\u03c0 \u00d7 2.50\u00b2 \u00f7 4)<\/td>\n<td>4.909<\/td>\n<td>mm\u00b2<\/td>\n<\/tr>\n<tr>\n<td>Calculated Weight per Metre<\/td>\n<td>38.53<\/td>\n<td>g\/m<\/td>\n<\/tr>\n<tr>\n<td>Target Package Weight<\/td>\n<td>20.00<\/td>\n<td>kg<\/td>\n<\/tr>\n<tr>\n<td>Required Linear Cut-off Length<\/td>\n<td>519.1<\/td>\n<td>m<\/td>\n<\/tr>\n<\/tbody>\n<\/table>\n<\/blockquote>\n<p>Entering 519.1 metres into the HMI triggers the shear cut automatically once encoder counts hit the target, maintaining weight repeatability within \u00b10.3% under constant wire draw tolerances.<\/p>\n<p><img decoding=\"async\" src=\"https:\/\/www.fhopepack.com\/blog\/wp-content\/uploads\/2023\/01\/wire-coil.webp\" alt=\"Steel wire coil tied with PP straps through the eye on a turntable plate\" \/><\/p>\n<h2>PP straps: 10\u00d70.8 mm and 75\u201380% joint efficiency<\/h2>\n<p>Securing wound wire coils requires strapping radially through the core eye to lock all concentric wraps against radial expansion.<\/p>\n<p>The machine uses industrial-grade polypropylene (PP) strap measuring <strong>10 mm in width and 0.8 mm in thickness<\/strong>. The strap feeder drives the banding through the coil ID and back along the front face before tensioning.<\/p>\n<p>Joint creation is performed via friction-vibration welding:<\/p>\n<ul>\n<li><strong>Joint Efficiency<\/strong>: The weld delivers <strong>75% to 80%<\/strong> of parent strap tensile strength.<\/li>\n<li><strong>Structural Integrity<\/strong>: Steel wire coils retain residual spring-back tension from the plastic deformation of coiling. During shipping, transit shock forces act directly on the packaging band. The friction-vibration joint is the primary load-bearing point; maintaining 75%\u201380% weld efficiency ensures the strap joint does not shear before the parent strap material yields.<\/li>\n<li><strong>Strapping Placement<\/strong>: Straps are placed across the front of the coil, allowing crane hooks and fork tines to handle packages without snagging joints.<\/li>\n<li><strong>Banding Quantity<\/strong>: Low-carbon wires require 2 opposed straps (180\u00b0 indexing); heavy-duty coils, agricultural wire, or higher spring-back coils utilize 3 straps (120\u00b0 indexing) or 4 straps (90\u00b0 indexing).<\/li>\n<\/ul>\n<p>Downstream protective packaging, such as stretch-wrapping with LLDPE film (300\u2013500 mm roll width, 20\u201340 \u00b5m thickness), operates as a separate dedicated station after strapping to prevent moisture ingress.<\/p>\n<h2>Changeovers<\/h2>\n<p>Batch transitions between wire sizes or coil formats are managed digitally through recipe presets on the touchscreen HMI:<\/p>\n<ol>\n<li><strong>Recipe Loading<\/strong>: Selecting the product code loads wire diameter, mandrel expanding diameter, traverse gear ratio, and target length.<\/li>\n<li><strong>Electronic Gearing<\/strong>: The traverse pitch adjusts automatically via servo synchronization, matching the linear guide travel to new wire gauges without changing mechanical gearboxes.<\/li>\n<li><strong>Tension and Strapping Profiles<\/strong>: Strap take-up tension (200 N to 2200 N) and weld dwell times are updated automatically to match coil weight and surface finish.<\/li>\n<\/ol>\n<p>Line operators can stage parameters for the next batch while the current coil winds, executing complete product transitions in under three minutes without mechanical strip-down.