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Wire Pair Twisting Machine

(Double Cores + Ground Wire + Longitudinal Wrapping) Single Pitch Cantilevel Wire Pair Twisting Machine

The number of pay-off rack heads can be expanded and configured. When ground wires are added to two or more signal wire cores for pair twisting with free internal stress back twist pay 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 single twisting machine unit is specially designed for the production line of (pair twisting + ground wire + tape wrapping shielding). The single twisting unit adopts a built-in capstan structure. The capstan wheel is set on the cantilever oscilating arm. The capstan motor and the cantilever motor are controlled by mechanical and electrical interlocking mechanism, synchronous operating, and thereby achieving stepless high-precision electronic pitch control. The pitch accuracy is close to one decimal place, which can be set digitally and runs stably and accurately. The pay-off part and the longitudinal wrapping part adopt an integrated centralized design to save space. The take-up reel adopts a servo motion controller in shaft arrangement structure, which does not damage the finished wire and makes the arrangement precise and beautiful.

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Product Details

COMPONENTS

Ø400 Integrated shaft active pay-off stand 3
Constant tension longitudinal taping machine 2
Wire concentrator 1
Centre rotating taping machine - optional 2
Telescopic Oven 1
Ø400 Cantilever Single Twisting Machine 1
Control System 1
Peripheral auxiliary equipment can be customized.


TECHNICAL SPECIFICATIONS

Pay-off structure The standard is a 3 heads integrated shaft active pay-off stand, with 2 heads for core wire pay-off and 1 head for copper wire pay-off. Other pay-off types can be customized.
Take-up structure The standard is a Ø400 cantilever single twisting machine with a ground shaft take-up. Ø500 type take-up reel can be customized.
Overall machine structure Arrange along the center line of the single twist mainframe, placed from pay-off to take-up respectively with a split structure
Suitable wire type It is suitable for the pair twisting of high-frequency wires such as HDMI, USB3.1, USB4.0, and LAN CABLE, as well as data cables and electronic cables (2 cores + ground wire + center or longitudinal wrapping) 
Core wire specification Range:Ø0.6-1.8mm, beyond this range, can be customized
Outer diameter of stranded wire range:Ø1.3-4.0mm, beyond this range can be customized.
Stranding die The standard mold outer diameter is 25mm.
Back twist method No
Back twisting ratio No
Stranding direction S/Z
Pay-off rotation speed
MAX1000RPM (no load), the actual operating speed can be set according to the wire specifications.
Taping speed MAX2000RPM (no load), the actual operating speed can be set according to the belt width and wire specifications.
Wire-speed range The formula to calculate wire speed is: single twist machine speed x pitch / 1000 = m/min, with a maximum speed limit of 50m/min.
Wire twisted pitch The optimal range for pitch is 10.0-50.0mm, with precision to one decimal place, continuously adjustable without steps, selected on the touchscreen.
Pitch accuracy During constant speed production, the pitch accuracy is ±0.4mm, and during start/stop processes, the pitch accuracy is ±0.6mm.
Cantelever material Lightweight low air resistance rectangular steel tubing structure
Cantelever power 3.7KW servo motor.
Host braking
Pneumatic disc brake.
Capstan type A double-wheel capstan is equipped on the cantilever on the single-twisting mainframe.
Capstan wheel diameter Ø159 wire capstan wheel with 4 grooves.
Capstan power 1.8KW servo motor
Pay-off specification Ø400 ABS tool wheels. 500 pay-off wheels can be customized.
Take-up specification Ø400 ABS tool wheels. 500 pay-off wheels can be customized, with a max speed at 800RPM.
Inner hole of the reel The standard size is Ø56mm, with customization available for other hole sizes.
Reel Spindle lifting Artificial pay-off reels, electrical lifting take-up reel
Reel tightening method Top cone nut tightening reel
Reel Loading weight MAX200KG
Pay-off reel power 0.4KW gear motor
Take-up reel power 1.3KW servo motor torque tension mode
Take-up wire position arrangement Ground row type, 0.75KW servo motor row position
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 Shaft lever active pay-off, movable and adjustifiable weight to adjust tension, PID control on pay-off speed. Torque tension take-up, can be customized into a servo motor to control tension.
Pay-off tension range 3N-40N/0.3kg-4kg/300g-4000g
Take-up tension range 8N-50N/0.8kg-5kg/800g-5000g
Tension accuracy ±25g
Taping material AL, MYLAR, COPPER FOIL, PTFE, PI
The outer diameter of the tape reel Standard pad material, OD 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 molds can also be customized
Oven parameters Telescopic thermostatic oven, move away when stopping to prevent baking the wire, and move in to bake the wire when starting.
Tension display Communication type digital display pressure sensor, tension overrun alarm, and automatic shutdown.
Spark detection Can be customized to add a spark tester
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.
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 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.

● Exclusive use: Suitable for high-speed twisting of various wire cores, it is the preferred equipment for pair twisting + tape wrapping series production line.

● High quality: The cantilever design with a capstan wheel rotating at a constant speed, ensuring stable wire pitch and high quality.

● 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 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.

● Efficient Wire Arrangement: The wire arrangement process adopts a box-shaped structure, where the wire spool moves back and forth in a straight line along with the wire storage box, ensuring a neatly organized arrangement.

● Stable Tension Control: The wire tension is controlled by a servo motor torque system, maintaining a constant tension when take-up from an empty to a full reel. 

● 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 panelEasy 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.
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.

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