The patented system combines controlled tension management with intelligent wire storage, thereby laying the foundation for higher quality, more stable processes, and significantly increased equipment availability.
In industrial wire processing, manufacturers have faced fundamental trade-offs for decades.
In strand production, two established methods compete: multi-wire systems offer high cost-effectiveness combined with a compact machine layout, while single-wire pay-offs enable precise, individually adjustable tension control. However, both approaches have inherent disadvantages, either in terms of geometric accuracy or efficiency.

How the box accumulator works
With the “box accumulator”, Kurre Systems has developed a solution that combines these requirements into a single compact module.
The system is based on three functions:
– Targeted temporary storage of wire after the unwinder
– Compensation for length and process variations
– Continuous tension control

The wire is actively fed into the storage unit and returned to the process under defined conditions. Depending on the application, this results in either significantly improved geometry (strands) or uninterrupted production (core extrusion).

Application in strand production: controlled core
In strand production, the box accumulator enables, for the first time, the precise guidance of the core wire within a strand wire process.
The controlled separation and tension control result in a so-called Controlled Core, a mechanically stabilized strand center with a defined tensile force.
This targeted core tension in the range of 0.2N or higher compensates for a major drawback of conventional strand wire systems: the lack of tension compensation for the geometrically shorter core wire.
The effects on the stranding process are significant:
– Reduction of loop formation and “birdcage” effects
– Improved roundness and dimensional accuracy
– Minimization of mechanical defects such as corkscrew effects

This achieves the precision of a single-wire system without having to accept its increased investment, space, and setup costs.

Application in wire production: continuous extrusion
In wire production, the box accumulator demonstrates its strength as a process buffer.
The wire is stored immediately after the unwinder and is then continuously available for extrusion. With a storage capacity of several hundred meters, the production process can be maintained even during a spool change.
In combination with a dual-unwinder system, this creates an uninterrupted material flow:
– One unwinder operates while the second is being prepared
– Wire ends are connect by using a cold weld system
– The box accumulator unit completely bridges the spool change operation

This enables continuous extrusion without any downtime.
The integrated tension control in the range from 2 N also ensures stable wire feed and smooth process control in the extruder.

Process and quality benefits
The use of the box accumulator unit leads to measurable improvements throughout the entire process chain in both applications:
Process Stability
– Consistent tension control
– Reduced vibrations and wire instability

Product Quality
– Improved strand geometry
– Consistent outer diameter of conductors
– Less scrap

Productivity
– Elimination of downtime in extrusion
– Higher system availability

System integration
– Compact design
– Retrofittability into existing lines

Industrial significance
The box accumulation system addresses two key technological gaps in the cable industry:
– The lack of a combination of efficiency and precision in strand production
– the lack of continuity in conductor extrusion

The unified system approach creates a new level of process control. Wire and cable manufacturers can significantly improve their production in terms of both output and product quality without having to make fundamental changes to existing plant structures. 

Kurre Systems
Industriestrasse 5
26683 Saterland-Ramsloh/Germany
Contact person is Thorsten Wilde
Tel.: + 49 4498 9250-120
thorsten.wilde@kurre-systems.de
www.kurre-systems.de