<\/p>\n<h2>Coiler envelope and 30\u2013100 m metering<\/h2>\n<p>Our coiling platforms accommodate distinct dimensional boundaries and packaging requirements across production scales:<\/p>\n<h3>Automatic Coiler S1000 platform specifications<\/h3>\n<ul>\n<li><strong>Wire\/Pipe Gauge Envelope<\/strong>: \u03a616 mm, 20 mm, 25 mm, and 32 mm<\/li>\n<li><strong>Coil Internal Diameter (ID)<\/strong>: 400 mm to 800 mm (expandable mandrel)<\/li>\n<li><strong>Coil External Diameter (OD)<\/strong>: 600 mm to 1000 mm<\/li>\n<li><strong>Package Coil Width<\/strong>: 150 mm to 250 mm<\/li>\n<li><strong>Target Coil Weight<\/strong>: 3 kg to 20 kg<\/li>\n<li><strong>Integrated Metering Range<\/strong>: 30 m to 100 m per finished bundle<\/li>\n<li><strong>Maximum Coiling Speed<\/strong>: Up to 100 m\/min<\/li>\n<li><strong>Strapping Configuration<\/strong>: 3 radial strap cycles through the eye<\/li>\n<li><strong>Protective Wrapping Integration<\/strong>: Secondary stretch wrapper utilizing LLDPE film (300\u2013500 mm width, 20\u201340 \u00b5m thickness)<\/li>\n<li><strong>Utility Supply<\/strong>: AC 380V, 50 Hz, 3-Phase 5-Wire<\/li>\n<\/ul>\n<h3>FCL series (FCL100 \/ FCL1000) packaging envelope<\/h3>\n<p>For operations requiring broader dimensional capacity or continuous high-output spooling:<\/p>\n<ul>\n<li><strong>Material Diameter<\/strong>: 15 mm to 45 mm<\/li>\n<li><strong>Coiling Heads<\/strong>: 1 or 2 winding heads (dual-mandrel continuous changeover)<\/li>\n<li><strong>Coil Internal Diameter (ID)<\/strong>: 400 mm to 1000 mm<\/li>\n<li><strong>Maximum Coil External Diameter (OD)<\/strong>: Up to 1000 mm<\/li>\n<li><strong>Maximum Coil Width<\/strong>: Up to 350 mm<\/li>\n<\/ul>\n<p>This envelope allows processing plants to standardize on a single automation architecture for both light wire bundles and wide heavy-gauge coils.<\/p>\n<h2>Controls and safety<\/h2>\n<p>Control hardware is centralized in an industrial PLC rack communicating via industrial Ethernet with servo amplifiers and variable frequency drives.<\/p>\n<h3>Safety architecture<\/h3>\n<ul>\n<li><strong>EN 415-10:2014 Compliance<\/strong>: Safety regulations for automated packaging and strapping systems.<\/li>\n<li><strong>ISO 12100:2010:<\/strong> risk assessment covering rotating mandrels, traversing carriages and pinch zones.<\/li>\n<li><strong>Emergency stop:<\/strong> dual-channel relays wired so a single fault cannot defeat the stop function.<\/li>\n<li><strong>Lockout\/Tagout (LOTO):<\/strong> lockable exhaust dump valves isolate the pneumatic supply before service.<\/li>\n<li><strong>Interlocked Guarding<\/strong>: Physical safety enclosures with coded magnetic or interlocked safety switches instantly halt high-speed winding heads if service gates open.<\/li>\n<\/ul>\n<h2>Selection checklist<\/h2>\n<p>To select the correct coiler layout and tooling configuration, prepare the following parameters for engineering review:<\/p>\n<ol>\n<li><strong>Material Properties<\/strong>: Wire metallurgy, tensile strength (MPa), and surface finish (bare, annealed, galvanized, coppered).<\/li>\n<li><strong>Diameter Envelope<\/strong>: Minimum and maximum wire diameter (mm).<\/li>\n<li><strong>Finished Coil Dimensions<\/strong>: Required coil internal diameter (ID), maximum external diameter (OD), and package width (mm).<\/li>\n<li><strong>Weight Requirements<\/strong>: Minimum and maximum package weights (e.g., 3 kg to 20 kg for S1000 series, or bulk custom weights).<\/li>\n<li><strong>Length Range<\/strong>: Minimum and maximum coil lengths per bundle (e.g., 30 m to 100 m or custom continuous runs).<\/li>\n<li><strong>Infeed Line Speed<\/strong>: Upstream extrusion or drawing speed (m\/min).<\/li>\n<li><strong>Strapping &amp; Packaging<\/strong>: Strap count (2, 3, or 4 radial straps) and downstream requirement for LLDPE stretch film wrapping.<\/li>\n<li><strong>Electrical Requirements<\/strong>: Plant supply voltage, frequency, and phase configurations.<\/li>\n<\/ol>\n<h2>Engineering FAQ<\/h2>\n<p><strong>What determines strap joint integrity on steel wire packages?