BS-5561-1979.pdf

BRITISH STANDARD BS 5561:1979 Specification for Spools for copper wire UDC 621.798.114:669.3 426 Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 This British Standard, having been prepared under the direction of the Non-Ferrous Metals Standards Committee, was published under the authority of the Executive Board and comes into effect on 31 May 1979 © BSI 12-1999 The following BSI references relate to the work on this standard: Committee reference NFE/12 Draft for comment 75/41940 DC ISBN 0 580 10207 6 Cooperating organizations The Non-Ferrous Metals Standards Committee, under whose direction this British Standard was prepared, consists of representatives from the following Government department and scientific and industrial organizations: Aluminium Federation Association of Bronze and Brass Founders BNF Metals Technology Centre* British Electrical and Allied Manufacturers Association (BEAMA) British Lead Manufacturers Association British Non-ferrous Metals Federation* Copper Development Association* Electric Cable Makers Confederation* Institute of British Foundrymen Institution of Mechanical Engineers Institution of Mining and Metallurgy Institution of Production Engineers Institution of Structural Engineers International Tin Research Institute Lead Development Association Light Metal Founders Association London Metal Exchange Magnesium Industry Council Ministry of Defence* National Brassfoundry Association Non-Ferrous Metal Stockists* Royal Institute of British Architects The Society of Motor Manufacturers and Traders Limited Zinc Development Association Individual expert The organizations marked with an asterisk in the above list, together with the following, were directly represented on the committee entrusted with the preparation of this British Standard: British Railways Board Covered Conductors Association Institute of Sheet Metal Engineering Post Office Rotating Electrical Machines Association (BEAMA) Telecommunication Engineering and Manufacturing Association (TEMA) The Metals Society The Transmission and Distribution Association (BEAMA) Wire Machinery Association Individual company Amendments issued since publication Amd. No.Date of issueComments Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 © BSI 12-1999i Contents Page Cooperating organizationsInside front cover Forewordii 1Scope1 2References1 3Materials and construction1 4Dimensions1 5Tolerances and limits2 6Driving mechanism4 7Wire anchor holes4 8Filling of spools4 9Wrapping and labelling4 Figure 1 Spool dimensions2 Table 1 Dimensions of spools1 Table 2 Dimensional tolerances and run-out (FIM), cylindricity and concentricity limits3 Table 3 Driving mechanism4 Table 4 Filling of spools4 Publications referred toInside back cover Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 ii © BSI 12-1999 Foreword This British Standard has been prepared under the direction of the Non-Ferrous Metals Standards Committee from a draft by the High Conductivity Copper Group of the British Non-Ferrous Metals Federation. The High Conductivity Copper Group recognized the need to establish a basis for the standardization of spools used for winding bare drawn copper wire for further internal processing by the manufacturer or for supply to customers for off-winding by established methods including ballooning over the flange. The progressive development of faster wiredrawing and processing speeds demands improved winding and tensioning control standards and in many cases larger package weights. In discussion with wiredrawing machinery makers, it was evident that the practical development of automatic controls to improve the quality of winding is seriously impeded by the wide variety of spools in current use. As a long term project, therefore, the High Conductivity Copper Group decided to establish a limited range of wiredrawing spool sizes in the interests of standardization. The first step was to determine a reasonable progression of nominal copper capacities and acceptable parameters for flange to barrel ratios suitable for ballooning and other non-rotational off-winding methods. In collaboration with manufacturers of spools and wiredrawing machinery, consideration was also given to other important features such as larger barrel diameters to reduce stress at elevated wiredrawing speeds, optimum bore diameters for secure spool mounting, standard driving mechanism and material availability. In addition, this standard is generally consistent with the requirements of the German Standard DIN 46397 which deals with annealing and machine spools. The selected dimensions generally conform to the R10/R20 basic series of preferred numbers but with certain exceptions which are related to practical considerations, including the availability of standard sizes of steel tube suitable