Like all the innovations we have introduced to the industry, our new Static Wire Guide technology began with a conversation with one of our clients about the challenges they face. In this particular case, it was a dry drawing operation looking for ways to improve their cost per ton.
More and more operations are recognizing that of the two factors that determine cost per ton (first, raw material cost; second, productivity / uptime efficiency) only one is in their control, and can separate them from their competition. Since all operations face basically identical material costs, improving uptime productivity presents a powerful opportunity to become more profitable. For dry drawing operations, the Static Wire Guide can enable next-level uptime performance.
Here is what one plant using Sjogren’s Static Wire Guide had to say about it:
“The static [wire guides] will save money, downtime, and improve the quality of the wire. I have found no cons, just all pros.”— Dan Rosenbaum, Plant Superintendent, Merit Steel (USA)
Our Static Wire Guide is designed to replace and out-perform the conventional bearing-based roller guides used in the dry drawing process (dancer rolls, traversing guides, roller boxes, etc.). It lasts roughly ten times longer and requires less frequent maintenance during its working life.
Sjogren’s own engineers designed the Static Wire Guide, and it is created entirely within our machining and fabrication facility. It looks similar to conventional roller guides but with one major distinction: it doesn’t “roll” at all.
A failed guide requires unexpected stoppage in production and spindle downtime. There is also the lost cost of excessive scrap due to damaged wire that a failed guide can cause. Sjogren is helping dry drawing operations avoid this potential downtime by eliminating bearings from the guides. Instead of rotating on bearings as the drawn wire passes, the Static Wire Guide remains fixed in place and guides the wire using two carbide rails.
Because of the typical dry drawing operation’s scale and complexity, wear on an individual guide is usually not noticed until it fails completely. The Static Wire Guide can be fabricated in nearly any dimension and configuration, so it can take the place of anything from a large dancer roll to an inlet guide roller box with rollers just a couple inches long. Virtually any kind of bearing-based guide throughout the operation can be replaced — and deliver improved uptime — by a Static Wire Guide.
The ten-times-longer durability is supported by a feature that enables each operation to get extended wear from the carbide rails that actively guide the wire. When wear marks eventually begin to appear in the rails where the wire touches them, the rails can be rotated within their cylindrical shafts to expose a new, unblemished portion of the carbide surface. This allows for months and months of reliable performance, maintaining wire quality and avoiding downtime associated with replacing typical rollers, which usually last just eight weeks or so.
Competing successfully in the twenty-first century means looking for new opportunities to improve cost-per-ton efficiency. The Static Wire Guide is just on of several recent innovation that Sjogren is bringing to the industry to enable our clients to find new and better approaches to profitable productivity.