<\/strong>\nThe friction-vibration weld creates a cohesive molecular bond in the 10\u00d70.8 mm PP strap, achieving 75% to 80% of parent material break rating. Because wire packages exert high dynamic shock on packaging during transit, this high weld efficiency prevents joint shearing.<\/p>\n<p><strong>Can the coiler produce short-meter coils for retail distribution?<\/strong>\nYes. Platforms such as the S1000 are optimized for linear ranges between 30 m and 100 m at winding speeds up to 100 m\/min, with automated cutting and 3-strap banding.<\/p>\n<p><strong>What is the difference between radial eye strapping and stretch wrapping?<\/strong>\nRadial strapping feeds a 10 mm PP band directly through the center eye to hold internal hoop stress and prevent wire shifting. Stretch wrapping (using 300\u2013500 mm LLDPE film) applies an external protective layer across the outer circumference to guard against environmental moisture, oil loss, and dust.<\/p>\n<p><strong>How does the line compensate for drawing block speed during coil transfer?<\/strong>\nThe line incorporates a pneumatic or counterweighted dancer accumulator tower. The dancer stores incoming wire during the brief cut, collapse, and manipulator extraction cycle, preventing upstream drawing lines from stopping.<\/p>\n<h2>Next steps &amp; engineering review<\/h2>\n<ol>\n<li><strong>Submit Line Specifications<\/strong>: Send your wire diameters, line speeds, and coil weight targets to our engineering team at <a href=\"mailto:info@fhopepack.com\">info@fhopepack.com<\/a>.<\/li>\n<li><strong>Review Layout Drawings<\/strong>: Receive a plant footprint drawing, cycle-time simulation, and mechanical proposal within 24 to 48 hours.<\/li>\n<li><strong>Technical Validation<\/strong>: Coordinate with our project engineers to verify dancer accumulator stroke, pay-off integration, and downstream strapping parameters.<\/li>\n<\/ol>\n<h2>Related packaging equipment<\/h2>\n<ul>\n<li><a href=\"https:\/\/www.fhopepack.com\/Wire-coil-wrapping-machine\/Automatic-steel-wire.html\">Automatic Steel Wire Winding and Strapping Machine<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-coiler\/Automatic-wire-coiler.html\">Automatic Wire Coiler Series<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-coiler\/Automatic-coiler-S1000.html\">Automatic Coiler S1000<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Automatic-coiler\/\">Automatic Coiler FCL Series<\/a><\/li>\n<li><a href=\"https:\/\/www.fhopepack.com\/Wire-coil-wrapping-machine\/Wire-coil-wrapping-machine-FPW-300.html\">Horizontal Wire Coil Wrapping Machine FPW-300<\/a><\/li>\n<\/ul>\n<h2>Reference standards<\/h2>\n<ul>\n<li><strong>Machinery Safety<\/strong>: <a href=\"https:\/\/www.iso.org\/standard\/51528.html\">ISO 12100:2010 General Principles for Design &#8211; Risk Assessment<\/a><\/li>\n<li><strong>Packaging Machinery<\/strong>: <a href=\"https:\/\/www.nen.nl\/en\/nen-en-415-10-2014-en-191845\">EN 415-10:2014 Safety of Packaging Machines &#8211; General Requirements<\/a><\/li>\n<li><strong>Electrical Controls<\/strong>: IEC 60204-1 Safety of Machinery &#8211; Electrical Equipment of Machines<\/li>\n<\/ul>\n<p><strong>Last reviewed:<\/strong> 2026-11-05<\/p>","protected":false},"excerpt":{"rendered":"<p>Automatic steel wire coiler for wire winding and strapping. Coil OD 400-700mm, wire diameter \u03c62-\u03c612mm. PET\/PP\/steel belt strapping. PLC control. Get quote from FHOPE.<\/p>","protected":false},"author":1,"featured_media":2343,"comment_status":"open","ping_status":"open","sticky":false,"template":"","format":"standard","meta":{"_seopress_titles_title":"Steel Wire Coiler for Wire Winding and PP Strapping","_seopress_titles_desc":"How our steel wire coiler counts, winds, cuts and straps each coil, how to set coil length for a target weight, and how the PP strap joint 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