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Back Twist Pair Twisting Machine for Automotive Data Cable

Back Twist Pair Twisting Machine for Four Cores Rotating Single Pitch Automotive Data Cable

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 a single twisting method. Compared with 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 payoff part, center rotating wrapping or longitudinal wrapping parts, and the single twisting part. Each part 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. The back twist pay-off part is of a horizontal frame rotating structure. The rotation of the frame body drives the frame to rotate and form a single-pitch back-twisting. The back-twisting rate can be set arbitrarily from 0 to 100%. The single-twist take-up part has a rotary ring structure, and the motor drives the rotary ring to rotate to drive the wire to rotate and twist at the wire collector plate to form a single twist. The twisted wires can be center rotating wrapped or longitudinal wrapped simultaneously to achieve external shielding of the wires. Using the 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 or close to zero (depending on the back twisting rate). 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 reputable to stable electrical performance. The take-up reel adopts a servo motion controller in a shaft arrangement structure, which does not damage the wire and makes the arrangement precise and beautiful.

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Product Details

COMPONENTS

Ø500 rotating ring type single pitch back twist pay-off. 4
Wire concentrator 1
Ø630 rotating ring single twister 1
Control system 1
Peripheral auxiliary equipment can be customized. customization


TECHNICAL SPECIFICATIONS

Pay-off structure Horizontal rotating ring type single pitch back twist pay-off. Frame rotating body drive reel to form back twist, the axis of the reel and the axis of the frame is 90 ° perpendicular to the intersection. The external pay-off motor drives the pay-off reel in the frame to rotate through the mechanical transmission mechanism to achieve active payoff, the standard pay-off configuration is 4 heads, other quantities can also be customized.
Take-up structure Horizontal rotating ring type body, shaftless pneumatic tightening take-up, ground movable traverse shaft wire arrangement, torque take-up, single pitch pair twisting
Overall machine structure Pay-off and stranding are arranged along the centre line of the single-strand mainframe with a split structure and can be customized to increase the peripheral auxiliary equipment for a variety of combinations.
Suitable wire type Suitable for high-frequency automotive data cable 7.5G, 10G, 20G HSD and other wire stranding, also suitable for Cat7, Cat8, HDMI, USB3.1, USB 4.0 and other wire stranding stranding.
Core wire specification Range:Ø0.6-1.8mm, 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 Achieve the twisting or pre-twisting, twisting means that the bows of the payoff machine and the twist pair rotate in opposite directions; 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. At a twist rate of 33 per cent, a single pitch is formed at pay-off, while two pitches are formed at take-off. Therefore, the total number of pitches is three.
Stranding direction S/Z
Pay-off rotation speed MAX560 RPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Take-up rotation speed MAX560 RPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Wire-speed range The formula for calculating line speed: Take-up speed x 3 x pitch / 1000 = m/min. The maximum speed limit is 30 m/min.
Wire twisted pitch Optimal range:10.0-60.0mm, 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.
Pay-off spinning frame material Lightweight titanium alloy aluminium frame
Pay-off spinning frame power The standard configuration is a 5.5KW  inverter motor that can also be customized for servo motors.
Take-up rotating ring power The standard configuration is an 11KW inverter motor, which can also be customized for servo motors.
Braking Pnenmatic disc braking
Capstan type A double-wheel capstan is built into the rotating ring stand
Capstan wheel diameter Ø185, 5-groove rubber-coated aluminium capstan roller + 5-groove split aluminium driven roller.
Capstan power 3KW servo motor
Pay-off specification Ø500 ABS tool wheels
Take-up specification Ø630 ABS tool wheels, compatible with Ø500
Inner hole of the reel The 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>300KG, with self-locking protection, pneumatic release spool
Reel Loading weight MAX300KG
Pay-off reel power The standard configuration is a 1.5KW inverter motor, which can also be customized for servo motors.
Take-up reel power The standard configuration is a 3.7KW inverter motor, which can also be customized for servo motors.
Take-up wire position arrangement Ground Row Type
Wire position arrangement power 0.75KW 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 pay-off is servomotor-adjusted unwinding tension, take-up is torque tension mode.
Pay-off tension range 3N-30N/0.3kg-5kg/300g-3000g
Take-up tension range 7N-70N/7kg-7kg/700g-7000g
Tension accuracy Pay-off tension fluctuation ±10g
Take-up tension fluctuation ±50g
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, 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
Towing shielding Active longitudinal taping can be added between pay-off and take-up.
Wrapped screen Center rotating taping machine 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.




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 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 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.

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 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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