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Stranding machine is an industrial equipment used in the manufacture of cables, wires, ropes and conductors. It is designed to twist multiple strands of wire or cable together to form a single larger conductor. This equipment is very common in cable and wire manufacturing.

Bunching and Stranding are two different processes used in the manufacturing of cables, wires, and conductors. Bunching is the process of twisting multiple strands of wires or cables together to form a bundle whereas stranding involves twisting multiple strands of wires or cables together in a specific geometric pattern or arrangement.

The Stranding process twists multiple strands of wire or cable together to create a single, larger conductor. The main steps include preparing the wires, forming the bundle, twisting, tension control, winding, quality control and final inspection. This process gives the cable strength, flexibility and conductivity, and is used in industries such as telecommunications, electrical and construction.

Frame stranding machines are used in the manufacture of cables, wires, ropes and conductors and are widely used in telecommunications, construction, aerospace, automotive manufacturing and energy industries.

The development trend of the frame stranding machine includes the application of automation technology, the development of intelligent control systems, the improvement of production efficiency and innovation in environmental protection. With the continuous advancement of technology, the frame stranding machine will become more intelligent, efficient and environmentally friendly to meet the ever-changing market needs.

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Frame Stranding Machine
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Tubular Stranding Machine

Cable stranding and cabling machine is used to manufacture cables and wires. It can twist multiple single wires or strands into a single larger conductor (stranding), and can also perform stranding of multiple conductors (cabling). The machine includes components such as rotating rollers or spools, tension control devices, torsion components and winding systems. It is suitable for industries such as telecommunications, electrical, construction and automotive manufacturing. With this machine, manufacturers can efficiently and accurately produce cables and wires that meet specification requirements.

Cable extruding and coating machine is used to manufacture cables and wires. It provides electrical insulation, mechanical protection and other necessary properties by extruding insulation or sheathing materials around the conductor. It includes extrusion process and coating process. The main components are extruder, cooling system, curing chamber (if any), traction system and control system. It is suitable for the production of various power cables, communication cables and special cables. Manufacturers can use this machine to efficiently produce cables that meet industry standards and specific needs.

The reason for the high temperature of the motor bearing is poor lubrication and severe wear. The solution is to lubricate the bearing and replace the worn bearing if necessary. Unstable head pressure may be caused by the change of the main motor speed and the inconsistent speed of the feed motor affecting the feed. The solution includes checking the main motor system and bearings, as well as checking the feed motor and control system.

Extruder maintenance and cleaning are essential in the electronic industry. Cleaning methods for the extruder screw include:

A. Epoxy resin cleaning: Uses resin glue to remove residual materials causing slow extrusion rates and color variations.

B. Disassembly and cleaning:

  1. Manually add washing material to match colors, then stop feeding and discharge.
  2. Gradually remove the feed pipe.
  3. Clean the screw, discharge residue, and remove packing.
  4. Check cleanliness, remove finished products, reinstall the screw, and clean the barrel.
  5. Reassemble for cleaning.

C. Fire burning method: Utilizes a gas furnace to remove plastic residues effectively by baking after screw use.

Extruder Maintenance:

Regular Inspection:

  1. Check screw and barrel for wear.
  2. Inspect heating and cooling systems.
  3. Monitor motor and gearbox.
  4. Verify temperature and pressure gauges.
  5. Assess cleanliness and lubrication.

Emergency Solutions:

