8:30 AM-5:00 PM
Fundamentals of Wire Manufacturing
The popular Fundamentals of Wire Manufacturing is a one-day, pre-conference course designed to give attendees a solid grounding in the essentials of wire and cable manufacturing. Scheduled for the day before the start of Interwire, it includes four general topics in the morning, and four each in a ferrous and nonferrous/electrical track during the afternoon. Lunch is included. It is valuable to those new to the industry, as well as a refresher for seasoned professionals. The course includes a 45-minute question-and-answer session following the end of the last class.
See "Fundamentals Course" tab under "Program" for more details.
1:00 PM-3:00 PM
Plant Tour Southwire
Bus loads at 11:45 a.m. and returns at 4:15 p.m.
SESSION – Opening Session
8:30 AM-9:00 AM
SESSION – Industry 4.0
9:00 AM-11:30 AM
9:00 AM-10:30 AM
Industry 4.0 Panel
Panelists: Willem Sundblad, Oden Technologies Ltd.; Ali Shehab, Cimteq Ltd.; and Albert Groothedde, InnoVites BV
Industry 4.0 has been available in some form for decades. But the vast majority of engineers, especially in wire and cable, don’t have access to usable data. In the last five years, new technologies have meant Industry 4.0 is now available to everyone in wire and cable. In this presentation, four speakers who offer technology that can be used as part of an Industry 4.0 solution share their expertise in a panel discussion. The panel discusses how to leverage rising processing power, abundant wireless connectivity, and limitless cloud storage, and what it means for the future of wire and cable. The topic is one that has gained traction, mostly in Europe, but increasingly in the U.S., where it is better known as the Smart Factory. There is a difference between the two, but the essence in common is that electronics and the ability to deploy it is taking place, and that it will have an impact on the shop floor.
10:30 AM-11:00 AM
“Liberating Data from Existing Equipment, and Making Sense of It!” by Willem Sundblad, Oden Technologies Ltd.
The latest advancements in technologies we take for granted in the rest of our lives —rising processing power, decreasing computing cost, abundant wireless connectivity, and limitless cloud storage—has finally made it possible to make existing extrusion lines truly digital. This presentation provides an update on the current Industry 4.0 landscape, where the market is heading and what concrete solutions looks like for wire and cable manufacturers. It also gives a demonstration of how deep learning algorithms can and are being used in wire and cable.
SESSION – Operations
1:00 PM-2:30 PM
1:00 PM-1:30 PM
“Separation and Recycling of Wire and Cable Waste Streams,” by Michael Kahl and Kevin Doyle, Encore Wire Corporation
This paper examines the process of separating and recovering valuable materials from wire and cable manufacturing waste streams. The most valuable material in these streams is copper, which can be extracted and turned back into pure cathode by an electrolysis process called electrowinning. Processes also exist and are described for separating the nonmetallic components with high accuracy which can then be replaced or incorporated into new products. These processes can reduce cost and minimize landfilled waste.
1:30 PM-2:00 PM
“Distraction--Is That a Risk You Want to Take?” by Karen Duff, General Cable Corporation
Distraction: a thing that prevents someone from giving full attention to something else. Whether you are at home, on the road, or at work, when there is a risk, a distraction can be life-changing, or even deadly. The intention of this presentation is to bring awareness to the risks we create, some intentionally and some not, when we become distracted. Distractions can be hard to control; habits will help decrease the risk. Join this discussion regarding distractions and their impact on accidents.
2:00 PM-2:30 PM
“How to Build a Safety Culture by Offering OSHA Safety Training,” by Terry Carroll, Enviroworld Consulting LLC
Safety Culture has been defined as “how the organization behaves when no one is watching”. Many organizations have struggled for years to implement a positive safety culture and still have a long way to go. This presentation helps attendees realize that the key to OSHA compliance, reduction of accidents and workers comp costs, and improving employee attitudes is to implement a company-wide “Safety Culture”. This presentation demonstrates how the 10-hour OSHA outreach general industry course can contribute to safety culture development.
SESSION – Continuous Casting
3:00 PM-4:00 PM
“ZnAl Rod From Upcast® Continuous Casting Process,” by Juho Kalliokoski, Upcast Oy
3:00 PM-3:30 PM
Upcast Oy has developed a new, cost-effective, and flexible process producing ZnAl rod, which can be processed further to ZnAl wire. The ZnAl wire is used for coating to protect steel against corrosion. In the Upcast® continuous casting process, the ZnAl rod is cast vertically upwards from the melt, and coiled after an optimized cooling.
3:30 PM-4:00 PM
“Developments in Upward Casting of Dilute Copper Alloys Using Rautomead Continuous Casting Technology,” by Brian Frame, Rautomead Ltd.
