KIESELSTEIN International GmbH - Hersteller moderner Drahtziehanlagen und Drahtziehschälmaschinen sowie Drahtverarbeiter
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Recent Projects

Thanks to our customers we have the opportunity to deal with unique projects over and over again, develop innovative solutions, implement exciting design tasks and assemble individual plants. We are proud of these projects that we realized for our customers together as team K and would like to present these projects at this point.

Double pay-off ALV-1

In front of a drawing plant for aluminium wire, our customer required a pay-off system for aluminium wire coils with some special requirements.

Coils with an outer diameter up to 1400 mm and various inner diameters are to be decoiled. The maximum coil weight is 2000 kg.

The special requirements were the highest possible availability as well as easy handling of the wire coils during operation of the system.

Our solution:
We implemented the customer's task in the form of a horizontal double pay-off with loading station.
The spooled wire coils are placed on the conically shaped loading stations by means of a crane or forklift. The loading stations are equipped with plastic sheets to protect the wire surface and prevent damage to the wire. By means of pneumatics, the loading station with the wire coil is moved up to the pay-off. This requires only a minimum of work for the operator.

The wire coil is fixed on the pay-off by the central internal adjustment of the reel core. This means that the pay-off can be used flexibly for wire coils with a wide range of internal diameters without the need for any changeover work.

Once the coil has been fixed, the operator fastens the counter flange by means of a screw connection and mechanical clamping. The fastening of the counter flange is variable, depending on the coil width and is easy to handle. This prevents wire rings from falling down during the pay-off operation.
The unwinding wire is guided into the following drawing machine via guide rollers. That guarantees a straight wire run and prevent twisting or damage to the wire. To simplify handling, the wire rolls can be pneumatically lowered in height.

To achieve maximum utilisation of the following drawing machine, the pay-off device is designed as a double pay-off. While one coil enters the drawing machine, the operator can already place the next coil, thus enabling an almost seamless transition from one coil to the next and reducing downtimes of the drawing machine to a minimum.

Our system concept is designed for maximum availability due to the two pay-off stations, high flexibility in the range of applications and easy handling even for inexperienced operators. Due to the simple design, the system is low-maintenance and low-wear.

Traversing Spooling Machine SH-TR 1000

The task:
Our customer operates a rolling mill for which he needed a spooling device for flat and round wire. The equipment shall be used with steel wire (round up to 5.50 mm, flat up to 8.00 mm x 1.50 mm), which shall be winded up onto spools. The device was supposed to be autonomous and was meant to be integrated into the control of the rolling mill. Thin wire should be winded up in cross laying and larger wire in layers. The device should be flexible for using different sizes of spools.

Our solution:
For this task we chose a horizontal spooling machine SH-Tr 1000 with a dancer magazine in front. By its robust design the equipment allows winding up spools within a range of up to 1000 mm outer diameter and a total weight of 1500 kg.

To guarantee a calm, vibration-free spool run and by that low noise emissions, the sleeve is borne in a special way.

A high level of flexibility is given because of the ability to include different spool sizes. Laying width and speed are continuously adjustable.

The traversing is reached by using of a ball screw and an electric drive. Therefore, the wire coming from the rolling mill always stays in line. Wire bends or twists are avoided and the quality of the wire is preserved.

To lay round and not only flat wire, the spooling machine is equipped with side guiding rollers, which guarantee a proper laying pattern.

The automatic shutdown with a full spool makes it easy for the operator to work with the device. A platform in front of the spooler makes it easier to insert an empty spool and to remove the full spool.

To ensure operational safety, the device is equipped with the necessary protective fencing.

The spooling machine has its own switch cabinet. Therefore, it can be used for the rolling mill, but can also upon need, be relocated to another wire manufacturing plant at a later time.

Shaving Unit DS-30

The task:
Our customer intends to remove defective surface areas of round wire with the least possible effort within the drawing process. The metallically bright surface reached is supposed to be suitable for the processing with rolling or drawing equipment. The customer process carbon steel, low-alloy steels, ferritic, martensitic and austenitic stainless steel as well as titanium. The inlet wire has a diameter of up to 6.00 mm; the finished wire is in a range of up to below 3.00 mm.

The customer disposes of a wire drawing / shaving plant from KIESELSTEIN and intends to us this shaving unit at this plant when required.
Our solution:
The wire shaving unit is designed for holding the calibration die as well as the shaving die itself. At the inlet side there is a drop lever wire breakage detector, that signalizes wire breakage or wire end.

The soap box is designed for wet lubricant and, by using an insert in the drawing die box, also for dry drawing. Inside the soap box there is an oiling tube. This is to ensure that even when using oil with a higher viscosity the wire is coated with oil all the time.

The drawing die holder contains the drawing die cassette with the drawing die and can be removed together with the soap box by loosening the fastening screws. The drawing die is directly water cooled. The drawing die cassette is clamped manually inside the drawing die holder.

The shaving flange holds the shaving die. In order to improve the chip forming the shaving die holder is designed conical. The additional indirect water cooling of the shaving die shall extend the tool lifetime.

A chip breaker inside the chip compartment crushes the chips in small pieces. With only a few handgrips the setup of the chip breaker can be made and is reproducible. The chip breaker consists of two rotating carbide blades of that are adjustable to the wire diameter and that can be removed as well as a continuously adjustable drive. The complete chip compartment has a wear resistant coating.

In order to install the wire shaving unit at the machine easily and quickly instead of a drawing die holder, there are boring bushes and quick-release levers. With very little effort a considerable improvement of the surface quality of the wire can be reached on an existing wire drawing plant.

Down-coiler WVZ 900

The task:
Our customer uses chemically descaled and coated wire rod. Partially, this is annealed before drawing, however the plant is supposed to process wire with a tensile strength of up to 1200 Mpa. The inlet diameter is in a range of up to 18.00 mm. The special requirements of the installation and the high productivity led to a special solution of the wire take-up.

Our solution:
Based on the desired production range and the requirements of the customer we designed a plant with a down coiler. The inlet material is put on a vertical wire pay-off ABV-Tka. The feeding is facilitated by a hydraulic tilting function. The pay-off speed is controlled by a dancer.

For the intended drawing task we chose a vertical down coiler WVZ 900. This machine is able to provide the necessary drawing force for the intended cross section reduction. For facilitating the drawing-in process and increasing the operator’s safety the machine disposes of an automatic pull-in dog. It is equipped with a drawing lubricant box which can be used both with dry lubricant and emulsion. For reproducing its position the drawing lubricant box is equipped with KPI (KIESELSTEIN position indicators).

The wire windings run from the vertically hanging drawing capstan down to a vertical double take-up with stem. During the drawing process, one rotating plate is in working position under the coiler, the other one is in unloading position. This enables to continue the drawing process during the unloading process. Unloading the coil is realized by means of a coil gripper.

The coils unloaded are hydraulically compacted and tied up in the provided tiltable coil compacting device. The scope of supply is completed by an advancing unit ensuring a straight wire run into the down-coiler, a welding machine as well as safety fencing around the complete work area.

For us it was important, as in many of our projects, to supply an overall concept to the customer in the form of an individual plant achieving the desired objectives. Entirely in the sense of „solutions - individually engineered“.