High-Standard Rigid Stranding Machine for Stranding and Wrapping of
Large Cross-Section Power Cables
1. Application: This machine is mainly used to produce large section and large
length ACSR,AAC wire and aluminum alloy wire; It can also be used
for pressing of copper round and aluminum sector conductor.
2. Overview of equipment composition
The whole machine is driven by separate motors driving. Each
section of the cage and capstan is driven by a independent motor.
The control of the whole machine adopts Siemens S7-200 series PLC
to ensure synchronization accuracy. In actual production, the
operator can set the process parameters such as the pitch of each
section of the stranding cage and the speed of the production line
on the touch screen according to the cable specifications to be
produced, and automatically calculate the speed of each
transmission part and control the pay-off tension through PLC when
starting up.
Siemens S7-200 series PLC and collective PROFINET fieldbus are used
for unified control of the whole machine operation to coordinate
the working state, operation and speed control of all parts of the
whole machine. The operation touch screen adopts Siemens color HMI
to control the operation
3.Main Parameter:
| 3.1 | Input wire diameter | Aluminum Ø 1.8－Ø 5.41mm |
| 3.2 | Max stranding OD | Ø50mm |
| 3.3 | Max rotation speed | 12 bobbins | 206r/min(Full bobbins) |
| 20 bobbins | 182r/min(Full bobbins) |
| 24 bobbins | 160r/min(Full bobbins) |
| 3.4 | Strand cage motor power | 12bobbins | 55KW(AC) |
| 20 bobbins | 55KW(AC) |
| 24 bobbins | 55KW(AC) |
| 3.5 | Strand pitch(set one PLC) | 12 bobbins | 41-738mm |
| 20 bobbins | 48-860mm |
| 24 bobbins | 56-1006mm |
| 3.6 | Wire broken detection stop machine | Vector pulse type |
| 3.7 | Taping machine max rotation speed | 1500r/min |
| 3.8 | Taping machine motor power | 3.0Kw AC |
| 3.9 | Taping machine wrapping pitch | 0-100mm (Stepless adjustable) |
| 3.10 | Traction line speed | 60m/min |
| 3.11 | Max traction force | 2500kg |
| 3.12 | Caterpillar motor power | 55KW(AC) |
| 3.13 | Pay-off bobbin size in cage | PND500 |
| 3.14 | Central pay-off bobbin size | PN800-PN1600 |
| 3.15 | Take-up bobbin size | PN1000-PN2000 |
| 3.16 | Machine center high | 1000mm |
12+18+24 bobbin stranding cage:
5.2.1. Specification of pay-off bobbin in cage: PND500
5.2.2. Applicable bobbin diameter: Ø500mm
5.2.3. Applicable bobbin width: 375mm
5.2.4. Broken wire stop machine system: full-automatic vector pulse
type
5.2.5. Loading and unloading bobbin method: centralized side bottom
automatic
5.2.6. Hardness of the tightening needle of bobbin: ≥ HRC50
5.2.7. Pay-off tension: pneumatic constant tension+mechanical
tension
5.2.8. Stranding cage drive form: direct connected independent
motor drive
5.2.9. Range of cage pitch: infinitely adjustable
5.2.10. Stranding cage structure: integrated welding
5.2.11. Lubrication method for the cage reducer: oil pump spray
lubrication
5.2.12. Strand pitch:
12 bobbin: 37-666mm
20 bobbin: 41-738mm
24 bobbin: 48-860mm
5.2.13. Maximum rotation speed of stranding cage:
12 bobbin: 206r/min
20 bobbin: 182r/min
24 bobbin: 160r/min
5.2.14 Motor power of each cage
12 bobbin: 55kw (AC)
20 bobbin: 55kw (AC)
24 bobbin : 55kw (AC)
5.2.15. Design principle: Each stranding cage is driven and
operated by its own separate motor. The motor and stranding cage
reducer box are connected through a coupling to directly drive the
hinge cage to operate, providing power for equipment operation and
slow positioning. This drive system eliminates the transmission of
power through toothed belts and reduces maintenance links. The
forward rotation, reverse rotation, neutral gear, start, stop,
emergency stop and other operation settings of the stranding cage
are all controlled by the electrical system
5.2.16. Structural form: Each section of the stranding cage is an
integrated 4-part structure. The stranding cage is supported on the
gearbox and front support by two sets of double row self-aligning
roller bearings, ensuring the bearing capacity of the cage's axial
movement.
