Large Section Rigid Stranding Machine for Aluminum Alloy Wire and Copper Conductor

Large Section Rigid Stranding Machine for Aluminum Alloy Wire and Copper Conductor

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:

5.2 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.