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Back Twist Pair Twisting Machine for Automotive Data Cable

Back Twist Pair Twisting Machine for Four Cores Industrial Ethernet Data Cable

With the strongly development of new energy vehicles in recent years, the electronic equipment inside the car has grown, such as engine control, ABS systems, airbags, AI smart functions, multimedia electronics, etc. In this way, the safety, comfortness, intelligence, energy saving, reliability, and convenience of automobiles can be improved, and emissions can be reduced. Corresponding, there are increasing requirements placed on bus systems to ensure reliable communication data transmission between the diverse control units. In particular, the safety of controls via bus systems such as Controller Area Network (CAN) or FlexRay systems is crucial and must meet the electromagnetic compatibility specifications. As the core of signal transmission carriers, automotive data cables have increasingly higher quality requirements: faster data transmission rate, delay performance, and fault tolerance.  The automotive data cable manufaction line adopts a twisted-pair taping structure, which can achieve a fast data transmission rate (CAN bus: 1Mbit/s; FlexRay bus: 10 Mbit/s), with definite delay and high reliability. Since the twisted pair of automotive data cables mainly requires the symmetry of paired twisted core wires, and when the cable is undergoing differential mode transmission, it converts the differential mode signal into a stable quantized value of the common mode signal, that is, the LCL value and lctl value. Besides that, the control of low attenuation and low echo difference also requires a stable and desirable performed pair-twisting machine. Since the establishment of the factory  20 years ago, Gemwell has been focusing on the research development, and innovation of twisting machines. Gemwell Back Twist Pair Twisting Machine for Double Cores Industrial Ethernet Data Cable have now become the reputable choice in the field of new energy data wires. The following is a conventional configuration of 2 pay-off reels, users can increase the number of wrapping heads according to different cable manufaction specifications. Depending on the variety of wire diameters, the specifications and types of take-up, pay-off, and capstan machines can also be customized and changed.

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Product Details

COMPONENTS

Ø500 Integrated frame-type double disc back twist payoff machine 2
Back twist payoff stand 2
Ø630 Double pitch constant tension pair twister 1
Control system 1
Peripheral auxiliary equipment can be customized. customization


TECHNICAL SPECIFICATIONS

Pay-off structure Horizontal forward-and-backward double-reel boat cradle shaftless pay-off, stranding bow double pitch back twist pay-off.
Take-up structure Horizontal portal cradle shaftless take-up, stranding bow double pitch pair twisting.
Overall machine structure Back twist pay-off and stranding take-up are arranged along the center line, with split type structure. The pay-offs are placed back-to-back with front and rear doors equipped; Place and collect of reels can be operated in the front of the machine.
Suitable wire type Mainly used for LAN CABLE CAT5, CAT5E, CAT6A, CAT7, CAT8 and other wires, but also for other signal transmission wires that require electrical testing.
Core wire specification Range:Ø0.6-2.0mm, beyond this range can be customized
Outer diameter of stranded wire range:Ø1.2-4.5mm, beyond this range can be customized.
Stranding die Standard mould OD size is 25
Back twist method Achieve the twisting or pre-twisting, twisting means that bows of payoff machine and the twist pair rotate in opposite direction; pre-twisting refers to the same rotating direction of the pay-off machine and pair twist, and can be selected on the touch screen.
Twisting/pre-twisting ratio 0-120%, continuously and steplessly adjustable, set on the touch screen, PLC automatic control, automatic tracking of twisting/back twisting speed.
Stranding direction S/Z
Pay-off rotation speed MAX2000 RPM/4000 TPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Take-up rotation speed Model 500 MAX2000RPM/4000TPM (no load).
Model 630 MAX1750RPM/3500TPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Wire speed range Formula for calculating line speed: Bow-twister speed x 2 x pitch / 1000 = m/min. The maximum speed limit is 100 m/min.
Wire twisted pitch Optimal range:5.0-50.0mm, 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 65Mn steel strip with ceramic eyelets, which can be customized to carbon fiber lightweight bow.
Pay-off bow power Standard configuration is 2-5.5KW  inverter motor can also be customized for servo motor.
Take-up bow power Standard configuration for 630 take-up is 7.5KW inverter motor, can also be customized for servo motor.
Stranding bow braking Electromagnetic brakes
Capstan type Double wheel capstan is built into the portal cradle take-up
Capstan wheel diameter Ø185, 5-groove rubber-coated aluminium capstan roller + 5-groove split aluminium driven roller.
Capstan power Standard configuration is 1.5KW inverter motor, can also be customized for servo motor.
Pay-off specification Model Ø500, compatible with Ø400, ABS tool wheels
Take-up specification Model Ø630,  compatible with Ø500, ABS tool wheels
Inner hole of 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 Standard configuration is 2-0.75KW gear reducer motor, also can be customized for servo motor.
Take-up reel power Standard configuration is 0.75KW gear reducer motor, also can be customized for servo motor.
Take-up wire position arrangement Standard is 30 polished rod traverse shaft unit, can be customized for servo motion controller rows.
Wire position arrangement power 0.2KW servo motion controller can be customized.
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 the tension by moving or adding balancing weights, PID control the speed of pay-off or take-up, or customize it to adjust the 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.
Formula management A custom formulation management system enables data such as tension, temperature, extrinsic diameter, pitch, S/Z, wire winding distance, 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
Towing shielding Active longitudinal taping can be added between pay-off and take-up.
Pre-Twist forming High-speed pre-twisters can be customized between pay-off and take-up.
Ground fill Filler power payoffs can be customized between payoff and take-up.
Power Standards The 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 spindle box is stress-relieved and annealed, it is durable and not deformed. 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.

● Stable tension: The servo motor can be customized as the tension element. After setting the total take-up tension, the pay-off tension of the two core wires is intelligently calculated. It also enablers precise controll of pay-off and take-up speed by the servo motion controller, thus achieving stable tension.

● Accurate pitch: The world exclusively "precision transmission mechanism of external power and internal capstan", uses complex mechanical transmission to transmits 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.

● Labor saving: Equipped with a flexible threader, can smoothly transit through the turning node of the angle bow, and the threading can be completed in 1 minute. Wire can be withdrawn in the reverse direction using the control panel, saving labor.

● 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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A Mature Factory You Can Count On

Gemwell Electrical Machinery Co., Ltd.
Founded in 2005, GEMWELL is a professional wire and cable equipment solution 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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