Spoolers and Coilers — Frequently Asked Questions

We've listed answers to some of our most common Spooler and Coiler questions for your convenience.

Why are spoolers and coilers used for?

Spoolers and coilers are useful for any application requiring neat, uniformly wound packages, with minimum defects. Spooling may also be used to provide for an off-line quality inspection system that will not interrupt the manufacturing process or as a remedial measure to compensate for poorly wound spools due to inadequate take-up equipment on older processing lines.

Spooling may be used to improve the uniformity of packaging on older processing lines, thereby fulfilling customer quality requirements and perhaps even opening up new markets. Repackaging of wire from larger reels, off-line inspection, and a considerable number of more specialized applications are all possible.

Is it possible to purchase an appropriate spooling system on a limited capital equipment budget?

What confuses the issue is the wide range of customized spooling systems available. Rarely are two ever the same. However, by matching requirements of the application with the appropriate options, it is possible to specify a moderate to low cost system that will get the job done effectively.

How do spoolers work?

A typical, cost-effective spooling application will have a master pay-off reel of approximately 100 lbs. paying off to 5 or 10 lb. reels. Usually spooling stops automatically at a predetermined count of meters or feet. As the spooler approaches the pre-set limit, the spool begins to slow down and stops at the target length allowing a single operator to monitor four to five machines.

What has to be considered in specifying spoolers?

There are literally dozens of custom variables that need to be considered when specifying even a modest system. Once the manufacturer has the complete story regarding the specific application, they can help you choose the basic body style of an optimal spooling system and the various options that will be required.

There are several key variables, which significantly effect the trade-offs between cost and capability. Regardless of how favorable the cost justification is for spooling, there are many companies today that have a firm cap on capital equipment spending. For such companies, the primary question is not what will it cost to achieve set goals, but rather, how much can I get with the dollars I have available.

How can we acquire a spooler that will be in our price range?

Sometimes a minor change in the specifications can go a long way toward reducing the cost of the spooler. If this is the case, the user and builder should seriously consider if it would be possible to revise the specifications to achieve the desired result. It is also possible to purchase very sophisticated spoolers with features such as computer interface for monitoring speed, tension, and traverse control, as well as automatic loading, unloading, and changeover of spools. Such systems have an important role to play in high-volume, fully automated manufacturing operations. The value of these benefits must be weighed carefully against the expense of the system.

What number and size of spools can be accommodated?

Spoolers can be designed to accommodate any number and size of spools, but for the small, cost-effective systems we are talking about, one or two spools will do nicely. Single pay-out/ dual take-up systems are very productive because while one full spool is being unloaded, an empty spool can be reloaded on the alternate spindle. The weight of the spool is very important because it dictates the size of the spindle and drive horsepower required. It is not unusual for a customer to have spools that fall in several different size ranges. In this case a dual spindle spooler with two different sized spindles might be recommended.

What are the most economical spooling speeds?

It is possible to design spoolers that operate at speeds greater than 5000 fpm, but to achieve those speeds, you have to pay disproportionately for a heavier duty machine and perfectly balanced components. A spooler that can take 3000 fpm in stride will literally be shaken apart at higher speeds. The costs of building a system rugged enough to withstand these additional forces could be as much as six times greater. Therefore, if you are looking for the best value for your machinery dollar, don't specify a spooler that runs at process speeds higher than your current application actually requires.

What are the benefits of constant vs. variable speeds?

Spooling can take place at constant or variable process speeds. Constant process speed costs more because it uses a tachometer or other feedback system to vary spindle rpm. It compensates for the increase in velocity as the spool increases in diameter. If it is important for you to ensure continuous spooling at maximum speed or if it is desirable to keep inspection conditions constant, choose constant speed.

What role does back tension play in spooling?

There is an ideal tension for each wire size, but very rarely is a manufacturing operation involved with just one size. For this reason, spoolers are provided with variable tension. However, the range of variable tension should be limited to a 5:1 ratio, keeping in mind that the physical braking system also has to deal with a wide variation in torque produced by the continually changing package core to package OD ratio. If you have a brake that is strong enough to create 10 lbs. of tension when a large spool is full, it probably would not have enough resolution to adjust down to 1 lb. or tension when a small spool is almost empty. Therefore, a spooler with a minimum tension of 1 lb. should have a maximum tension of 5 lbs. If the minimum tension is 1/2 lb. then the maximum should be no greater than 2-1/2 lbs. Tension ratios greater than 5:1 require non-standard systems. Like winding speed, tension is related to the reel diameter at any time, but in this case, is inversely proportional.

What factors are involved with constant tension?

If constant tension is desired, a system such as a dancer, which monitors line tension between the payoff and the take-up, automatically adjusts the payoff drag. This provides constant tension accurate to ± 5%. If an even more accurate constant tension is desired, it could be measured in process by a load cell-type system or some other means.

What about sensitive or light gauge product?

For very sensitive or light gauge product, it is desirable to have minimal tension. Minimal tension can be within grams. A powered payoff is usually required to eliminate breakaway tensions on start-up. For material requiring minute tension, long ramp times are generally required.

What ramping factors should be considered?

Ramping can be smooth and gradual or the process could be at speed instantaneously (shock loaded). For example, a 1000 lb. reel can be brought up to a speed of 1000 fpm in 20 seconds using a 2-hp drive. To get the same reel moving at 1000 fpm in 6 seconds calls for a 5-hp motor. Accumulators in the system provide smoothness and control.

What is the difference between wire traverse vs. oscillating spool?

The traverse system moves the wire back and forth along the horizontal face of the spool to provide uniform winding. The better the traverse system selected, the better the winding and the more costly. However, even the best designed and engineered wire traverse tends to put camber in the wire and for such applications as flat wire and fiber-optics, this cannot be tolerated. In such cases it is best to oscillate the spool while the centerline of the product remains fixed through accurate guiding.

Can the spooler be used as an inspection system?

Even today you can go into some plants and see little machines with a payoff and a take-up running at 100 fpm. Standing between them is an operator who is checking for flaws. This is a terribly inefficient use of manpower. A spooler used as a simple off-line inspection system can count the number of flaws it finds on the spool. More complex systems use “auto reversing to flaw”. When a flaw is detected, an alarm is sounded, and the spooler automatically stops so that an operator can repair, tag, or remove it, as required. Automatic flaw detection systems incorporate a sparker, laser mike or optical inspection devices. Such a system can operate at speeds of 1500 fpm and greater.

What is the key to acquiring a cost effective spooling system?

A good spooling system adds value to the end product and can usually withstand the most stringent cost justification analysis as long as the specified system does not significantly overstep the requirements of the application. Requesting excess capacity on the chance that it might be needed sometime in the future, typically increases system costs exponentially. Therefore, the key to acquiring the spooling system you need at a reasonable cost is to keep the specification as close as possible to the current requirements.

Why do I need to fill out an “Application Data Sheet"?

Our specifications are broad guidelines. Any spooler can be customized and matched to your specifications. Please consult us about your special needs. Our engineers will review each order before filling it to assure that it meets your requirements.