Automatic Take-up Options

A question on the mind of many of our customers has been “how can they reduce their fence roll size and boost productivity of their machines without compromising product quality?”. Producing a roll of fence which is presentable, not over tensioned, and the optimum roll diameter for standard palletizing configurations is becoming difficult to achieve with the wide range of products now expected by the market.

At South Fence we have done extensive research on this topic and have determined that this issue is as a result of inefficient stacking/layering of the fence as it is wound onto the roll. This results in knots sitting on top of one another rather than besides each over, causing the roll to stack quickly and the diameter to bulk. A common technique used on older machines to solve this is to increase the torque of the windup to effectively “crush” the roll. However, this compromises roll quality as the line-wires can be stretched past their breaking point resulting in damage to the product and loss of crimp.

The solution to this pressing issue is dynamic fence layering control that can now be achieved with South Fence’s range of Automatic Take-up Options. This system drives the fence layering, ensuring precise controlled layering of the fence as it is wound onto the roll and prevents over-torquing conditions. We have also taken the opportunity to implement various degrees of automation with each take-up option, boosting productivity and safety for our customers

Learn more about the options below, contact our team for quotes and further information. These take-ups are suitable for both Stiff Stay and Fixed Knot machines, with retrofit options available to existing machines currently in the market.

Option 1 (AT-OP1) – Drive Roller Take-up

Our base level option that achieves dynamic fence layering control. This allows for rolls up to 10% smaller in diameter to be produced without over tensioning line-wires and improving fence crimp.

Option 2 (AT-OP2) – Option 1 + Clamping Trolley Take-up

Options two utilises the same dynamic fence layering control coupled with the clamping trolley. The clamping trolley enables rolls to be clamped before they are cut free from the machine. The roll can then be stripped straight away without the need to “tie in” the fence roll. The roll is captured to prevent roll off when producing large rolls, and when the roll is removed the trolley can be returned automatically to beneath the mandrel. This helps to reduce machine downtime as well as unnecessary operator interaction.

Option 3 (AT-OP3) – Option 2 + Automatic Cutter Take-up

Option three takes option two one step further with the integration of an automatic cutter that locates and cuts the roll free from the machine. As the roll is clamped by the clamp trolley, the slack section of cut fence can be rolled up and stripped automatically. This further saves time for the operator as well as eliminates Repetitive Strain Injuries related to frequent cutting of high tensile wire.

Option 4 (AT-OP4)– Fully Automatic Clamp, Cut, Strip & Reload Take-up

Option four is our premium option that allows for full automation of the take-up process. Fence rolls are clamped, cut, and stripped by the machine with no operator interaction. The machine then feeds fence into the mandrel and restarts the fence roll winding process. No operator interaction is needed, allowing the operator’s time to be utilised on other aspects such as preventative maintenance. Automation of the entire stripping process allows for consistent roll stripping of one minute per cycle.

The Take-up Options have a full complement of safety systems to ensure your operator's safety. A full and comprehensive risk assessment is conducted on all South Fence machines in line with international safety regulations and CE compliancy.

Machine Safety Features:

Monitored Light Curtains on both the front and rear of the machine
Area Scanners to detect workers operating in hazardous zones
Siemens safety PLC to monitor all safety related control features
Punch panel fixed guard system for easy visibility
Festo pneumatic safety valves and regulators
Comprehensive machine warning signage
HMI operator fault banner system
Safe speed monitoring of all axes for machine set-up and fault finding

Compliance Standards:

ISO 12100:2010	General Principles for Design – Risk assessment and reduction
ISO 13857:2008	Safety Distance to prevent hazard zones being reached by upper and lower limbs
ISO 13855:2010	Positioning of safeguards with respect to the approach speed of parts of the human body
ISO 13850:2015	Emergency stop function – Principles of Design
ISO 13849-1:2015	Safety-related parts of control systems – General principles for design
ISO 13849-2:2012	Safety-related parts of control systems - Validation
EN 60204-1:2006 + A1:2009	Electrical equipment of machines – General requirements
EN 62061:2015	Safety of machinery - Functional safety of electrical, electronic and programmable electronic control systems
AS 4024.1-2014	Safety of Machinery
AS 1657-2013	Fixed platforms, walkways, stairways and ladders – Design, construction and installation
AS 1554.3:2014	Structural steel welding – Welding of reinforcing steel

	AT-OP1	AT-OP2	AT-OP3	AT-OP4
800 Diameter Rolls at 500 meters	✔	✔	✔	✔
10% Roll Diameter Reduction	✔	✔	✔	✔
Reduced Line-wire Stretch & Improved Fence Crimp	✔	✔	✔	✔
Clamping Trolley to Eliminate "tie in" Time	✘	✔	✔	✔
Automatic Roll Cutting to Eliminate Operator Fatigue	✘	✘	✔	✔
Fully Automated Roll Cut, Strip , Feed, and Restart to Guarantee 1 minute Roll Stripping Time	✘	✘	✘	✔
Additional Operator Time Gained Through Automation	✘	✘	✘	✔
Compatible Fence Machines	Stiff Stay Machine Fixed Knot Machine
Retrofit to Existing Machines	Available on request
Automatic Label Inserters	Available on request
Maximum Roll Length	500m (1640ft)*
Maximum Roll Diameter	800mm (31.5")*
Maximum Roll Weight	1000 kg*