• adjustment angle
  • adjustment philosophy
  • adjustment
  • defined straightening
  • distance between straightening rolls
  • exponential adjustment
  • individual adjustment
  • positioning
  • roll adjustment
  • roll setting
  • setting of the straightening rolls
  • straightening conicity
  • straightening roller positions
  • straightening gap
  • straightening angle
  • type of adjustment
  • wedge adjustment

For the characteristics of a material to be changed by alternating forming on a straightener, the straightening rolls have to be adjusted relative to each other. This adjustment is understood to be the absolute position of a straightening roll relative to a specific zero line. Technologically there are various ways of making such adjustments. Rail adjustment and individual adjustment are two relevant options. With the rail adjustment method, a least one row of rolls is fastened to a rail which can be positioned by rotation and translation. Being able to rotate the rail the operator can obtain various pitches between the straightener's rolls according to the angle of rotation. With the individual adjustment method it is possible to position each single roll. Commonly used types of straighteners include those with one row of fixed rolls while the other rows can be individually adjusted, and those on which all the rolls can be separately positioned. The highest degree of roll adjustment freedom exists, of course, when all the rolls of a straightener can be individually adjusted. In this case it is possible, for example, to change the initial curvature exponentially to the final curvature.

For the effective changing of initial curvatures in the initial curve zone it is recommended to select large adjustments in the front - pre-bending - section of the straightener. This results in a maximal curvature which is then reduced to the required final curvature by alternating forming in the follow-up straightening section using smaller adjustments. 

Analysis of straightened material production

  • analysis of straightened material production
  • straightened material production process

A correct straightening process set-up depends on an analysis of the straightened material production process as well as on an analysis of the product to be straightened and an analysis of the final product.

A product's material characteristics are constantly affected from the production of the original material, e.g. its melting, to the final processing operation. The history of these effects adds up to the material's memory.

Each individual process creates stresses in the product. Incorrect handling of the product to be straightened has a negative impact on the constantly changing state of internal stress, whereas its correct handling helps to prevent additional stress factors, keeping the internal stress conditions practically constant throughout the processing.

The stress factors active during the production of a straightened material can be divided into “avoidable” and “unavoidable” stresses. Needless to say, it is far easier to design a constant straightening process and thus achieve continuously better straightening results and hence final products of reproducible quality if steps are taken to prevent the avoidable stresses.

Processes with unavoidable stress factors should be followed as directly as possible by corrective measures in order to reduce or neutralise the stresses. If not, the stresses will be increased by a multiple.

The only way to obtain constant conditions of internal stress is with selective corrective measures. Uniform directions of rotation and defined deflections with unchanged curvature courses ultimately lead to constant input parameters for the resulting controlled straightening process.

Analysis of the final product

  • analysis of the final product
  • objective

A correct straightening process set-up depends on an analysis of the final product as well as on an analysis of the material to be straightened and an analysis of the straightened material production process.

A final product's characteristics are defined above all by its specified tolerance fields, i.e. final curvature, final helicity, stretching limit and tensile strength. These are supplemented by quality features which result from the mechanical and physical requirements imposed on the final product. It is essential, therefore, for the straightened product to fulfil these preconditions and to display these quality features.

The objective of a final product's quality features must be to meet realistic requirements. Its tolerances should not be set any closer than is justified, nor should they be subordinated to process-oriented targets. Quality-oriented and environment-friendly production is likewise an important basis of any sensible improvements. Energy consumption has an important role to play in this connection.

Quality enhancement takes on special significance in economic terms, too. 

Analysis of the product to be straightened

  • analysis of the product to be straightened
  • analysis of the material to be straightened

A correct straightening process set-up depends on an analysis of the product to be straightened as well as on an analysis of the straightened material production process and an analysis of the final product.

In an analysis of the product to be straightened conducted in connection with setting up the correct straightening process, efforts are first concentrated on recording the product's geometrical parameters, regardless of the material parameters which need to be determined.

Basically speaking, the product remains in constant directions and zones of curvature during the most diverse process transitions in the course of its production. It is important to scan and measure these parameters:

  1. Constant curvature on one plane
  2. Curvature zone on only one curvature plane
  3. Curvature zone with a pronounced increasing or decreasing radial offset on only one curvature plane
  4. Constant curvature and or curvature zone on the same or different curvature planes (helicities)

Case 1 provides good conditions for a constant follow-up process. All the other cases require a more elaborate follow-up process with what are sometimes less constant results. Each non-constant process input will give rise to different outputs, no matter how elaborate the applied corrective measures are.

The use of so-called helix straighteners or killing-straighteners can exert only a limited effect on the quality of the final product.

An analysis of the product to be straightened should include a definition of the straightened material parameter. 

Automatic roll positioner

  • actuator
  • adjuster
  • adjusting tool
  • automatic roll positioner
  • computerized tool
  • electronic positioner
  • positioning
  • roll positioner
  • straightening positioner
  • straightening roller positioner

The automatic roll positioner for the individual positioning of at least one straightening roll is an innovation combining well-known conventional and semi-automated straightening technology from WITELS-ALBERT. The high effort required with semi-automated systems is reduced by using just a single actuator with a corresponding sensor to position several rolls. It also makes no difference whether the rolls are on one and the same straightener or straightening system or on different straighteners or systems.

The use of a single intelligent tool to perform the roll adjustment functions flexibly on numerous systems, including those of different types, has resulted in a new category of wire straightening. With the automatic roll positioner it is possible to position straightening rolls objectively, exactly, reproducibly, flexibly and cost-effectively. Information about the materials in contact with the rolls and about the boundary and ambient conditions of the rolls themselves is taken into account for the positioning. Adjustments have to be specified. Data on positions, roll identification and the actual process are automatically scanned, saved, documented, visualized and made available to higher-order systems.


  • automatic straightening unit
  • automation
  • defined straightening
  • intelligent straightener
  • verified straightening

We understand the automation of straightening to be the use of offline and online data, a basic automation system, at least one straightener, a geometry operator, a stretching limit operator and an adjustment operator. Information flow takes place in a loop using all the previously mentioned elements and is aimed at the automatic positioning of the straightening rolls with due consideration of the production, product and process data identified online and of the technology, equipment, product and quality data determined offline. Automatic straightening permits a straightened product to be manufactured in the quality required, regardless of any fluctuations in diameter and stretching limit over the length of the material to be straightened.