  1. Clear blockages promptly.
  2. Reduce temperature for overheating.
  3. Investigate production drops.
  4. Shutdown and seek professional help for electrical issues.
  5. Keep spare parts for quick replacements.
  • High temperature can cause excessive brightness, low temperature can lead to poor appearance and uneven discharge pressure, potentially damaging the machine.
  • Hairy and uneven appearance may result from rubber moisture; use a dryer at around 60°C when pouring rubber into the hopper.
  • Check if delivered products meet requirements, inspect cables for scratches and correct arrangement.
  • Compare wire samples to ensure color and surface quality meet standards.
  • Unstable outer diameter may be due to uneven tension or improper mold distance.
  • Concave appearance suggests small inner eye issues; check and correct semi-finished product shaking.
  • Set spray content per instructions, ensuring consistency and proper spacing.
  • Check wire surface smoothness and diameter tolerance.
  • Ensure sheath fit is neither too tight nor loose, core is secure, with a minimum 0.5mm thickness.
  • Avoid extended shutdown to prevent burning of screw and head rubber.
  • Check take-up line condition and spacing adequacy.
  • After 12-hour operation, disassemble machine head, replace filter screen to prevent wire impurities.
  • Continuously monitor wire diameter, appearance, and spray content to maintain wire quality.
  • Check and replenish lubrication in equipment parts and gear oil in the reduction box to the marked line. Ensure quality meets standards.
  • Power up the control box circuit.
  • Start the lubricating hydraulic pump to distribute oil to each part, verifying proper function.
  • Inspect hopper and barrel for foreign objects; ensure the magnetic frame is operational.
  • Test lubricating oil pump motor direction and start pump, checking oil spray position and pipeline leaks. Lubricate for 3 minutes if all is well.
  • Start screw motor at low speed, monitoring ammeter and voltmeter for abnormalities. Power consumption should not exceed 15% of rated value.
  • Verify correct screw rotation and check for barrel friction.
  • Inspect pipelines for leaks, correct connection mode, and flow direction.
  • Stop screw rotation, examine screw and barrel for damage. Replace if necessary.
  • Conduct screw speed adjustment test using tachometer, comparing with instructions.
  • Test emergency stop button functionality.
  • Reinstall the screw once everything is normal.
  • Barrel heating sequence:
    a. Heat each barrel section to process temperature requirements under supervision.
    b. Maintain temperature for 1 hour after reaching target temperature.
    c. Use a mercury thermometer to verify barrel temperatures against instrument settings.
    d. Ensure heating resistance alarm in barrel heating device functions accurately.
    e. Turn off barrel heating, start cooling system, check operation, water flow, and for leaks.

Precautions for Extended Extruder Inactivity:

  1. Use soft water for cooling systems handling materials with internal heat. Fill the water tank with soft water to the specified level.
  2. Check heater insulation using a megger; ensure resistance is below 0.5 Μ Ω.
  3. Clean storage bin and hopper, then fill with materials after ensuring no foreign objects.
  4. Add lubricating oil to mid-level in the tank, test pump for lubrication, and top up to mid-level.
  5. Ensure unblocked water, oil, and vacuum pipes, with leak-free valves.
  6. Verify screw barrel configuration suits materials; adjust if needed.
  7. Confirm proper installation of detection elements like thermocouples.
  8. Check main and feeding motor rotation directions; main machine should rotate clockwise.
  9. For oil vacuum exhaust, fill condensate tank with tap water to specified level, and check exhaust chamber seal.
  10. Cool extruder main machine with soft water.
  11. Inspect electrical wiring for accuracy and tightness.

Poor Plasticization in Cable Extruder Raw Materials: Causes and Solutions

Poor plasticization in extruder materials is evident through toad skin extrusion, dark and crack-prone surfaces, and seams in cladding layers. Causes include:

a. Low temperature control, especially at the head.
b. Mixing of incompatible plastic particles in insulating/sheathing materials.
c. Excessive screw rotation leading to incomplete plasticization.
d. Quality issues within the plastic material itself.

To address these issues, focus on rational temperature control, verifying material quality, avoiding excessive output speed, proper material storage (especially during drying), appropriate die matching, and enhancing extrusion pressure and screw reflux.

Additionally, scorching is a common defect in plastic extrusion, characterized by high temperature displays, smoke, odors, popping sounds, coke particles, and bubbles at joints. Causes include:

a. Excessive temperatures causing plastic thermal degradation.
b. Accumulated scorched materials in the screw due to poor cleaning.
c. Prolonged heating/shutdown times leading to plastic decomposition.
d. Temperature control instrument malfunctions.
e. Inadequate cooling resulting in material overheating due to friction.

