Charter Wire LLC

Strecker Success Story Old machine, new shine:
Successful repair saves new investment

The challenge

To enable continuous operations, the end of the working wire coil must be connected to the beginning of the next coil during production.

Especially with larger dimensions, it is very strenuous for operators to pull out the wire ends to be welded so that they can be joined in a horizontal line using a conventional welding machine.

In 2014, an investment was made in a new system that was equipped with a vertically operating welding machine for joining hanging wire coils in the coil radius.

This made the entire work process a great deal easier.

After a few years in operation, the welding machine was taken out of service and stored for later use.

In 2022/2023, the question arose as to whether the machine could be taken out of storage and used at a new location in the company. Was the machine still operational? This was a matter for the manufacturer's expertise.

The solution

Strecker is the first choice for individualized complete welding technology solutions.

With us, customers not only get a machine, but a partner at their side!

Our team provides tips for optimal application, helps to determine parameters, including for difficult materials, and provides support during start-up – even after long downtimes, as was the case with Charter Wire.

Our well-qualified employee on site in the USA inspected the condition of the welding machine at the customer's plant and determined the measures required to restore everything to perfect working order.

During a second visit, parts were replaced, safety-relevant functions were tested and preventive maintenance tasks were carried out.

The installation of the machine at the new location was supervised, and its commissioning as well as the training of operators was carried out.

Old production line before the machine was put into storage: Butt welding machine was installed on a large, high platform.

New system: The butt welding machine is arranged on the floor in an optimal position to enable easy and ergonomic handling of the wire ends to be joined without causing excessive physical strain for operators.

Innovation from Strecker
Strecker Type SS120-FPC Vertical with hydraulic gripper arms to facilitate work

  • Excellent weld quality due to double upsetting; nearly all the heated and therefore molten material is pressed out of the joint, which produces a weld with extremely high strength.

  • The automatic deburring integrated into the process provides welded joints with exactly the same diameter as the original material. Reworking through manual deburring is unnecessary, meaning the associated debris is eliminated. This is an enormous step forward considering that earlier, using conventional welding machines, the welding burr had to be removed through time-consuming, laborious manual work! Automatic deburring means not only enormous time savings, but also simplification of the operator's work.

    Additionally, there is no risk of wire breaks due to excessive deburring, i.e. a reduction of the cross-section at the welded joint.

  • Repeatable, exactly reproducible welded joints of the highest quality with the same diameter, even with difficult materials, form a solid, reliable basis for further manufacturing processes and contribute to quality assurance.

  • The machine offers simple, user-friendly operation even for personnel without special qualifications. Further facilitating the work are the hydraulic gripper arms, which drastically reduce the physical strain on the operators when clamping the two ends of the coils to be joined into the welding machine. The workstation is usually manned by only one operator, thus saving personnel capacity in production.

The result

There was no need for the customer to invest in a new welding machine. Thanks to the competent work of the Strecker service engineer in the USA and the support of specialists from our headquarters in Germany, the welding machine, which was over 10 years old, was made operational once again.

The device is being used optimally at the new location and delivers repeatable, high-quality welding results.

The employees appreciate the reduced effort required to operate the welding machine, as the work is easier to handle and the entire workflow is simplified.

Our native-speaker service engineer remains in regular contact with the customer and provides support with questions relating to operation, preventive maintenance or, as needed, repairs, and carries out training if required.

Charter Wire LLC Logo

The Customer
Charter Wire LLC, Milwaukee (Wisconsin)
Leading manufacturer of cold-rolled and formed steel since 1936

  • Founded in Milwaukee in 1936, Charter Wire has grown to become a leading supplier and manufacturer of formed wire and cold-formed rod, as well as cold-formed and stamped components for a variety of sectors, including automotive, agricultural, construction, consumer products, industrial, and the oil and gas industries.
  • With two plants in Milwaukee, the company is well positioned to support customers with cold rolling and forming technology needs.
  • Charter Wire LLC is a member of the privately owned Charter Manufacturing group of companies, and jointly they are ideally equipped to provide world class support, service and short turnaround times.
To the customer’s website

Machine from the success story Charter Wire LLC

Structural Steel Diameter from 8 to 30 mm

SS120-FPC-VERTIKAL
SS120-FPC-VERTIKAL
To the Strecker Machine Finder

Write to us
Do you have questions about this Strecker success story?

Being available for our customers is very important to us. If you have any questions or requests, simply use our contact form to write to us.

Sigrun Möbus
sales director, authorised officer
German / French / English / Spanish
Phone: +49 6431 / 96 10 - 15
s.moebus@strecker.de

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