for machining to the smaller barrel diameters. Because of the very large capital investment in existing spools and, in some cases, the problems associated with machinery limitations, no rapid change is envisaged. In the longer term, however, the increasing use of standard spools will facilitate the development of improved automatic winding controls and simplify the design of spooling and off-winding equipment. A British Standard does not purport to include all the necessary provisions of a contract. Users of British Standards are responsible for their correct application. Compliance with a British Standard does not of itself confer immunity from legal obligations. Summary of pages This document comprises a front cover, an inside front cover, pages i and ii, pages 1 to 4, an inside back cover and a back cover. This standard has been updated (see copyright date) and may have had amendments incorporated. This will be indicated in the amendment table on the inside front cover. Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 © BSI 12-19991 1 Scope This British Standard specifies the dimensional requirements for reception spools for bare copper wire drawn and wound at elevated speeds and suitable for batch annealing where required. It includes recommendations for tolerances, bore profiling and driving mechanism. 2 References The titles of the publications referred to in this standard are listed on the inside back cover. 3 Materials and construction Spools shall be so constructed and made from such materials that they are of adequate strength for their intended use. The flange rims may be plain or with heavy duty curled edges. Normally, spools are constructed from a grade of steel suitable to withstand the mechanical stresses imposed in winding at high speeds of rotation and suitable for repetitive batch annealing. For applications not involving batch annealing, spools may be constructed from other materials such as moulded plastic or aluminium alloy at the discretion of the purchaser. Constructional details shall be the responsibility of the spool manufacturer unless otherwise agreed between the purchaser and the supplier. 4 Dimensions The spool size shall be denoted by the nominal copper capacity and flange diameter required. The dimensions of the spools shall be as detailed in Table 1 and may be identified by reference to Figure 1 which does not necessarily illustrate the spool construction. Table 1 Dimensions of spools Nominal capacity Flange dia. D1 Barrel dia. D2 Bore dia. D4 Traverse L2 Flange barrel ratio D1/D2 Max. overall width L1 kg 10 25 a25 50 100 250 450 600 650 1 000 mm 160 250 224 315 400 560 630 710 710 800 mm 95 175 145 190 224 315 355 400 400 450 mm 80 127 127 127 127 127 127 127 127 127 mm 160 200 200 224 250 315 400 400 450 560 1.68 1.43 1.54 1.66 1.79 1.78 1.77 1.78 1.78 1.78 mm 180 240 235 270 300 370 460 460 510 630 b10 b25 178 235 107 150 97 133 152 176 1.66 1.57 165 200 a Alternative spool size for 25 kg capacity. This size provides a lower cost spool for applications where the smaller barrel diameter is acceptable. b These are the actual dimensions of spools in common use in UK and many European Countries for fine copper wire production. They are therefore shown separately as established sizes which may be phased out in the longer term. Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 2 © BSI 12-1999 5 Tolerances and limits It is recommended that the dimensional tolerances and run-out limits should be agreed between the purchaser and the supplier and defined on individual spool drawings. In cases where such requirements are not specified, the following tolerances and limits are offered as a general guide. 5.1 The tolerances on spool dimensions should conform to those shown in Figure 1 and detailed in Table 2. 5.2 General notes on tolerances and limits. Spools of 10 kg and 25 kg capacity are normally machined all over; suitable tolerances are shown in Table 2. Run-outs, cylindricity and concentricity on such spools are negligible and are therefore excluded from the table. For spools of 50 kg capacity and larger, the tolerances given are based on a curled edge flange construction with barrel and bore machined concentrically. 5.3 Bore taper. Except where parallel bores are specified, the bore extremities shall be machined to an included angle of 40° ± 0.5° and to a nominal depth of 12 mm. To avoid damage to the outer edge of the taper, a radius or chamfer should be incorporated. 5.4 Traverse. The traverse width shall be measured on the barrel line. 5.5 Overall width. The overall width shall be measured through the bore. 5.6 Run-out of flange face (FIM) Limit (1). This measurement shall be taken 20 mm below the periphery of the flange. Every effort shall be made to ensure that the angle between flange and barrel is not less than 90°. 