Serious challenges are currently being placed on the wire and cable industry to provide solutions in the automotive, railway, aerospace, and electronics industries for cables with high conductivity and variously high tensile strength, high ductility, high softening temperatures, and low creep while avoiding materials presenting toxicity hazards. This paper describes recent development work to meet these demanding requirements.
SESSION – Nonferrous/Electrical
9:00 AM-1:00 PM
9:00 AM-9:30 AM
“Electrical Linear Resistance Measurement of Large Cross-Section Conductors,” by Boris Dardel, Patrick De Bruyne, and Vincent Arbet-Engles, AESA SA
Measuring the linear resistance of large-section conductors relies on mastery of the related uncertainties. Factors like exactness of the length, proper temperature of the Cable Under Test (CUT), or adequacy of the micro-ohmmeter unit may be common to most testing situations, but contacting the CUT in a way that current density is radially uniformly distributed in the section requires specific means of instrumental importance. This presentation discusses both the on-the-line and sample test measurement methods as well as the corresponding challenges in obtaining well-controlled global accuracy.
9:30 AM-10:00 AM
“High-Capacity, High-Performance Composite Core Conductors,” by Dave Bryant, CTC Global Inc.
In an effort to mitigate congestion on the electric power grid while enabling the deployment of more renewable generation, the High-Capacity, Low-Sag (HCLS) Aluminum Conductor Composite Core (ACCC®) bare overhead conductor was developed. The ACCC conductor uses a high-strength, light-weight carbon fiber core that enables greater spans between fewer and/or shorter structures to reduce upfront capital costs and environmental impact. The technology, deployment and benefits are described in this paper.
10:00 AM-10:30 AM
“Increasing Building Wire Voltage Ratings from 600 V to 1000 V,” written by Justin Hrbacek, Encore Wire Corporation. Presented by Michael Kahl, Encore Wire Corporation.
The effort to harmonize North American electrical standards initiated investigation of the ability of 600 V conductors to operate at 1,000 V. Associated changes to product standards are currently debated. This paper presents data to illustrate the behavior of PVC and XLPE insulations when exposed to 1,000 V. Variables such as additives, insulation thicknesses, and measurement technique greatly affect results. The lastest testing allows manufacturers to offer XHHW-2 at a new 1,000 V rating.
10:30 AM-11:00 AM
“Danieli Endless Aluminum Rod Mill: Mission Accomplished at Sural,” by Stefano Lodolo and Alberto Voltolina, Danieli
The goal of the customer was to have the most innovative aluminum rod mill with a high level of automation marking a technological gap of at least 10 years compared to its competitors; a plant with high flexibility and capable of processing small lots of various alloys (from 1xxx to 8xxx series) with a fast changing time. The results are presented jointly with Sural.11:00 AM-11:30 AM
“Aluminum and Alloy Wires in Automotive Applications,” by Enrico Conte, SAMP SpA, Sampsistemi Division
This paper presents the latest technical solution available and new advancements to guarantee a better quality of final product and a reliable and efficient production process for aluminum flexible multiwire and GMAW aluminum wire for automotive application. Topics include aluminum and alloys for automotive application and production process; aluminum multiwire applications; GMAW and rivets aluminium wires; technical and technological solutions on multiwire drawing and annealing in-line process; technical and technological solutions on GMAW drawing process; and future areas of development and conclusions.11:30 AM-12:00 PM
“Manufacturing of High-Strength and High-Ductility Tough-Pitch Copper Wire by Alternate Wiredrawing,” by Kazunari Yoshida, Hidetoshi Nagashima, and Shintaro Takamiya, Tokai University
This paper proposes that the alternate wiredrawing method markedly improves the ductility of a nonferrous metal wire. This method makes it possible to produce high-ductility wire due to its ability to inhibit the additional shearing strain near the wire surface. The increase in ductility was confirmed by comparison of mechanical properties and FEA results between conventional and alternately drawn wires, which proves the possibility of production of high-ductility nonferrous wires.
SESSION – MEMBER REWARDS LUNCHEON & MORDICA MEMORIAL LECTURE
12:00 PM-1:15 PM
SESSION – Nonferrous/Electrical Workshop on Fines and Annealing
9:00 AM-12:00 PM
“Nonferrous Workshop on Fines and Annealing,” by Horace Pops, Horace Pops Consulting Inc.
This workshop expands on the essential topics of the Fundamentals of Wire Manufacturing course by delving into two more subjects in greater detail. First, it examines the formation, analysis, and measurement of fines. It presents an analysis of the origin, microstructures, and make-up of fines in nonferrous products during rod production and wiredrawing. The second part discusses principles of annealing, annealing of copper and aluminum wire, and annealing problems. Specific topics include definitions, structure—property changes, general concepts, engineering rules and guidelines, stages of annealing, and the role of work hardening. Lastly, the program covers some of the rich history of copper and wiredrawing, tracing development of techniques through the ages.
