BEAD WINDING CATALOG

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Zoe Cole
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1 BEAD WINDING CATALOG

3 MARSDEN TECHNOLOGIES, INC. WHO WE ARE Marsden Technologies, Inc. (formerly Adirontech, LLC) is a multifaceted engineering firm located near Chattanooga, TN. The company was formed in 1998 in Poland, NY to fill a growing need for machine designers in the central New York region. In 2015 the company relocated to Tennessee to take advantage of the industrial growth and to be more centrally located to it s tire manufacturing customers. We specialize in custom industrial machinery, gages, fixtures and devices. We also provide a multitude of other services, some of which are listed in the following pages. MTI engineers have a diversified background of experience to draw on, from industries like; tire, firearms, textile, aero-space, automated assembly lines, laser cutting, water-jet cutting, and press operations to name a few. Our experience is complimented by some of the newest computer design technology available. Parametric solid modeling and finite element analysis software gives us the ability to enhance a project by reducing design time while increasing design integrity and quality. What this means to our customers is MTI has the ability to provide them with a high quality, affordable solution to their needs. OUR PHILOSOPHY We view every job as a challenge, not a problem, and welcome the opportunity to explore and expand our design capabilities while answering that challenge. OUR COMMITMENT The staff at MTI is committed to providing quality products and services to our customers, on time and to their specifications. I encourage you to give us a call if you have any questions concerning our services or products.

4 Table of Contents Engineering Services... 5 Guide Chutes... 6 Quick-release Brackets... 7 Build-up Wheels... 8 Dies & Baffles... 9 Stationary Gripper Plungers... 9 Former Grippers Wire Cutters: In-line Lever Style Build-up Head Assemblies Spindle Related Products Other Products... 18

MARSDEN TECHNOLOGIES, INC. ENGINEERING SERVICES Custom Machine Design MTI can design a machine to your specifications to perform your unique task.

5 MARSDEN TECHNOLOGIES, INC. ENGINEERING SERVICES Custom Machine Design MTI can design a machine to your specifications to perform your unique task. We can perform all of the work ourselves or as an addition to your engineering staff assisting in the design of a particular part of the machine. Machinery Retrofits Do you have a machine that you would like to perform a different task than it was designed for? Do you have a machine that needs to be modernized or rebuilt with different components? Do you have a machine that is a maintenance nightmare, always being repaired? MTI can work with you to modify these machines to get the performance out of them that you require. Fixture Design Everybody needs fixtures for one thing or another. Whether you use fixtures to hold parts for machining, assembly or inspection MTI can design a fixture to suit your needs.. and much more! Page 5

Guide Chutes The 40WG is a direct replacement for the Bartell guide chute on the SWS-3000, SWS- 4000 and SWS-6000 bead winders.

A very gentle lead-in chamfer is used where the insulated wire enters the guide chute.

6 Guide Chutes The 40WG is a direct replacement for the Bartell guide chute on the SWS-3000, SWS and SWS-6000 bead winders. A heavier gage material is used for increased strength, 16 gage (.059 ) compared to the OEM s 18 gage (.048 ). A very gentle lead-in chamfer is used where the insulated wire enters the guide chute. This helps to reduce the occurrence of rubber being stripped from the wire and eventually plugging the chute. The nose bevel is ground in a fixture for accuracy and repeatability instead of by hand like the OEM. This reduces the chances of the chute scraping on the side wall of the former groove. At approximately 30% less than the cost of the OEM guide chute, the MTI guide chute is much more economical. Page 6

MARSDEN TECHNOLOGIES, INC. QUICK-RELEASE BRACKETS Guide Chute Guide Chute Arm Mounting Block To the right is an illustration showing the new two-piece quick-release guide chute bracket.

The guide chute arm is attached to the mounting block by two pins, one permanent and one retractable (called the locking pin).

7 MARSDEN TECHNOLOGIES, INC. QUICK-RELEASE BRACKETS Guide Chute Guide Chute Arm Mounting Block To the right is an illustration showing the new two-piece quick-release guide chute bracket. The mounting block, which is adjusted just like the OEM bracket, is attached to the pay-on arm using the existing mounting holes and stays attached even when the guide chute is removed. The guide chute arm is attached to the mounting block by two pins, one permanent and one retractable (called the locking pin). The locking pin is engaged and disengaged by a simple 1/4 turn twist with a screw driver. If the locking pin is disengaged the arm can rotate away from the build-up wheel, allowing easy access to the wheel. Then by sliding the arm forward it is disengaged from the rear pin allowing the arm to be removed from the machine for cleaning or replacement of the guide chute without losing the adjustment setting. To reinstall the guide chute, simply place the arm back into position and engage the locking pin. If a spare set of arms is purchased a new or clean guide chute can be installed on the spare arm and be ready for immediate installation back onto the machine. By using spare arms, all six guide chutes could be changed in less than 1 minute, instead of at least fifteen minutes, as is the case with the original equipment. Now the worn or plugged guide chute can be replaced or cleaned while the machine is running. This assembly is a direct replacement for the OEM guide chute bracket and OEM guide chutes mount directly to the quick-release arm, no modifications required. Or for even more savings use MTI guide chutes. Page 7

DURABILITY / INTEGRITY: The BW101 build-up wheel takes advantage of new materials and manufacturing techniques to improve durability and integrity, while keeping the cost low.