5.7 Surface texture. Recommended levels of surface texture are as follows. 5.8 Dynamic balancing. It is recommended that spools for use at high rotational speeds shall be dynamically balanced. The permissible residual unbalance shall be agreed between the purchaser and the supplier and shall comply with the requirements of ISO 1940. The recommended grade is G.40. NOTEDependent on the rotational speed and balance quality grade selected, a dynamically balanced spool may require a finer cylindricity limit (2) than that detailed in Table 2. Figure 1 Spool dimensions General machining1.6 4m Ra (Roughness grade number N7)a Wire contact surfaces 0.8 4m Ra (Roughness grade number N6) a See BS 308-2 Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 © BSI 12-19993 Table 2 Dimensional tolerances and run-out (FIM), cylindricity and concentricity limits Flange dia. D1 Barrel dia. D2 Bore dia. D4 Traverse L2 Max. overall width L1 Limit (1) (run out) see 5.6 Limit (2) (cylindricity) Limit (3) (concentricity) mmmmmmmmmmmmmmmm 160 ± 0.595 ± 1.0 250 ± 0.5175 ± 1.0 224 ± 0.5145 ± 1.0 315 ± 1.0190 ± 1.00.400.200.60 400 ± 1.0224 ± 1.00.600.250.60 560 ± 1.5315 ± 1.50.800.300.80 630 ± 1.5355 ± 1.50.800.401.0 710 ± 1.5400 ± 1.51.00.401.0 710 ± 1.5400 ± 1.51.00.401.0 800 ± 1.5450 ± 1.51.00.401.0 178 ± 0.5107 ± 1.0 235 ± 0.5150 ± 1.0 NOTEDimension D3 is sometimes used to denote the diameter of flange support plates if required but does not appear as such in Table 1 and Table 2. 80+ 0.25 0 160+ 0 0.25 180+ 0 0.25 127+ 0.25 0 200+ 0 0.25 240+ 0 0.25 127+ 0.25 0 200+ 0 0.25 235+ 0 0.25 127+ 0.25 0 224+ 0 0.60 270+ 0 0.60 127+ 0.25 0 250+ 0 0.60 300+ 0 0.60 127+ 0.40 0 315+ 0 0.60 370+ 0 0.60 127+ 0.40 0 400+ 0 1.0 460 + 0 1.0 127+ 0.40 0 400+ 0 1.0 460 + 0 1.0 127+ 0.40 0 450+ 0 1.0 510 + 0 1.0 127+ 0.40 0 560+ 0 1.0 630+ 0 1.0 97+ 0.25 0 152+ 0 0.25 165+ 0 0.25 133+ 0.25 0 176+ 0 0.25 200+ 0 0.25 Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 04 13:47:54 GMT+00:00 2006, Uncontrolled Copy, (c) BSI BS 5561:1979 4 © BSI 12-1999 Table 3 Driving mechanism 6 Driving mechanism As a general guide, the number, diameter and PCD of drilled driving holes should be as detailed in Table 3. The driving holes shall be equidistantly spaced in both flanges. The provision of external driving or tensioning lugs, if required, shall be by agreement between the purchaser and the supplier. It is recommended that the nominal diameter of driving holes should not be exceeded. 7 Wire anchor holes The provision of inner and outer wire anchor holes in one or both flanges to secure the starting and finishing wire ends shall be by agreement between the purchaser and the supplier. If specified, a shallow inclined slot or groove may be provided in the flange rim so that a wire tail from the starting end may be secured to an outer flange face to permit the welding of wire for continuous off-winding. 8 Filling of spools Spools shall not be completely filled. In all cases there shall be an adequate radial freeboard between the outer layer of wire and the rim of the flange. The radial freeboard will vary according to the size and type of spool and diameter of wire to be wound. Typical values and calculated copper wire capacities are detailed in Table 4. 9 Wrapping and labelling 9.1 Protective wrapping. The contents shall be protected by a suitable wrapping which shall have no deleterious effect on the copper wire. The type of protective wrapping will be dependent on the method of handling and storage but shall be adequate to prevent damage to the wire in transit. 9.2 Labelling. A label giving a description of its contents shall be affixed to each spool. Spools supplied to customers on a returnable basis shall be suitably identified with the manufacturers name, reference number and tare weight if required. Table 4 Filling of spools Nominal capacity Flange diameter Barrel diameter Driving holes per flange numbernom. dia.PCD kgmmmmmmmm 1016095 25250175 a25 224145 50 100 250 450 600 650 1 000 315 400 560 630 710 710 800 190 224 315 355 400 400 450 2 4 4 4 4 4 4 16 20 25 25 35 35 35 155 175 250 250 320 320 320 a Alternative spool size for 25 kg capacity. No driving holes required Nominal capacity Flange diameter Radial freeboard Packing factor Copper capacity kg 10 25 a25 50 100 250 450 600 650 1 000 mm 160 250 224 315 400 560 630 710 710 800 mm 7.5 7.5 7.5 15.0 15.0 22.5 22.5 22.5 22.5 25.0 0.80 0.80 0.80 0.80 0.75 0.75 0.75 0.75 0.75 0.75 kg 10.7 27.5 25.3 56.3 114 274 453 592 665 1 056 Sizes in common use 10 25 178 235 7.5 7.5 0.80 0.80 12.8 25.4 NOTEThe greater radial freeboard allowed for nominal spool capacities of 50 kg and above is intended to cover spools with curled edge flanges. a Alternative spool size for 25 kg capacity. Licensed Copy: sheffieldun sheffieldun, na, Mon Dec 0