5.2.17. Manufacturing process: The front and rear support frames of
the entire stranding cage are supported by double supports, with
seamless steel pipe support in the middle. The frame body is mainly
made by high-strength welding of the steel plate connection surface
after processing, and the welded overall frame is subjected to
high-temperature annealing in the annealing furnace to accelerate
the aging treatment of the deformation and stress generated by the
steel plate welding. After 72 hours, it naturally cools to the
natural temperature, effectively enhancing the mechanical strength
of the entire frame. There is machining allowance for the brake
surface of the hinge body, and there is allowance for the top
mounting hole. All holes are drilled, milled, and then precision
turned on a heavy-duty horizontal lathe at the gantry machining
center. The hinge base plate is welded with rectangular tubes,
which effectively enhances the stability of the hinge compared to
ordinary channel steel base plates and is more suitable for
high-speed rotation of the hinge. The dynamic balance experiment
after the assembly of the hinge meets the requirements of
high-speed and stable operation.
5.2.18. Wire breakage monitoring: The DXJ fully automatic wire
breakage detection system is used, and the electrical switch output
is precise and reliable. It can stop and brake in a timely manner
when the wire is broken or used up, and can prompt on the
human-machine operation interface.
5.2.19. After centralized loading bobbin, the pneumatic top needle
is used for clamping. After the bobbin is tightened, a separate
locking cylinder drives the mechanical stop device to lock the top
needle. And the locking status is monitored by the electrical
detection device, and the host cannot be started in an unlocked
state.
5.2.20. Form of tension for pay-off in the cage: The pay-off in the
cage adopts dual tension settings of pneumatic constant tension and
mechanical friction tension. The working principle of pneumatic
constant tension: From full bobbin to empty, the constant tension
output is controlled by PLC, and the tension of the wire is uniform
and stable. The tension can be adjusted through the human-machine
interface. Equipped with clamp type mechanical tension, it can fine
tune the tension of each disc and serve as a backup tension output
reserve.
5.2.21. Braking form: The main cage brake adopts a disc shaped flat
air brake to reduce the impact of emergency stop inertia on the
transmission components. Working principle of overall braking:
Coordinated by a programmable logic controller (PLC), the variable
frequency motor controller, braking resistor, air pressure
proportional valve, etc. jointly complete the slow stop, fast stop,
emergency stop and other operations of the entire machine.
5.2.22. Pre-former device: Each section of the host is equipped
with a single line pre-former device at the front end. Prefabricate
stranded pitch to improve the quality of finished wire. The
pre-former device is equipped with a sheet metal safety protective
cover, and the operating side of the protective cover is equipped
with an acrylic observation window. The cover can be pushed and
pulled open, and there is a mechanical locking device.
5.2.23. Stranding cage pass wire form: After the wire inside the
cage is released, it passes through the internal guide roller
group, wire hole, pre-former device, and distribution board of the
twisting body to finally form a cable. The wire passing holes and
the dividing plate are internally embedded with alloy wire passing
molds, and the inner holes of the wire passing molds are polished.
5.2.24. Safety protection: The cage is equipped with a single side
wall type safety protection net, covering the entire machine's cage
position at the beginning and end of the operating side. The host
protective net is installed using perforated plates or high-density
mesh grids supported by columns, and each section of the hinge cage
is equipped with a door opening, totaling 3 doors. All three doors
of the safety net are equipped with sound and light alarm lights.
After opening the door, there is a sound and light alarm prompt.
The host control system can choose between two states: A door
opening alarm prompt, equipment normal operation, B door opening
alarm prompt, and overall braking
5.2.25. Each section of the cage is equipped with an independent
air storage tank to ensure gas supply. At the same time, provide a
one-time brake air supply for unexpected power outages and other
situations.
5.2.26. The front operating position of each section of the e cage
is equipped with control buttons such as emergency stop, jog,
disconnection control selection, positioning, and up/down panel for
easy operation.
5.2.27. The entire machine is operated by a color touch screen with
a human-machine interface, and is coordinated and managed by a
programmable controller PLC.
