Wire Straightening: Back to Basics

BRISTOL, Conn. - May 24, 2019 - PRLog -- Here at Novo Precision we are regularly confronted with issues related to the manufacture of small wire components  that, more often than not, are a direct result of the wire not being straight enough prior to the forming operation.  As a matter of fact, this was the driving force that led Novo Precision into the development of our standard line of Precision Wire Straighteners (PWS) in 1981.  Being unable to find an off-the-shelf wire straightener that had the precision and features necessary to satisfy a demanding wire application we were tooling, it required that we design and build one for the job.  As our customers saw the unit in operation, more and more of them insisted that we make them one.  The rest is history, as they say, and resulted in our first standard product line.

What makes our Precision Wire Straighteners unique, you ask?

The center to center distances on our bearings are the closest on the market.  This feature, coupled with the smaller diameter bearings we incorporate means that our PWS reacts to fine adjustments more aggressively.  Typically, a .001" adjustment on our bearing setting will have an effect on the wire.

The 120° "V" groove we utilize is precision ground into each bearing.   If the groove-to-ID concentricity is not held, the straightening results will not be consistent.  Thus, inferior bearings will not work in a Novo Precision PWS.  When dealing with softer materials or tubing where the minimization of marking or deformation of the OD is critical, the precision bearings can be ground with a radius to match the wire diameter. Note that this makes the bearings specific to that particular wire diameter.

The "Q" Bearing Contact and "S" Datum Edge are precision surfaces.  The dimension used for a specific set up can be accurately recorded and repeated for subsequent set ups.  This can take much of the guess work out of straightener set up.  We all know that variations  from lot to lot in wire runs will affect the straightener settings.  The recorded dimensions will get you back in the "ballpark" much faster, and allow the operator to concentrate on fine tuning the adjustments as required.

For optimum straightening results, we always recommend our 4 plane configuration.  This set up provides for controlling the wire from eight different directions, and can be useful for situations where the wire supplied has a high degree of helix present.  What if you already have a Novo 2 plane PWS?  Not to worry. You can purchase a standard adaptor bracket to convert your 2 plane over to the standard 4 plane configuration.

With each PWS we ship, a comprehensive manual is included.  In this manual, our recommended settings for specific wire diameters are indicated.  We start with a "QS", or Quick Set dimension, which is the dimension to set the lead-in bearings at the point that they just make contact with the wire.  From there, setting dimensions for percentages of wire break on the remainder of the bearings are listed.  Click on the link at the bottom of this page in the blue box which will bring you to the standard Novo Precision PWS Instruction Manual. You can also go to our website homepage and  navigate to the same manual by clicking on "Precision Wire Straighteners", then go to the "Click Here For Specifications" link, scroll down to the "Manuals" heading, and click on "PWS-0-05 Instructions 042304.PDF",  and you will be linked to the manual.

In the manual you will find the suggested and proven method we developed for setting up a TAK PWS that can be applied to most wire types.  It should be noted that other set-up processes and methods have been used that prove to be just as effective, however we find that starting with the process outlined in the manual will generally provide acceptable results.

We are always receptive to feedback concerning successes (and failures) of those using our products.  What better way to make improvements than by utilizing input from hands-on experiences? Drop us a note describing your trials and tribulations.  We'll put it to good use. For now check out our latest wire straighteners at https://www.novoprecision.com/products/wire-straightener-...

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