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(Double Cores Back Twist + Ground Wire + Center Rotary Wrapping) Single Pitch Bow Type Wire Pair Twisting Machine Manufacturers

Wire Pair Twisting Machine

(Double Cores Back Twist + Ground Wire + Center Rotary Wrapping) Single Pitch Bow Type Wire Pair Twisting Machine

When ground wires are added to two or more signal wire cores for twisting with free internal stress back twist pays off, and when metal or non-metallic tape materials are added for center rotating wrapping or longitudinal wrapping, it is usually recommended to use bow-type no internal stress bact twist pay-off + center rotating wrapping + static take-up. Compared with a double twisting method, the single twisting method has lower production efficiency, but it can obtain better physical appearance and electrical performance of tape wrapping quality. This machine is specially designed for the production line of free internal stress back twist payoff + ground wire filling + tape wrapping shielding + pair twisting. The whole line includes the back twist pay-off part, and center rotating wrapping take-up parts. There are external and internal pay-off parts of the back twist payoff. The external pay-off is led through the rotating angle bow to the hole of the wire-stranded die deviated from the rotation center, and the internal pay-off is directly led to another hole on the symmetrical side of the wire-stranded die deviated from the rotation center without passing through the angle bow. The rotating angle bow drives the wire-stranded die to rotate so that the two core wires are twisted in a single pitch with 100 % back twist pay-off to form the pitch. The twisted pair no longer rotates but advances in a linear movement to go through center rotating wrapping (can not use longitudinal wrapping), capstan, and take-up. The Capstan motor, angle bow rotating motor and taping motor operates synchronously through mechanical and electrical interlock control, thereby achieving stepless high-precision electronic pitch control. The pitch accuracy is close to the first decimal place and can be set digitally while maintaining stable and accurate. In addition, the pay-off and twisting part use the same angle bow spindle, causing the speed cannot be adjusted, thus resulting into a constant back twist ratio already preset at 100%. Using the 100 % back twisting method, the traditional passive rotational and external twisting forced is transformed into the active rotational twisting of two or more core wires under the combined action of back twisting and the twisting force. The internal stress of torsion and the external stress of twisting cancel each other out, so that the rotational stress of the twisted product from the inside to the outside cancels each other out to zero. The two core wires after twisting are in close contact with no gaps and are naturally straight with no rebounding force. The maintaining a stable physical structure can lead to stable electrical performance. 

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Product Details

COMPONENTS

Ø500 portal cradle shaftless active pay-off for core wire inside the stranding bow 1 unit
Ø400 portal cradle shaftless active pay-off for copper wire inside the stranding bow 1 unit
Ø500 shaftless active pay-off outside the stranding bow 1 unit
Ø400 double-wheel capstan 1 unit
Centre rotating taping machine 2 unit
Ø400 double-wheel capstan 1 unit
Telescopic Oven 1 unit
Ground shaft take-up 1 unit
Control system 1 unit
Peripheral auxiliary equipment can be customised.    