To mitigate these issues, ensure normal operation of heating and cooling systems, set ejection temperatures as per process requirements and screw speed, and control heating temperatures effectively.

Key points for operation, maintenance and repair of cable extruder: Operation: Operate according to the manual, monitor parameters and comply with safety regulations. Maintenance: Clean and lubricate regularly and check electrical components. Repair: Stop the machine when a fault is found, diagnose and repair, and use original parts. Proper operation, regular maintenance and timely repairs can ensure the performance and life of the extruder.

  • Copper and aluminum conductor drawing:
    Using a wire drawing machine, copper and aluminum rods can be elongated and strengthened by passing through die holes at normal temperature. Wire drawing is the initial step in wire and cable manufacturing, with die matching being a critical process parameter.

  • Single wire annealing:
    Heating copper and aluminum monofilaments to enhance toughness and meet wire and cable requirements by recrystallization. Key focus is on preventing copper wire oxidation.

  • Conductor stranding:
    To enhance flexibility and ease of installation, multiple monofilaments are used to create the conductive wire core. Stranding can be regular or irregular, with irregular options including bundle, concentric compound, and special stranding.

The basket type rope stranding machine enhances production efficiency by streamlining the process from strand to rope making, resulting in minimal waste and improved aesthetics. The tube type rope closing machine efficiently produces multiple strands simultaneously, boasting a compact structure, ease of operation, high product quality, and low maintenance. With adjustable twist settings, ropes can be tailored without the need to pre-manufacture strands.

In the basket type machine, yarns are twisted into strands in the opposite direction to the yarns’ twist according to technical specifications. The automatic braiding device organizes and spools the rope seamlessly, allowing for customizable length and weight adjustments. The machine halts automatically when reaching user-set values. The tube type machine suits industries using sisal fiber, plastic, and nylon as raw materials.

The machine is mechanically segmented into stretching and winding parts, with electrical control comprising stepless speed regulation for stretching and synchronous tension control for winding. The feedback control system adjusts tension pendulum positions automatically. By regulating the winding motor speed, constant tension and synchronized speed across stretching and winding processes are ensured, enabling uniform winding of finished metal wire at varying speeds.

Arrange the yarns: First, according to the technical requirements, multiple yarns are arranged together at a certain line density.
Twist into ropes: The yarns are twisted together in the opposite direction of the yarn twisting to form ropes. This twisting process will cause the yarns to entangle with each other, and finally form a strong rope structure.
Automatic weaving: The basket rope machine has a built-in automatic weaving device, which can automatically weave the ropes onto the bobbin in an orderly manner. This helps to maintain the neatness and beauty of the rope.
Production control: The machine is able to count according to production needs and adjust the length and weight of the rope according to requirements. When the machine reaches the value set by the user, it can automatically stop working.
Application field: The basket rope machine is suitable for the rope manufacturing industry using raw materials such as hemp fiber, plastic and nylon filament.
The basket rope machine is known for its efficient production, simple operation and high-quality ropes. It is an important equipment in the rope manufacturing process.

Steel wire armoring machine:

  • Composition:

    1. Pay-off System
    2. Wire Feeding Mechanism
    3. Armoring Unit
    4. Tension Control System
    5. Take-up System
  • Application:

    • Cable Manufacturing
    • Mechanical Protection
    • Outdoor and Harsh Environments
    • Military and Defense
    • Oil and Gas Industry

The machine adds steel wire armor for mechanical protection, essential in cable production for various industries and applications.

Composition:

  1. Pay-off System: Feeds the cable/core wire into the machine.
  2. Wire Feeding Mechanism: Supplies steel wires for armoring.
  3. Armoring Unit: Twists steel wires around the cable/core for protection.
  4. Tension Control System: Regulates wire tension during armoring.
  5. Take-up System: Collects the armored cable post-armoring.

Application:

  • Cable Manufacturing
  • Mechanical Protection
  • Outdoor and Harsh Environments
  • Military and Defense
  • Oil and Gas Industry

Steel wire armoring machines are crucial for enhancing cable strength and durability in various industries and applications.

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