18/03/2024 – Replacing slip-rings with wireless technology

Modernising cable lines

With a strong commitment to innovation and customer service in today’s fast-paced manufacturing industry, upgrading their machines is a necessary step for improving efficiency, productivity, and safety.


Left: Receiver of the "FMS-Cradle Guard". Right: Control panel with mounted receiver. © FMS


Left: Coil carrier with mounted transmitter of the "FMS-Cradle Guard". Right: Transmitter. © FMS


Haggie Wire and Strand is a South African manufacturer and supplier of concrete reinforcing products. Established in 1921, the company has grown and evolved over the years to become a leading supplier of high-quality wire products. One of the major challenges faced by Haggie Wire and Strand is maintaining ageing equipment that is prone to breakdowns. Here we will discuss how SA Power, distributor of FMS in South Africa, has assisted with the upgrading of some of their machines, the process involved while maintaining production demand.

The necessity to upgrade
The rotating cable machines were using traditional slip ring systems. These require frequent servicing and regular inspection of the brushes on the slip rings. They are prone to mechanical wear and tear. The FMS system provided a wireless solution replacing the slip rings. It is a low-maintenance system only requiring the recharging and replacement of remote batteries on a four-day cycle.

First step was preparing the functional specification
The first step when proposing such solutions is the preparation of the Functional Specification. This is carried out in close collaboration between Engineers from Haggie Wire and Strand and SA Power and clearly defines the requirements and expectations of the upgrade. In addition, the role of each party during the upgrade. This is essential to manage communication and expectations. In this case it required the replacement of slip-rings with a wireless solution. Once the FS is completed, budgets, orders and resources are allocated to undertake the upgrade.

Upgrade using FMS
The upgrade involved removing the slip rings and installing two “FMS-Cradle Guard” receivers between the six cradles. An “FMS-Cradle Guard” transmitter was installed at each cradle. All safety proxies and line break proxies were wired from the pintle to each transmitter on each cradle. The receivers outputs were wired into the machine safety and other signals which were tested and certified completing the upgrade.

Key success factors
During the upgrade process, it is essential to maintain productivity and meet demand to avoid any significant disruptions to the production process. This was done by carrying out the upgrade in phases where only a section of the machines was taken offline at any given time. The upgrade process was planned for off-peak production periods to minimise the impact on production levels.

In conclusion, upgrading client machines is a necessary step for improving efficiency, productivity, and safety in the manufacturing industry. The upgrade process involves securing necessary resources, removing old systems, and installing new systems. Strategies for maintaining productivity and meeting demand during the upgrade process include carrying out the upgrade in phases and scheduling the upgrade process during off-peak production periods. By implementing these strategies, manufacturers can upgrade their client machines while minimising the impact on production levels.
Combined synergies: SA Power and FMS both place high value on efficient data exchange to meet customer’s expectation. Project execution involved the end-user, the distribution and service partner and FMS (Force Measuring Systems).

wire 2024, hall 11 booth E 32

FMS Force Measuring Systems AG
Aspstrasse 6, 8154 Oberglatt/Switzerland
Contact person is Renata Lupsic
Tel.: +41 44 8528080

About FMS
FMS Force Measuring Systems AG is the market leader in the field of web tension measurement, control and specialist for web guiding solutions. For the wire industry we are the only manufacturer offering a complete range of technologies for force measurement, data processing and radio transmission of signals.