IT’S ALL ABOUT TIME
A NEW AND INNOVATIVE PROCESS LETS SLINGMAKERS SWAGE STEEL SLEEVES ON FLEMISH EYE SPLICES WITH ONLY ONE CLOSE OF THE DIE.
NEW WORLD VERSUES OLD WORLD
Most wire rope sling fabricators in North America make wire rope slings by hand splicing flemish eyes over which a steel sleeve is mechanically swaged. The swaging is done with a hydraulic swaging machine or “swager” using the appropriately sized dies. This fabrication method is designed to hold 65 to 75 percent of the rated capacity of the sling even without the steel sleeve intact.
Traditional swaging systems “press” a round carbon steel sleeve on the wire rope with repeated multiple closing of the die until the sleeve is completely swaged. This “multi press” system of swaging steel sleeves on wire rope is a severe process that requires considerable amount of movement of the steel. The exact number of die closures depends on the wire rope diameter. The larger the diameter, the greater the number of die closures. According to one manufacturer’s instructions, a steel sleeve 7/8” diameter wire rope sling must be positioned and pressed six times before the sleeve is completely swaged. All “multi press” type swaging system require the use of 2 stage dies on larger diameter ropes and sleeves. Typically on the diameters of 1” and larger, two dies are necessary, requiring an extra die change. The total number of recommended die closures for 1-1/2” diameter could be as many as five to ten closures, in the first stage die alone, plus five in the second stage die. Operators of the swaging machines must use their best judgment to determine exactly where and how much swaging must take place during each close of the die, making sure not to “over swage” the sleeve, since swaging can lead to work hardening of the steel. This multi press swaging process is repetitive and time consuming, even with the most experienced workers.
Most wire rope sling fabricators outside of North America produce a “loop fold-back” or “turn-back” type splice. Then they swage an aluminum sleeve with just one close of the die to form an eye. The rationale is that if the correct aluminum sleeve is swaged with the correct die on the correct diameter and construction of the wire rope, then 100% efficiency is achieved, thereby eliminating the need for back up hand splice as provide for in the North American system. The “fold-back” or “turn-back” process requires significantly less time and therefore costs less compared to the system used by most wire rope sling makers in North America.
THE BEST OF BOTH WORLDS
Now wire rope sling fabricators and users can have the best of both worlds. A new and innovative process lets wire rope sling makers swage steel sleeves on Flemished eye splices with only one close of the die. This Patented* process is called One Press® Swaging. One Press® Swaging is a proven and tested process that allows slingmakers to swage steel sleeves from 1/4” up 1-1/2” over flemished eye splice; the preferred North American method, with only one close of the die, in a matter of seconds.
*See Wire Rope News & Sling Technology February, 1999 issue, Inventors Corner, page 56, “Ergonomic Flemish eye- easy to make- easy to handle”, U.S. Patent #5,816,094 .
THE SECRET IS…………
One Press® Dies are required to swage One Press® Carbon Steel Sleeves with just one close of the die. Using the One Press® Swaging process, every sleeve is swaged to its correct finished dimension when the die is closed the first time. One Press® Swaging combines the advantages of the Flemish eye splice with a swaged steel sleeve and the benefits associated with the speed and efficiency of closing the die only once. The secret of the One Press® Swaging is in its simplicity. It is the simple single “compression” process of the One Press® that differentiates it from the more complex multiple “compression” process of multi press swaging. All multi press swaging systems compact the steel sleeve on the wire rope with repeated closures of the die in order to compact and swage the sleeve completely. A simple single compression swage is faster, more efficient, and costs less than multi press systems, but none are as fast, efficient or as easy to use as the One Press® Swaging System.
SEE AND FEEL THE DIFFERENCE
The One Press® Swaging System, consisting of the One Press® Steel Sleeves and One Press® Dies produces a distinct after swage shape that differs from its original before swage shape. Second stage dies are not required. The distant after swage shape clearly indicates to the slingmaker and users that the One Press® Sleeve has been swaged right. For the first time, slingmakers can see and feel the correct after swage shape. The use of the correctly sized One Press® Dies and the corresponding size of the One Press® Sleeves consistently produces the correct after swage shape. To guarantee 100% plus efficiency and fail safe One Press® Swaging, no other combination of dies or sleeve sizes or brands of dies and sleeves will work together to produce the correct after swage shape and desired results.
THE ECONOMICS & ERGONOMICS OF JUST ONE PRESS
One Press® Swaging eliminates the need for repeated positioning of the wire rope sling or assembly, multiple closing of the dies, and the use of a second stage die entirely. One Press® Swaging eliminates the risk of over swaging and the potential for working hardening. One Press® Swaging is both a product and process improvement, the advantages of which go beyond the obvious time and labour savings. They include reduced investment in inventory and capital equipment, less wear and tear on people and machinery, not to mention the fast delivery of the product and improved customer service opportunities. The ergonomics benefits for workers are numerous. The potential for back, hand and repetitive strain and stress injuries is significantly reduced or eliminated completely, since the number of die closures and amount of man handling required is drastically decreased while working with a One Press® Machine.
In addition to One Press® Sleeves and One Press® Dies, a complete line ergonomically friendly Fast™ Swagers are available in six standard capacities from 150 to 3000 tonnes. The 350 tonne (385 tons) and 600 tonne (660 tons) models are the most popular, swaging 1/4”-1” and 1/4” – 1 – 1/2” diameter One Press® Sleeves respectively.
All Fast™ Swagers incorporate a unique rotating die holder. The rotating die holder swivels 360° allowing the operator to easily line the dies with the wire rope sling, multi leg bridle, or assembly to be swaged. This feature eliminates the need to manhandle the master link/ring or line up the work piece with the dies. Fast™ Swager is compact and have limited moving parts. This translates into less wear, reduced maintenance, and lower operating costs. The operating noise level of the Fast™ Swager is significantly quieter than other swagers on the market today.
All 385 and 660 ton Fast™ Swagers are available with an “ all in one” or Universal die holder that accommodates not only One Press® Dies but also larger die blocks often used in other makes and brands of swagers. Dies to swage multi press sleeves, sockets, ferrules, and buttons are also available to fit directly into the standard die holders of all Fast™ Swagers.
MORE GOOD NEWS
The One Press® Swaging system is competitively priced. The cost of One Press® Swaging systems is no more expensive than other swaging systems and often costs less. The biggest savings is in the increased productivity associated with greater production with the same or less labour and man hours. One Press® Sleeves, One Press® Dies and Fast™ swager are available as a system or separately. Although One Press® Dies and One Press® Sleeves work best with Fast™ Swagers, they are also available for other makes and brands of hydraulic swagers.
One can only wonder what the cost of not adopting this time saving product and process improvement might be. Only time will tell.
