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SEMI AUTOMATIC RESPOOLING

Shortest Cycle Time thanks to: Shortest Ramp times, Fastest Respooling speed, Limited Downtime.

The POLI series is by no means an icon relating to past markets, but is in actual fact still a standard for quality, excellence and productivity. Today it stands out among its competitors, and compared to data that emerges from research in similar products that come from developing countries, the numerous advantages the POLI offers are obvious.

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The POLI can achieve a productivity at least a third higher compared to some emerging market respoolers.

semi_automatic_respooling_graph.jpg

Results based on the same operator spool change-over time and minimum required quality wire and spools characteristics.
* 30m/s top speed – 20s acceleration-deceleration ramps ** 20m/s top speed – 30s acceleration-deceleration ramps

This implies that the same productivity is obtained with 2 POLIs as opposed to 3 of the other machines, 2 operators instead of 3, one less machine to maintain and one third less of the floor- space occupied!

Gimax respoolers have another distinctive feature – since before the turn of the century, these machines have been equipped with systems to recover energy.
The respooling process has continuous moments of acceleration and deceleration.

Energy recovery Gimax

Thanks to the innovative concepts utilized electronically, it is possible to recover kinetic energy during the moment of deceleration, which generally lasts as much as the acceleration.

The capability to recover and return energy to the network can potentially allow considerable savings in terms of energy since the energy supply is not dissipated in the form of heat when the brake is applied to slow down the machine.

POLIDIGITAL SERIES

The “POLI” of respoolers has been manufactured by Gimax since the 1980s and the units are a standard in the industry.

Since this machine made its debut on the market, Gimax has sold around 1300 and quite a few of the very first ones sold are still in operation.

  • Precision layer and random winding

  • Operator required to start / terminate respooling operation

  • Standard Siemens control system with Profinet communication protocol

  • Touch screen user interface and ethernet connection

  • Regenerative inverter & high efficiency motors

  • Highest flexibility

  • Gimax Industry 4.0

SAW version for sub-arc wire, with additional

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  • Spool-less coil option

  • Extractors for effortless removal of heavy coil/spool

  • Large dancer pulleys

  • Optional discharge system

POLIDIGITAL

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

WIRE DIAMETER

From 0,8mm (0,032”) up to 2,4mm (0,094”)*

TYPE OF PACKAGE

Wire baskets, plastic spools (with or without grooves), fiber spools

SPOOL/BASKETS FLANGE SIZE

From 100 to 350mm(4” to 14”)

MAX. LINE SPEED

35 metres / sec(6900 feet/min)

PAY-OFF REEL SIZES

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

POLIDIGITAL SAW

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

WIRE DIAMETER

From 0,8mm (0,032”) up to 5,0mm (0,196”)**

TYPE OF PACKAGE

Wire baskets, plastic spools (with or without grooves), fiber spools and coils (with or without liner)

SPOOL/BASKETS FLANGE SIZE

From 100 to 435mm(12” to 17”)

MAX. LINE SPEED

20-25 metres / sec(4000-4900 feet/min)

PAY-OFF REEL SIZES

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

*2,4mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 2,2mm
**5,0mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 4,5mm

OMNI SERIES

The semi-automatic “OMNI” series offers highly increased flexibility and production – the machine handles a large range of wire diameters and spool size.

The line is operator frendly, requires an operator but the number of operations the operator is required to do are limited; load the empty spool and hook the wire, and at the end of the process, cut the wire and hook it to the side of the spool.

The tooling holding the spools or wire baskets can be automatically adjusted electronically to compensate tor any tolerances in the wire diameter. The line is also equipped with a PLC to control all the functions and to signal status of the line or any alarm conditions. Like all Gimax respoolers, one of its main advantages is the capability of automatically detecting any error in the precision winding and to return to a point prior to the error so that it can be corrected.

  • One operator easily handles two machines

  • Automated discharge system for finished spools or coil without interfering with the operators

  • High degree of flexibility, Omni can handle many spool sizes and types

  • Large range of wire diameters

  • Precis1on layer or Random winding

  • Siemens integrated control system with Profinet communication protocol

OMNI

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

WIRE DIAMETER

From 0,8mm (0,032”) up to 2,4mm (0,094”)*

TYPE OF PACKAGE

Wire baskets, plastic spools (with or without grooves), fiber spools

SPOOL/BASKET FLANGE SIZE

From 100 to 350mm(4” to 14”)

MAX. LINE SPEED

35 metres / sec(6900 feet/min)

PAY-OFF REELS SIZE

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

OMNI SAW

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

TYPE OF PACKAGE

Wire baskets, plastic spools (with or without grooves), fiber spools and coils (with or without liner)

SPOOL/BASKET FLANGE SIZE

From 100 to 435mm(12” to 17”)

MAX.LINE SPEED

30-35 metres / sec(6000 feet/min)

PAY-OFF REELS SIZE

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

WIRE DIAMETER

From 0,8mm (0,032”) up to 5,0mm (0,196”)**

* 2,4mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 2,2mm.
** 5,0mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 4,5mm.

***All the conditions indicated above can vary depending on the type of material that the machinery has to handle, on the ability of the operator, on the settings of the machine, on the level and quality of maintenance, on the type of reels, wire baskets and spools used and on residual operation attributed to the operators.

SPECIAL

 POLIDIGITAL K400

The POLI K400 is designed to handle 400mm wire baskets that have a width of 215mm.

This version of the POLI SAW has an extended frame making it capable to handle the K400 wire baskets that have an external width of 215mm (8,5”), designed to hold 40kg (90lbs) of aluminium wire precision layer wound.

As well as the K400 basket, the unit can make coils of the same size, and also handle K300 (12”), K415/435 (16/17”), basket and coils and D300 (12”) plastic spools.

  • Precision layer or Random winding.

  • Siemens integrated control system with Profinet communication protocol.

POLIDIGITAL K400

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

WIRE DIAMETER

From 1,6mm (0,063”) up to 5,0mm (0,196”)*

TYPE OF PACKAGE

Wire baskets, plastic spools, coils

SPOOL/BASKETS FLANGE SIZE

OD 400mm (15,7″) and external width from 90 to 215mm (8,5″)

MAX. LINE SPEED

Up to 20 metres / sec (4000 feet/min)

PAY-OFF REEL SIZES

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

*5,0mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 4,5mm

SPECIAL

 POLIDIGITAL K800

The K800 is designed for larger capacity  wire baskets, but maintaining all the standard features of the POLIDIGITAL SAW.

Like the standard POLI SAW, this unit is suitable for precision layer winding of large diameter solid or tubular (sub arc) wire onto wire baskets up to 415 / 435mm (16" / 17") but can also handle 800mm (32") wire baskets. The unit will also be able to make coils (with ties) of the same sizes as the wire baskets.

POLIDIGITAL K800

TYPE OF WIRE

Low carbon steel, stainless steel, flux cored wire, aluminium alloy wire, brazing wires

WIRE DIAMETER

From 1,6mm (0,063”) up to 5,0mm (0,196”)*

TYPE OF PACKAGE

Wire baskets and coils (with or without liner)

WIRE BASKETS SIZE

From 415mm to 800mm (16" to 32")

MAX. LINE SPEED

Up to 20 metres / sec (4000 feet/min)

PAY-OFF REEL SIZES

Up to 700kg (1500lb) with flange size 760mm (30“)
Up to 1000kg (2200lb) with flange size 800mm (32“)
Up to 1500kg (3300lb) with flange size 1000mm (39“)

*5,0mm with aluminium and with flux cored wires, with solid steel and stainless steel, max. diameter is 4,5mm

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