8 Build-up Wheels The BW101 build-up wheel is an aftermarket direct replacement for the Bartell SWS-3000, SWS-4000 and SWS-6000 pay-on wheels. The BW101 was designed with three primary design objectives: increased durability / integrity, ease of installation and lower cost. DURABILITY / INTEGRITY: The BW101 build-up wheel takes advantage of new materials and manufacturing techniques to improve durability and integrity, while keeping the cost low. The material selected for the wheel has 2-3 times the wear-resistance and twice the impact strength of it s OEM counter part. What this means is the wheels will not break, chip or wear out as quickly. All of the components are manufactured to very stringent tolerances for improved assembly accuracy and repeatability. Axial play (or bearing slop) is eliminated through the use of needle thrust bearings, contributing to a more accurate and repeatable placement of the wire during bead building. EASE OF INSTALLATION: The goal here was to provide a design that was quick and easy to install, preferably without the need for tools. The BW101 is a complete self-contained assembly which can be easily installed with one hand, without tools. Where the OEM version consists of multiple components which need to be assembled at the time of installation. LOWER COST: The cost of the BW101 assembly is at least 50% less than the OEM equivalent. And since the wheel will last longer the yearly consumption is reduced making this design even more economical. One way we kept the cost down was to take the approach that the assembly would be non-repairable and disposable. When you consider the cost of labor, inventory and/or downtime to rebuild this assembly versus the cost of the pre-assembled unit, it doesn t make financial sense to rebuild. Page 8

Call us with your wire and insulating specifications and we can provide you with a die and baffle combination to fit your needs that will

9 MARSDEN TECHNOLOGIES, INC. DIES & BAFFLES Direct replacement dies & baffles are available for both single wire bead machines and ribbon bead machines. Call us with your wire and insulating specifications and we can provide you with a die and baffle combination to fit your needs that will last every bit as long as, if not longer than, the OEM - for less money. STATIONARY GRIPPER PLUNGER Made from hardened tool steel with a threaded stud permanently bonded in place these stationary gripper plungers are directly interchangeable with the OEM version. Page 9

Former Grippers The model FG101 former gripper assembly is an aftermarket direct replacement for the Bartell SWS-6000 former gripper assembly.

10 Former Grippers The model FG101 former gripper assembly is an aftermarket direct replacement for the Bartell SWS-6000 former gripper assembly. This assembly was designed to be a less expensive alternative to the OEM version with some added benefits. Although at first glance this assembly may look very similar to the OEM version there are many differences. This entire design is centered around the fixed gripper. The fixed gripper is of a one-piece design with four gripping surfaces per wire path. The gripper can not only be rotated to use the second grip surface but it can also be flipped and rotated for the third and fourth grip surfaces. This one-piece fixed gripper is equivalent to 12 OEM fixed grippers. The grip surfaces are tightly toleranced from one end as to eliminate tolerance stacking from wire path to wire path. This one-piece design facilitates easy installation of the gripper assembly into the former segment since there are no loose parts which can become separated and rotate out of position. The moveable grippers are also noticeably different. These grippers are not keyed to the keyway in the former segment. The moveable grippers utilize the side plates of the fixed gripper, which is keyed to the former segment, to control rotation. This makes the installation of the key much easier since there are no independent keyways to become misaligned, just one common keyway in the fixed gripper. This also allows for more space in the gripper pocket. This additional space helps to reduces the occurrence of a common problem, buildup of debris in the bottom of the gripper pocket. This debris sometimes causes the moveable gripper to not grip the bead wire securely resulting in misgrips and downtime for cleaning. The most important advantage to this design is that both the fixed and moveable grippers can be re-sharpened. Page 10 One-piece Fixed Gripper Moveable gripper

11 MARSDEN TECHNOLOGIES, INC. Former Grippers Exploded assembly view of the FG101 former gripper. Fixed gripper comparison MTI OEM Features: One piece construction Tighter tolerances Stronger design Longer lifespan (twice as many grip surfaces) Re-sharpenable Less expensive 12 of these grippers are equivalent to 1 MTI gripper. Tolerance stacking problem. Can not be re-sharpened. More expensive Page 11

12 TO ORDER CALL: FORMER GRIPPERS MTI has a full compliment of former gripper mechanisms 100% compatible with the original equipment. All of these designs utilize a version of our superior gripper design detailed on the previous pages. Linear Gripper Simple push/pull action to grip/release the wire. Page 12

wire followed by a rotary action to push the gripped tail

13 MARSDEN TECHNOLOGIES, INC. FORMER GRIPPERS Stitcher Gripper Linear action to grip the wire followed by a rotary action to push the gripped tail up into the bead. Conversion Gripper Replaces a stitcher gripper with a linear gripper Page 13

INLINE CUTTERS 200CU shown here. Cylinder Fixed Moving Connector Block Blade Bushing This new cutter design is a direct replacement for the OEM lever arm version.

