How Pull-Type Cantilever Winding Made Our Copper Twisting Machine More Accurate and Efficient

Read Time:5 Minute, 18 Second

In modern cable manufacturing, particularly for network and power cables, achieving precise winding and maintaining stable tension are critical to product quality. Any deviation in wire tension or winding alignment can lead to insulation damage, uneven conductor lay, or compromised signal integrity. Traditional vertical-type winding machines often struggle to maintain consistent tension, especially when winding from empty reels to full reels.

Jinghan Machinery, leveraging over two decades of innovation in cable production systems, introduced a pull-type cantilever winding mechanism for copper twisting machines. This design significantly improves both accuracy and operational efficiency. Below, we explore how this system works, why it outperforms traditional winding methods, and how it benefits high-speed cable production.

1. Pull-Type Cantilever Winding: Core Mechanism

The pull-type cantilever winding system operates on a principle of direct tension regulation:

Pull-Type Operation: The wire is pulled through the winding system by a controlled tension source rather than relying solely on reel inertia. This ensures that the tension remains constant throughout acceleration, deceleration, and full-speed operation.
Cantilever Design: The spool is supported at one end, allowing it to rotate freely without interference from structural supports. This reduces mechanical resistance and ensures smooth wire movement.

Benefit: By combining pull-based tension control with cantilever support, the system prevents over-tightening or slack, achieving highly uniform winding.

2. Precise Tension Control Through PLC Automation

Maintaining consistent tension is the key to winding accuracy:

PLC-Controlled Tension: Operators can set the desired tension via a touch screen. The PLC continuously monitors and adjusts puller and belt speeds to maintain constant tension.
Stable Under Varying Loads: Whether the reel is empty or near full, the system compensates automatically, preventing fluctuations that could affect wire alignment or cause insulation damage.
Acceleration & Deceleration Compensation: Pull-type cantilever winding adapts tension dynamically during line speed changes, eliminating manual adjustments.

Outcome: Wire tension remains uniform throughout the winding process, which directly improves winding accuracy, conductor alignment, and insulation integrity.

3. Axial Arrangement for Optimized Winding

Jinghan Machinery’s latest model allows flexible axial arrangement:

Custom Row Width and Spacing: Operators can adjust the row width and spacing to match different wire diameters and production requirements.
Even Layer Distribution: Axial winding ensures that each layer is precisely aligned, reducing the risk of wire overlap or gaps.
High-Speed Capability: The cantilever design minimizes friction and mechanical resistance, allowing higher rotational speeds compared to traditional vertical-type machines.

Effect: Enhanced precision and efficiency result in higher-quality spools and faster production rates.

4. Impact on Copper Twisting Machine Accuracy

Pull-type cantilever winding improves several critical aspects of twisting machine performance:

Pair Pitch Stability: Precise tension reduces conductor stretching or compression, ensuring consistent pair pitch for data cables.
Concentricity and Roundness: Stable winding preserves core alignment, enhancing EMI resistance and signal integrity.
Outer Layer Uniformity: The uniform tension maintains consistent insulation thickness and prevents wire deformation during winding.

Result: Products meet high industry standards for both network and power cable applications.

5. Operational Efficiency and High-Speed Production

Efficiency is significantly enhanced through this winding method:

High Rotational Speeds: Cantilever support reduces mechanical drag, enabling twice the production efficiency of vertical-type machines.
Reduced Manual Intervention: Automated tension and PLC control minimize the need for constant operator adjustments.
Streamlined Material Handling: Pull-type operation ensures continuous feeding from empty reels, eliminating production delays caused by tension fluctuations.

Impact: Faster, more reliable production without sacrificing wire quality.

6. Integration with Multi-Strand and Multi-Core Applications

Pull-type cantilever winding is highly compatible with complex cable structures:

Multiple-Strand Core Wires: Maintains uniform tension across all strands, ensuring perfect twisting and minimizing crossovers.
High-Frequency and Data Cables: Stable tension preserves conductor alignment and reduces crosstalk.
Power Cables: Prevents insulation damage, even at high extrusion speeds or heavy conductor sizes.

Benefit: Provides versatility for manufacturers producing Cat5e–Cat8 network cables, industrial power cables, and specialty high-frequency wires.

7. Belt Tension Optimization and Mechanical Stability

Stable belt and line tension are crucial:

Integrated Belt Tensioners: Pull-type systems monitor and adjust belt tension in real-time.
Mechanical Stability: The cantilever design reduces mechanical stress on bearings and supports, prolonging machine lifespan.
Reduced Vibration: Smooth winding reduces micro-slippage and maintains consistent layer distribution.

Outcome: A combination of belt tension and cantilever support ensures high precision with minimal maintenance requirements.

8. Quality and Precision Control Features

Jinghan Machinery’s pull-type cantilever winding incorporates advanced features for quality assurance:

Touch Screen Tension Settings: Allows operators to fine-tune parameters for different wire types.
Real-Time Monitoring: Continuous feedback prevents deviation in winding tension and diameter.
Automatic Correction: The system compensates for sudden tension changes, reel inconsistencies, or line speed variations.

Result: Every spool produced meets strict tolerances for diameter, roundness, and insulation uniformity.

9. Comparative Table: Pull-Type Cantilever vs Traditional Vertical Winding

Feature	Traditional Vertical Winding	Pull-Type Cantilever Winding
Tension Stability	Moderate, requires frequent adjustment	High, automated PLC-controlled
Winding Accuracy	Variable	Precise, uniform layers
Production Efficiency	Moderate	High-speed, twice the output
Operator Intervention	Frequent	Minimal
Multi-Core Compatibility	Limited	Excellent
Mechanical Wear	Higher due to friction	Lower, reduced drag & vibration
Layer Uniformity	Less consistent	Highly consistent

FAQ

Q1: How does pull-type cantilever winding improve conductor alignment?
By maintaining constant tension and precise axial arrangement, the wires are wound uniformly without shifting or twisting, preserving core alignment.

Q2: Can this system handle empty to full reel transitions smoothly?
Yes. Real-time tension feedback compensates for changing reel diameter, maintaining stable tension throughout.

Q3: Does this method reduce operator workload?
Significantly. Automated tension control and PLC monitoring minimize manual interventions, allowing operators to focus on production oversight.

Q4: Is it compatible with high-frequency network cables?
Absolutely. Stable tension preserves pair pitch and reduces crosstalk, ensuring signal integrity in Cat5e–Cat8 cables.

Q5: What maintenance is required for optimal performance?
Routine inspection of belt tensioners, bearings, and puller alignment is sufficient due to reduced mechanical stress and vibration in the cantilever design.

Conclusion

Pull-type cantilever winding has revolutionized copper twisting machines by combining automated tension control, axial arrangement, and cantilever mechanical design. This results in higher accuracy, consistent conductor alignment, uniform insulation layers, and enhanced production efficiency. Jinghan Machinery’s advanced winding solutions enable cable manufacturers to achieve superior product quality, faster output, and reduced operator workload. For high-speed, multi-strand, and multi-core applications, pull-type cantilever winding is a game-changing innovation that elevates the standard of cable production.

www.jinhanmachinery.com
Jinghan Machinery (Dongguan) Co., Ltd.