Wire transport

The “Basics of Wire Transport” page on Migal.co discusses the importance of proper wire transport system design for welding applications, focusing on the need for bulk wire systems and the factors affecting wire feed consistency, such as friction in conduits. It highlights key products like various types of conduits and drums, provides calculations for wire transport forces using the Euler-Eytelwein formula, and gives friction coefficients for MIGAL.CO conduits. This information ensures optimal wire transport and reliable welding in large-scale production.

The “Overview of Wire Feed Systems” page on Migal.co provides detailed guidance on wire transport solutions for different wire types, including un- and low-alloy steel wires, high-alloy steel and non-ferrous alloys, and aluminum alloys. It highlights MIGAL.CO’s range of Eco- and Jumbo-Drums and links to downloadable PDFs that showcase wire feed system components tailored to each application.

The “Drum Transport Trolley” page on Migal.co describes the UFTW 1 trolley, designed for handling various wire bulk packs such as drums of different shapes and sizes. The trolley features adjustable height, lockable wheels, and a sturdy handle for easy maneuverability. It also offers the RoboDock feature, which includes a sensor to monitor the wire level and provide early warnings for automated welding systems. This setup helps minimize downtime in production.

The “Spreader Bar” page on Migal.co presents the Universal Spreader Bar ULT1, a tool designed for transporting wire drums using forklifts or cranes. It has an adjustable working width (500-700 mm), supports up to 500 kg, and is powder-coated with a CE mark. It includes a chain hanger, assembly parts, and documentation. This product works in tandem with the drum trolley UFTW1 to streamline wire drum handling.

The “Drum Hoods” page on Migal.co presents hoods designed for round, octagonal, and square drums, ensuring protection against contamination. Made from recyclable LDPE, these hoods are compatible with a variety of drum sizes and include PVC windows for viewing. Specific models such as the RND-520, QUA-600, and OCT-520 cater to different shapes and capacities, supporting both Eco and Jumbo drums.

The “Decoiling Aids” page on Migal.co explains various aids used for efficiently unwinding wires from drums, preventing tangling or knotting, particularly for aluminum and copper alloys. It covers different products like the ASH 81 for Eco-drums and the TOU400/580 for Jumbo-drums, which help reduce downtime in automated welding systems by managing wire tension and ensuring smooth decoiling.

The “Drum Connectors” page on Migal.co features the AER-201 and AER-201-K connectors, designed for attaching conduits to drum hoods. These connectors come in two variants: a plastic insert for non-ferrous wires and a ceramic insert for steel wires. They provide a secure connection with both 1/4” internal and 1/2” external threads, ensuring compatibility with a variety of conduits.

The “Pulley, Wire Straightener” page on Migal.co details tools designed for straightening and guiding wire from drums during welding. It describes different pulley models (ULR-2 and ULR-3) for precise wire alignment and the RoboStraight wire straightener, which uses 14 adjustable rollers for reliable operation. These devices help prevent wire tangling and ensure smooth feeding in sensitive welding processes, especially for alloys like aluminum.

The “Wire End Control” page on Migal.co describes the DES-2 sensor system, which detects the end of the welding wire using a non-contact proximity switch. The system operates at 24 volts and includes a 10-meter power cable. It connects via drum connectors and ensures accurate wire detection to prevent interruptions during welding processes.

The “Rolliner NG” page on Migal.co introduces a new generation of wire feeding technology, which eliminates friction and reduces wear on wires. The system uses rollers to guide the wire, ensuring smooth feeding and minimal maintenance. With a flexible design, the Rolliner NG is lightweight, adaptable, and ideal for dynamic welding applications. It supports various wire diameters and offers customizable lengths for different setups.

The “Rolliner 3G” page on Migal.co describes an advanced wire feeding hose system designed for welding applications. It uses roller-guided elements to reduce friction and ensure smooth wire transport, supporting up to 1.6 mm wire diameter. The system is maintenance-free, easy to assemble without tools, and improves wire feed stability over long distances. It’s suitable for various materials, including steel and aluminum.

The “Rolliner XL2” page on Migal.co introduces a friction-reducing wire feeding system for welding applications. The system uses roller-guided elements for smooth wire transport, supporting wire diameters up to 4 mm. It is maintenance-free, extendable, and can be assembled without tools. The low friction design allows for longer wire runs and reduces the need for additional drives, ensuring stable welding performance.

The “RoboBend” page on Migal.co describes a wire transport system designed to reduce friction in curves by combining RoboBend elements with standard liners like Softliner, Duroliner, and Toughliner. It supports wire diameters up to 1.6 mm and uses replaceable Rolliner 3G components. The system ensures efficient wire transport in fixed sections, with easy installation via push-on connectors.

The “Conduits” page on Migal.co highlights different wire conduits used for welding, including the Toughliner, Toughliner Extra, Toughliner Flex, Softliner, and Duroliner. Each conduit is designed for specific wire types and welding environments, balancing flexibility, friction reduction, and durability. The page also details technical specifications, such as diameter and weight, and offers accessories like strain relief and wall brackets for mounting.

The “Couplings and Connectors to Wire Feeders” page on Migal.co details screw and quick couplings for connecting wire conduits (such as Rolliner NG, 3G, and XL2) to drum hoods or wire feeders. It includes plastic inserts to prevent wire damage and offers compatibility with various welding systems. Different adapters and connectors, including universal options for non-ferrous and steel wires, are also listed.

The “Pneumatic Feed Assist” page on Migal.co describes the DLDA-1, a system designed to reduce wire friction during welding, particularly over long distances. It uses adjustable air pressure to apply force on the wire, helping it move smoothly through the conduit. The system is compatible with different liner types and can be installed on a drum hood or within the conduit itself.

The “RoboFeed” page on Migal.co describes a feed assist system designed to reduce friction and support wire transport over long distances, ideal for robotic welding applications. It uses an electrically driven feed motor, adjustable pressure settings, and works independently or with the main wire feeder. RoboFeed supports various wire diameters and lengths, optimizing welding processes with minimal manual intervention.

The “RoboFeed WireManager” page on Migal.co details a powerful wire feed assist system designed to improve welding efficiency over long distances. It offers features like real-time wire consumption tracking, automated threading, and integration with IoT protocols such as MQTT and OPC UA. It supports wire diameters up to 1.6 mm and is capable of wire speeds up to 50 m/min, significantly reducing friction and optimizing wire transport for robotic welding applications.

The “Cutting Tool” page on Migal.co describes the CTY1 tool designed for cutting Softliner and Rolliner NG conduits used in wire transport. It offers precise cuts with minimal effort and is a lightweight, easy-to-use tool for optimizing conduit length adjustments during installation and maintenance.

The “Ceramic Spray” page on Migal.co introduces the KRA-1000 ceramic surface protection spray, which extends the life of welding nozzles, contact tubes, and other components by protecting them from spatter and high temperatures (up to 1000°C). It reduces cleaning and maintenance needs, improves welding stability, and increases the lifespan of fixtures.

he “Basket Spool Adapters” page on Migal.co details adapters for basket spools, specifically the B-300 model. These adapters allow the basket to be attached to standard 52 mm mandrels of common wire feeders. The environmentally friendly design supports the use of recyclable wire baskets, and the adapter is easy to assemble. Custom designs are also available upon request.