A high-tech company specialized in the design and production of electrical wires and connectors needed a customized curvilinear handling system to transport coils of electric wires through nine processing stations. The choice fell on Rollon® Nadella AXNRQ circular system in ring configuration.
With the continuous global rise of automated production systems, manufacturing companies face the challenge of integrating automation to maintain a competitive edge.
For operations focused on industrial automation wire, automation boosts both efficiency and flexibility, making it easier to keep pace with evolving product designs and fluctuating production needs.
Automation also helps cut down on human error and delivers more consistent product quality, which makes it a smart investment for today’s manufacturing operations.
The challenge of the electric wire production process
A high-tech company specialized in the design and production of electrical wires and connectors needed an advanced automation solution to streamline its production process. Specifically, the company required a customized curvilinear handling system to transport coils of electric wires through nine machining stations while maintaining a cycle time of under two seconds between each stage.
Additionally, the system needed to support the demands of electrical wire manufacture, including sufficient load capacity for coils of varying weights (8, 10, or 12 kg) and compatibility with a 10-meter-long support structure already in place at the plant.
With industrial automation playing an increasingly vital role in enhancing efficiency, flexibility, and product quality, finding a solution that optimized space, reduced manual intervention, and ensured high-speed operation was essential.
AXNRQ Application example
The solution
After a thorough analysis of the application requirements, Rollon Nadella engineers proposed the AXNRQ circular system in-ring configuration. This solution was selected due to its ability to meet the key operational demands of the project, offering:
- High load capacity with robust guide rollers that support loads in all directions, helping ensure smooth and stable transportation of coils.
- Optimized acceleration and speed, meeting the stringent stroke time requirement between machine stations.
- Space-efficient design, allowing seamless integration onto the existing 10-meter-long support structure within the plant.
The system provided features a 10-meter-long circular track equipped with 24 carriages, ensuring continuous operation across all machining stations.
Built to handle automated wire products, the system features a 10-meter-long circular track with 24 carriages, enabling nonstop operation across all machining stations.
Furthermore, to enhance reliability and minimize maintenance efforts, the solution includes an automatic lubrication system that helps ensure optimal performance over extended operational cycles.
10-meter-long AXNRQ Circular System
The AXNRQ circular system supports the electric wire production process with a fully integrated, ready-to-use circuit that allows manufacturers to achieve the desired performance while reducing footprint and engineering time. The core components of the system include:
- Aluminum base for lightweight strength and easy installation.
- Guide rails and carriages for precise and smooth movement.
- Transmission system with gearbox and toothed belt for efficient motion control.
- Lubrication units for extended durability and reduced maintenance.
- Carriage indexing system to ensure accurate positioning at each processing station.
This setup was ideal for a facility focused on electrical wire manufacture, where cycle time and accuracy are key drivers of success.
The automatic lubrication system
The drive pulley directly mounted on the gearbox output shaft
The results
The implementation of the AXNRQ circular system has brought several benefits to the customer’s production process:
- Improved motion control: the guide rollers enable stable, precise movement, essential for positioning coils accurately during the electric wire manufacturing process.
- Efficient use of space: The machined aluminum alloy base, directly connected to the gearbox, supports a compact and easy-to-install system.
- Adaptability to specific needs: The modular and configurable design allows customization for various production setups, helping reduce installation time and engineering workload.
By adopting Rollon Nadella’s AXNRQ circular system, the company was able to implement an automation solution that aligns with its operational requirements, supporting efficiency and productivity improvements while optimizing the use of available space.
This project showed just how effective a custom-built system can be when you’re dealing with the demands of a complex electric wire production process. It met tight timing requirements, worked within limited space, and delivered consistent performance—exactly what the customer needed.
If you’re thinking about upgrading your electric wire manufacturing process, Rollon’s engineering-focused approach gives you a reliable, flexible solution. Whether you’re trying to make your current setup more efficient or looking into newer, more advanced wire products, the right automation system can make a real difference.
For more information on Rollon’s linear motion solutions and to connect with Rollon application engineers in your area or region, please get in touch with us.
