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Triple Pitch Pair Twisting Machine for Network Cable

Integrated Type Triple Pitch Pair Twisting Machine for Network Cable

Triple twisting machine can realize three functions: single twisting, back twisting, and pair twisting. The whole machine includes a single twisting part for back twist pay off and pair twisting part. The pay-off part and the take-up part adopt an integrated design with upper and lower layers stacked up to save space. There are external and internal pay-off parts of the back twist pay off. 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 first pitch. The twisted wires then enter the twisting bow for the second and third times of twisting to achieve the triple twisting function. The triple twisting machine has high efficiency and accurate pitch and is very suitable for the CAT5/CAT5E/CAT6 network core wire twisting process.

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Product Details

COMPONENTS

Ø500 portal cradle shaftless active pay-off inside the stranding bow 1
Ø500 shaftless active pay-off outside the stranding bow 1
Ø500 Double pitch constant tension pair twister 1
Control system 1
Peripheral auxiliary equipment can be customized. Customization


TECHNICAL SPECIFICATIONS

Pay-off structure One head 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 Horizontal portal cradle shaftless take-up, stranding bow double pitch pair twisting.
Overall machine structure Integrated upper and lower structure. Gantry crable shaftless active pay-off is placed on the top part of the inteagted machine. The shafless active pay-off is placed on the right part. The stranding take-up is placed on the bottom part of the integrated machine. 
Suitable wire type Mainly used for LAN CABLE CAT5, CAT5E, CAT6A, etc..
Core wire specification Range:Ø0.6-1.2mm, beyond this range, can be customized
Outer diameter of stranded wire range:Ø1.2-2.5mm, 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 payoff machine and pair twist, and can be selected on the touch screen.
Twisting/pre-twisting ratio 0-100%, 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 percent, 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 MAX1800 RPM (no load).
The actual startup speed is set according to the requirements of different wire grades. 
Take-up rotation speed MAX1800RPM/5400TPM (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: Bow-twister speed x 3 x pitch / 1000 = m/min. The maximum speed limit is 100 m/min.
Wire twisted pitch Optimal range:5.0-30.0mm, 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 The standard configuration is a 5.5KW  inverter motor that can also be customized for servo motors.
Take-up bow power The standard configuration is a 5.5KW inverter motor, which can also be customized for servo motors.
Stranding bow braking Electromagnetic brakes
Capstan type A double-wheel capstan is built into the portal cradle to take up
Capstan wheel diameter Ø185, 5-groove rubber-coated aluminium capstan roller + 5-groove split aluminium driven roller.
Capstan power The standard configuration is a 1.5KW inverter motor, which can also be customized for a servo motor.
Pay-off specification Ø500 ABS tool wheels.
Take-up specification Ø500 ABS tool wheels. 630 take-up wheels can be customized.
The 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>200KG, with self-locking protection, pneumatic release spool
Reel Loading weight MAX300KG
Pay-off reel power The standard configuration is a 2-0.75KW gear reducer motor, which also can be customized for a servo motor.
Take-up reel power The standard configuration is a 0.75KW gear reducer motor, which also can be customized for a servo motor.
Take-up wire position arrangement The 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 the tension by moving or adding balancing weights, PID controls the speed of pay-off or take-up or customizes 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, 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 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.

● Less space occupied: It adopts an integrated structure, which saves more than 50% of the occupation compared with the traditional split-type back twist pair twisting machine.

● Low Energy Consumed: Electrical energy can be save above 50% compared to the traditional back twist pair twisting machine.

● 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 enables 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 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.

● 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 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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Gemwell Electrical Machinery Co., Ltd.
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