SESSION – MORDICA MEMORIAL LECTURE
12:45 PM-1:15 PM
“2017 Mordica Lecture: Continuous Casting and Rolling of Copper Rod—Where it All Started,” by Hal Moss, Lucent Technologies (Ret.)
This presentation discusses how the process for continuous casting and rolling of copper rod got started back in the early 1960s. It touches on the joint development project to prove feasibility and the trials and tribulations to make it into a production process. Once the initial process was proven and accepted worldwide, there were other production techniques put into practice, which are also discussed. This process is now completely accepted by industry as the method of producing copper rod.
SESSION – Keynote
2:00 PM-2:40 PM
“Our 3-D Printed Future: How to Position Yourself and Your Organization to Successfully Navigate This Historic Shift,” by Rick Smith, 3-D Printing Expert, Bestselling Author
3-D printing production will change the world more in this century than the industrial revolution has over the last 300 years. So says author and entrepreneur Rick Smith in this provocative and entertaining talk based on his upcoming new book. Smith lays out a compelling framework to explain the growth and inevitability of 3-D printing as it permanently displaces conventional manufacturing. He reveals a brave new future where objects are 3-D printed using plastics and steel, skin and stem cells, chocolate and Kevlar, where pipes are printed that can automatically repair themselves and batteries are printed the size of a grain of sand, where global supply chains collapse, and the wealth of nations is flipped on its head.
In pursuit of this radical future, Smith introduces audiences to some of the modern pioneers of 3-D printing while also moving further back in history to the fascinating cast of characters who shaped other great technological shifts. This talk answers two questions that strike at the heart of every leader in every organization: How will the future unfold in front of us? And how can we position ourselves and our organizations to successfully navigate this historic shift to our greatest benefit?
SESSION – Processes
3:00 PM-5:00 PM
3:00 PM-3:30 PM
“Practical Considerations in Measuring Wire Drawing Die Diameters,” by Kevin Johnson, Fort Wayne Wire Die Inc.
The ability to meet customer specifications on drawn wire diameter is in large part dependent upon the capability of the measuring system. This presentation examines critical factors for understanding and managing a capable wire die measurement system.
3:30 PM-4:00 PM
“Introduction to New Optical 3D Roughness Measurement Technology for Real-Time In-Production Surface Measurement of Extruded Wires and Cables,” by Juha Säily, FocalSpec Inc.
This paper discusses how surface roughness of an extrudate depends on extrusion processing conditions. Results of sample test runs with varying extruder barrel temperature, screw speed, and pull tension are presented. This paper also discusses how real-time roughness monitoring can be used as an efficient tool in optimizing cable extrusion processes resulting in improved quality and increased production volume. It is applicable to manufacturing of all types of extruded wires and cables, from thin wires to consumer electronics cables, telecommunication cables and high-capacity power transmission cables.4:00 PM-4:30 PM
“How Atmospheric Plasma Surface Treating Enables Inkjet Printing on Wire and Cable,” by Ryan Schuelke, Mark Plantier, and Galen Quinsey, Enercon Industries Corp.
In-line atmospheric plasma technology enables efficient and economic inkjet printing on wire and cable. Plasma cleans, etches, and functionalizes surfaces to improve wettability and bonding. The resulting ink adhesion passes the demanding durability tests required by wire and cable manufacturers. This paper reviews the capabilities of atmospheric plasma on materials commonly printed by wire and cable manufacturers. Lab data are provided along with recommendations for successfully implementing pretreatment in the field.
4:30 PM-5:00 PM
"Revolutionary Application of the Properzi Microrolling® Mill for Producing Annealed Copper Wire Without an Annealer," by Carmelo Maria Brocato, Continuus-Properzi SpA
The patented Properzi Self Annealing Microrolling® (SAM) method makes use of the Properzi Microrolling® technology and replaces the conventional drawing/annealing processes to obtain the same result while requiring approximately half the energy. The energy of the rolling process increases the wire temperature to a level that provides the desired characteristics of an annealed wire ready for subsequent processing in multiwire drawing applications. Developments with different
outlet diameters are currently under evaluation.
SESSION – Production Solutions
3:30 AM-5:00 PM
See "Production Solutions" tab under "Program" for more details.
SESSION – Manufacturing Management Workshop
9:00 AM-12:00 PM
See "Workshops" tab under "Program" for more details.
SESSION – Ask the Expert
11:00 AM-1:00 PMSee "Ask the Expert" tab under "Program" for more details.