TECHNICAL SPECIFICATIONS

Pay-off structure Two heads of the portal cradle shaftless active pay-off inside the stranding bow + One head of shaftless active pay-off outside the stranding bow
Take-up structure Standard configuration is Ø500 ground shaft-type take-up machine, Ø630 or other types can be customized.
Overall machine structure Arrange along the centre line of the wrapping machine with split structure
Suitable wire type Suitable for USB3.1, USB4.0, HDMI and other two-core back twisted + ground wire + taping cable
Core wire specification Range:Ø0.6-2.0mm, beyond this range can be customized
Outer diameter of stranded wire range:Ø1.2-4.0mm, beyond this range can be customized.
Stranding die The standard mould OD size is 25
Back twist method 100% twisting before entering the mould, 100% back twisting instantly after passing through the mould, and no stress inside the wire after stranding.
Back twisting ratio 100%, twisting and back-twisting are done instantly at the mould, but the back-twisting rate is not adjustable.
Stranding direction S/Z
Pay-off rotation speed MAX1200 RPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Take-up rotation speed MAX1200 RPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Wire-speed range Formula for calculating line speed: Take-up speed x pitch / 1000 = m/min. The maximum speed limit is 30 m/min.
Wire twisted pitch Optimal range:10.0-50.0mm, accurate to one decimal place, with a continuously adjustable level, selectable on the touchscreen.
Pitch accuracy Pitch accuracy ±0.3mm during fixed speed production, ±0.5mm during start-up/shutdown.
Stranding bow material The standard material used is a 65Mn steel strip with ceramic eyelets, which can be customized to a carbon fiber lightweight bow.
Pay-off bow power 5.5KW inverter motor
Take-up bow power 1.8KW servo motor
Stranding bow braking Electromagnetic brakes
Capstan type Double wheel capstan
Capstan wheel diameter Ø400, 5-groove rubber-coated aluminium capstan roller + 5-groove split aluminium driven roller.
Capstan power Standard configuration is a 1.5KW inverter motor, which can also be customized for servo motors.
Pay-off specification Ø500 ABS tool wheels.
Take-up specification Ø500 ABS tool wheels. 630 pay-off wheels can be customized.
The inner hole of the reel Standard is Ø56mm, other sizes can be customized.
Reel Spindle lifting Electric lifting, skateboard loading and unloading spool.
Reel tightening method Powerful elastic cylinder assembly tightening spool, tightening force>200KG, with self-locking protection, pneumatic release spool
Reel Loading weight MAX300KG
Pay-off reel power 0.75KW gear motor
Take-up reel power 0.75KW gear motor also can be customized as a servo motor.
Take-up wire position arrangement Standard is 30 polished rod traverse shaft units, which can be customized for servo motion controller rows.
Pay-off material run-out detection Alarm and automatic stop when the core wire is about to run out/alarm and automatic stop when the wire is broken.
Tension-type The standard is to adjust tension by moving or adding/removing weight blocks, and PID control of the pay-off or take-up speed. It can also be customized to regulate tension with a servo motor.
Pay-off tension range 3N-30N/0.3kg-3kg/300g-3000g
Take-up tension range 5N-50N/0.5kg-5kg/500g-5000g
Tension accuracy ±25g
Tension display Communication type digital display pressure sensor, tension overrun alarm and automatic shutdown.
Taping material AL, MYLAR, COPPER FOIL, PTFE, PI
The outer diameter of the tape reel Standard sheet material, O.D. Ø300, customized shaft material available.
Tape width 3-20mm
Hole of the tape reel 50.8/76
Taping power 1.8KW servo motor
Taping tension 1NM Hysteresis clutch
Taping strip storage length 400mm, strip change without cutting the wire.
Strip breakage inspection Automatic stop when tape is about to be exhausted and broken
Overlap rate 0-50%, programme setting
Longitudinal taping tension units 1NM magnetic powder brake 
Longitudinal taping mould Standard is seamless type tubular wrapping paper tube, other types of longitudinal wrapping moulds can also be customized
Oven parameters Telescopic thermostatic oven, move away when stopping to prevent baking the wire, move in to bake the wire when starting.
Recipe management A custom formulation management system enables data such as tension, temperature, extrinsic diameter, pitch, S/Z, wire winding distance, and barometric pressure to be fed into the PLC, supporting data collection and import for digital production.
Safety protection Automatic detection and prediction of temperature /vibration /noise /pressure can be customized according to CE/CSA/UL standard design.
Spark detection Can be customized to add a spark tester
Power Standards Standard is 3-phase 380V/50Hz and the power supply can be customized for different countries and regions.
Intelligent software Customisable to add "the best production speed automatic matching function" software, to achieve production efficiency and product quality at the same time.
Core wire over-oil device A core wire oiling device can be customed and added. The insulating core wire is coated with a volatile lubricating oil to reduce friction during wire pair twisting.




PRODUCT FEATURES

Fast speed: The rotating stranding angle bow is statically balanced and dynamically balanced for testing and correction. It has a small vibration and low noise. The spindle does not generate heat during long-term continuously high speed operatione, and the spindle rotation speed is fast.

Without internal stress: With a unique back-twisting pay-off structure, the core wire is flexible and obtain no internal stress after twisting, resulting in physical performance.

Less bending: The pulleys and guide rollers are designed with large diameters to reduce the bending of the wire, avoiding damage to the twist pitch.

Accurate pitch: The world exclusively "precision transmission mechanism of external power and internal capstan", uses complex mechanical transmission to transmit the motor power outside the twisted bow to the capstan wheel inside. Setting the main capstan as the movement benchmark, adopt servo motion controllers for both the twisting bow and the main capstan to conduct precise chain motion control and obtain precise pitch at any speed.

Intelligent: Recipe management, one-click SOP recipe retrieval, one-click start-up preparation, one-click start; dynamic feedback of twisting pitch, back twisting ratio,  fault detection/disconnection detection/stop when meter reaches, intelligent control panel

Low failure rate: The electrical control components in the stranding angle bow are all installed on the cradle, and all signals are closed-loop electrically controlled inside the stranded bow. The carbon brush collector ring only provides three-phase power to the inside of the stranding angle bow without transmitting signals in order to avoid poor contact, interference, and a low failure rate.

Easy maintenance: Customers outside China can customize to obtain the Profinet bus control, which ensures fast signal transmission and low interference. Troubleshooting and maintenance are available regardless of the machine's location in any country or region worldwide, as long as there is a communication network, then remote fault detection, troubleshooting, and maintenance services can be quickly provided.

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    Intellectual property

A Mature Factory You Can Count On

Gemwell Electrical Machinery Co., Ltd.
Founded in 2005, GEMWELL is a professional China (Double Cores Back Twist + Ground Wire + Center Rotary Wrapping) Single Pitch Bow Type Wire Pair Twisting Machine manufacturers and (Double Cores Back Twist + Ground Wire + Center Rotary Wrapping) Single Pitch Bow Type Wire Pair Twisting Machine Factory provider in design, manufacture and sales for the United States, Canada, Mexico, Germany, Italy, India, Thailand, Russia and etc. more than 40 countries in the world.

The success of customer is our goal to get success!

● Focus on technological innovation, quality stability, precision manufacturing and considerate service.
● Insist on making all in detail well, repay every customer with high quality.
● Take customer's success as the embodiment of our enterprise value.

The enterprise spirit of dedication, dedication, enterprise and exploration encourages us to innovate and transform the technology of wire and cable into advanced productive forces, in order to build GEMWELL into a new name card of China facing to the world.
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