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Back Twist Pair Twisting Machine for Network Cable

Integrated Type Back Twist Pair Twisting Machine for Network Cable

In the core wire pair twisting process, the pitch accuracy and the tightness of the paired-wire are very important, which have a significant impact on the electrical and physical properties of the finished cable. This machine is equipped with an independent capstan wheel within the rotating angle bow of the main twisting part. The motor power of the capstan wheel is transmitted from the outside of the angle bow to the inside through the mechanical transmission in the rotating main shaft, avoiding the unreliable factors caused by the traditional carbon brush type transmission. Additionally, the capstan motor and the angle bow rotating motor operate synchronously via electrical interlock control, thereby achieving stepless high-precision electronic pitch control. The twisting pitch can be set digitally and formed stably and accurately. In addition, the back twisting pay-off adopts the rotating angle bow structure, which transforms the traditional passive rotation and external stranding force into the active rotation and stranding of the two core wires under the combined action of the 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. After twisting, the two core wires fit tightly without gaps, and are naturally straight and without rebounding force. The maintaining stable physical structure can lead to stable electrical performance.

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Product Details

COMPONENTS

Ø500 Horizontal upper-and-lower double-reel portal cradle shaftless pay-off 2
Back twist payoff stand 2
Ø500 Double pitch constant tension pair twister 1
Control system 1
Peripheral auxiliary equipment can be customized. customization


TECHNICAL SPECIFICATIONS

Pay-off structure Horizontal upper-and-lower double-reel portal 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 back-to-back, with an integrated structure. Both pay-off and take-up sides are equipped with doors for reel pay-off and take-up operations.
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:Ø1.2-4.0mm, 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.
Stranding direction S/Z
Pay-off rotation speed The actual startup speed is set according to the requirements of different wire grades, with a maximum of 2000 RPM/4000 TPM (no load). 
Take-up rotation speed The actual startup speed is set according to the requirements of different wire grades, with a maximum of 2000 RPM/4000 TPM (no load). 
Wire-speed range The 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 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 2-5.5KW  inverter motor that can also be customized for servo motors.
Take-up bow power The standard configuration is a 3.7KW inverter motor, which can also be customized for a servo motor.
Stranding bow braking Electromagnetic brakes
Capstan type A 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 The standard configuration is a 1.5KW inverter motor, which can also be customized for a servo motor.
Pay-off specification Model Ø500, compatible with Ø400, ABS tool wheels.
Take-up specification Model Ø500 is compatible with Ø400. ABS tool wheels
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.
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 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 operations, 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.

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, and the speed of pay-off and take-up are precisely controlled by the servo motion controller, thus achieving stable tension.

Accurate pitch: The world exclusively " precision transmission mechanism of external power and internal capstan", transmits the motor power outside the angle bow to the capstan wheel inside the angle bow through a complex mechanical transmission mechanism. With the main capstan as the movement benchmark, adopt servo motion controllers for both the twisting angle 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: Distribution mode 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 ransmitting signals 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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