This arrangement eliminates the cutter arm and pivot pin, which are a maintenance issue. Another enhancement in this design is in the blades.

14 INLINE CUTTERS 200CU shown here. Cylinder Fixed Moving Connector Block Blade Bushing This new cutter design is a direct replacement for the OEM lever arm version. In this design the cylinder is directly connected to the blade via the connector block. The connector block is bolted to the cylinder rod and interlocks with the blade. This arrangement eliminates the cutter arm and pivot pin, which are a maintenance issue. Another enhancement in this design is in the blades. Each blade has two cutting edges which provides twice as much life per blade as the OEM version. Since the blade interlocks with the connector block it is very simple and fast to change blades. The moving blade incorporates a hardened bushing in each slot that acts to retain the moving blade and controls the clearance between the fixed and moving blades to ensure proper shear action. To change or rotate the blades simply loosen and remove the two hex nuts and washers, slide the moving blade over the mounting posts, loosen and remove two flat head screws, then slide the fixed blade over the mounting posts. Page 14

15 MARSDEN TECHNOLOGIES, INC. LEVER STYLE CUTTER (OEM) Actuator Arm 100CU00 shown here. Clamp Collar Pivot Shaft Needle Roller & Hardened Sleeve Support Block Cutter Blades This new cutter design is much improved over the older OEM designs. The air cylinder is centered over the actuator arm, whereas the OEM s original design has the actuator offset. Because of this offset the OEM version has problems with premature bushing wear and breakage of the actuator arm and pivot shaft. The OEM s later designs moved the cylinder inline with the actuator arm and replaced the bushing with needle thrust and roller bearings. But, there is still a problem with pivot shaft breakage. This is due to the way in which the pivot shaft is installed into the support block. There is a clearance between the pivot shaft and the hole in the support block. This allows the pivot shaft to move slightly (or chuck) in the hole every time the cutter is actuated. This chucking eventually leads to premature fatigue failure of the pivot shaft and the hole gets elongated, compounding the problem. This upgrade design utilizes a larger pivot shaft, a needle roller bearing on the shaft and needle thrust bearings on either side of the actuator arm. The pivot shaft is made out of a tougher material and heat treated to a higher hardness. The pivot shaft is lightly pressed into a hardened sleeve in the support block. The hardened sleeve strengthens the hole to eliminate deformation around the hole. By having a light press fit between the pivot shaft and sleeve chucking is eliminated. Removal of the cutter blades and maintenance of the pivot shaft and bearings has been simplified. The actuator arm and bearings are held onto the pivot shaft by a simple clamp collar. This cutter design uses the same cutter blades as the original equipment. Page 15

BUILD-UP HEAD ASSEMBLY Improvements over OEM: The arms are manufactured to tighter tolerances than the original equipment and the thrust bearings used between each arm are of higher precision.

16 BUILD-UP HEAD ASSEMBLY Improvements over OEM: The arms are manufactured to tighter tolerances than the original equipment and the thrust bearings used between each arm are of higher precision. When combined with the MTI Build-up Wheel the Build-up Head assembly has an assembled tolerance from one wheel centerline to the next of.875±.002 (compared to OEM.875±.010 ). This produces a better quality, more consistent bead across all six wire paths. The build-up wheel has been moved to the opposite side of the arm which allows easier access to the wheel for replacement. This also eliminates the problem of wheels loosening up on right hand machines. The rotation of the wheel is now in the direction that tightens the threads. The air cylinders and their mounts have been changed. The cylinders have larger diameter rods. The rod end clevis and body clevis are also stronger. This combats the inherent problem with the cylinder rods becoming bent. Considerably less expensive. Page 16

MARSDEN TECHNOLOGIES, INC. SPINDLE RELATED PRODUCTS These direct replacement components meet or exceed the original equipment specifications.

17 MARSDEN TECHNOLOGIES, INC. SPINDLE RELATED PRODUCTS These direct replacement components meet or exceed the original equipment specifications. We can provide complete assemblies or individual components that are the exact OEM designed replacement or our own enhanced designs. Winding Heads Linkage style (shown here) - Modeled after the OEM version, but with numerous improvements for ease of assembly and manufacturing. Linear style (not shown) - MTI s own design incorporates wedges and linear bearings to expand/collapse the segments. Former Tooling Rotary Couplings Page 17

18 OTHER PRODUCTS Sheaves Stationary Grippers Let-off Equipment Page 18

20 Marsden Technologies, Inc. 108 Morningside Drive Soddy Daisy, TN Phone: (423) Fax: (423) Cat. ver.16

Tooling Assistance Center

Tooling Assistance Center Safeguards are designed into this application equipment to protect operators and maintenance personnel from most hazards during equipment operation. However, certain safety precautions must be taken by