THE COMPLETE SYSTEM, WINDING GUNS,
COIL WINDING TOOLING

Coil winding rejections can be reduced by using the complete IMP de-reeling system.  Wire breakage and inability to un-spool all fine magnet wire can cost dollars and valuable production time.  Good coil winding calls for rapid tangle-free removal of magnet wire from its container and compact tight coils in the product.  To accomplish this, tension must be applied to the wire during the winding operation.  Tension blocks, spring loaded balls, tension capstans and other wire-tensioning devices which apply tension to one small length of wire cause elongation, nicking and reduction of cross-sectional area.  These distortions later from trouble areas and hot spots in finished coils.  Excessive tension for a particular wire size also has the same detrimental effects.  Wire manufacturers recommend over-the-head de-reeling from stationery spools or reels.  Our De-reelers are designed around this recommendation.  IMP wire tensioners function on the offset principle.  This unique principle is very forgiving as to imperfections in the wire coating.  Another unique feature is a wave pattern is imparted in the wire that acts as a shock absorber.  On start up, energy is absorbed straightening the wire and slowly increasing wire acceleration.  This assures uniform tensioning of the wire and elimination of possible "nicked" high resistance areas in the finished coil.  Because wire tension is a measure of tension through the entire de-reeling/winding system, tension can only be accurately measured at its final exit.  For this reason, tension should be measured with a hand held tension meter at the exit point.  This tension should be kept constant.   

(Fine Wire De-reeling/Tensioner)
THE COMPLETE SOLUTION

Industrial Machine Products is the only company that addressed all of the problems associated with the dereeling/tensioning of wire for the coil winding industry. Wire tension must remain constant for all coils wound off the wire reels and spools.  Until now this was next to impossible, requiring constant monitoring and adjustment of tension as the reel or spool empties.  In some instances in dereeling of fine wire tension can accelerate to a point that a spool or reel cannot be completely emptied.

(The Wire Dereeling Solution)

IMP has solved these dereeling problems by incorporating the "Hardesty Power Top De-reeler".  This unique De-reeler incorporates a power disk that completely shrouds the spool/reel end.  The disk is power rotated in the same direction the wire is dereeling.  By powering this disk the wire is assisted when needed in de-spooling.  By using the Hardesty Power Top De-reeler", the wire can now de-reel at near zero effort throughout the entire de-spooling operation.  For the first time coil winders can actually set their wire tension and forget it.  With the IMP "Hardesty Power Top De-reeler" fine wire dereeling problems are a thing of the past.  

(The Wire Tensioning Solution)

The dereeling system is not complete without the IMP Wire Tensioner.  We use the offset principle to tension the wire.  Think of it as a series of wire guides the wire passes over.  Nothing could be gentler to the wire.  In fact our tensioner has been scientifically engineered to generate an energy absorbing wave in the wire itself.  The IMP Wire Tensioner incorporates diamond polished ceramic wire guides.  Ceramic guides have a high wear resistance, as much as 10 times that of carbide.  Ceramic also dissipates heat at a very rapid rate so insulation damage heat build up present in steel or carbide designs has been eliminated with the IMP Tensioner.

(Accurately Setting The Wire Tension)

To complete the dereeling solution you must set you tension to the proper limits.  We recommend a hand held tension meter to check the tension at the exit end of the wire winding system.  You must think of the tensioner as the adjustable link in the total tension of the system.  All the turns the wire takes from spool/reel to the exit imparts a degree of over all tension to the wire.  Wire gage also affects how the system contributes to the overall tension.  If people are trying to sell you a tensioner that is supposed to be calibrated with a read out at the tension, don't expect consistent results.  A reading at this point is only relative and for the most part useless.  Remember the tensioner is only one part in the over all tension/dereeling system.

(The In-slot/Bobbin Winding Solution)

If your coil winding involves in-slot winding or the winding of coil bobbins your total dereeling solution would not be complete without the use of the IMP built winding eyes (nozzles, gun, guides, tubes, etc.).  Here at IMP, our process involves using the finest grades of tool steels for a combination of toughness and wear ability.  Our steels can outwear other common tool steels by a factor of 10.  We know having the proper radiuses for wire entrances and exits is very important.  Our winding eyes have smooth flowing radiuses that are highly polished and honed on our own specially designed equipment.  Our winding eyes are built to your specific requirements and held to exacting standards.  The result is a consistent ready to use winding eye that delivers wire to your coil form with increased longevity and superior results.

     Increased production, lower down times, and improved quality have been directly attributed to the use of the IMP winding eyes.  Because IMP winding eyes have a wear factor up to 10 times that of other tool steels, a significant cost savings can also be realized by lowering the overall quantities used in a specific production time period.

CONTACT IMP to learn more about our unique
dereeling and winding solutions.