This new machine features an innovative linear wire feeding mechanism that replaces the traditional wire rolls with a system that uses grippers. This technological advancement offers multiple benefits in terms of efficiency, accuracy, and ease of use, catering specifically to technicians and professionals in the manufacturing sector.

Composition and mechanics

 The linear wire feeding system in the CS 663 LF is composed of two grippers: one fixed and one moving. The design of the moving gripper ensures continuous control of the wire throughout the feeding process. During operation, while the feeding gripper pulls the wire, the fixed gripper remains open. The fixed gripper then closes before the moving gripper opens to return to its set pulling position, ensuring uninterrupted wire control and feed consistency.

One of the critical aspects of this system is the integration of electronic and mechanical components. While the setting of the cutting length is managed electronically via the machine’s Human-Machine Interface (HMI), the movement of the grippers during production is controlled by a mechanical cam. This hybrid approach ensures maximum reliability, even at the high speeds required for large-volume production. The electronic setting also plays a fundamental role in Carlo Salvi’s Rapid Tool Exchange system, drastically reducing machine downtime during tool changes and significantly increasing overall production time and efficiency.

Advantages

 The adoption of a linear wire feed system offers several notable advantages over traditional wire roll feeds. Firstly, both grippers are designed to accommodate the full range of wire diameters the machine can handle. This eliminates the need for hardware changes when switching tools, simplifying the setup process and reducing potential downtime.

Secondly, the system does not require a wire stop, which is typically necessary in conventional roll feed machines. The absence of a wire stop minimises unwanted stress on both the wire and the machine, leading to increased longevity and reliability. Additionally, the linear wire feed guarantees high accuracy and perfect cutoff quality, maintaining consistency within 0.05 mm. This precision is crucial in high-volume production environments, where even minor deviations can result in significant issues.

Implementation and retrofitting of existing machines

 The linear wire feeding technology is not limited to the new CS 663 LF model. Carlo Salvi has also made it possible to retrofit older models of the CS 663, originally equipped with roller feeds, with the new linear feeding system. This smart solution allows customers to upgrade their existing machines, enhancing performance without the need for a complete overhaul. The ability to revamp old models with new technology extends the operational life of the machines and provides a cost-effective way for manufacturers to stay current with the latest advancements.

Conclusion

 The introduction of the CS 663 LF with its linear wire feeding system marks a significant technological advancement in the field of high-speed cold forming. By replacing traditional wire rolls with a more precise and efficient gripper system, Carlo Salvi has addressed key issues related to accuracy, reliability, and ease of use. The integration of electronic settings with mechanical operations ensures optimal performance during high-speed production, while the ability to retrofit older models provides added value to existing customers. Overall, the linear wire feeding system enhances the efficiency and productivity of Carlo Salvi machines, making it a valuable innovation for technicians and professionals in the industry.

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