Automatic Wire Tensioner in CNC Hot Wire Cutting
In heavily twisted 4-axis cuts wire length changes constantly. Without compensation wire breakage is likely. The automatic wire tensioner solves this.
What Is an Automatic Wire Tensioner?
In 4-axis cutting left and right sides of the wire move independently. In heavily twisted cuts - truncated cones, conical columns, aerofoils - the effective wire length changes constantly during the cut. The wire alternately stretches and relaxes. Without compensation tension peaks arise that lead to wire breakage. The automatic wire tensioner compensates for these length changes automatically.
How the Automatic Wire Tensioner Works
The automatic wire tensioner works independently of the machine and software. A sensor continuously measures the wire tension. When the tension rises - because the wire is being stretched - the motor gives way and lengthens the wire path. When the tension drops - because the wire relaxes - the motor takes up the slack and shortens the wire path. This happens in real time, automatically, with no operator intervention.
When Is the Automatic Wire Tensioner Needed?
- Truncated cones - top and bottom have very different sizes
- Conical columns with strong tapering
- Wings with strong twist
- Asymmetric 3D bodies with extreme angle differences
- Cuts in which the wire length changes by more than 50 mm
Without a wire tensioner on heavily twisted cuts: the wire is over-tensioned in one place - wire breakage. Or it sags - the cut becomes inaccurate. Either way it costs material, time and nerves. For simple 2-axis cuts and normal 4-axis cuts the wire tensioner is not needed - the standard coil spring is sufficient. But for extreme 4-axis cutting it is essential.
Available for CUT2500S and CUT3000S
The automatic wire tensioner is available as an optional extension for the CUT2500S and CUT3000S. It can be retrofitted at any time - no conversion of the machine is required. For businesses that occasionally make heavily twisted cuts, retrofitting is the more economical solution.
Frequently Asked Questions
The key questions and answers on this topic.
Do I need an automatic wire tensioner?
Only for heavily twisted 4-axis cuts - truncated cones, conical columns with strong tapering, wings with strong twist. For normal 2-axis and light 4-axis cuts the coil spring is sufficient.
Which machines is the wire tensioner available for?
As an optional extension for the CUT2500S and CUT3000S. Retrofittable at any time.
How does the automatic wire tensioner work?
A sensor measures the wire tension in real time. A motor compensates for changes in length automatically - independent of machine and software.
Retrofit a wire tensioner?
We advise you on whether the automatic wire tensioner makes sense for your application.
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