Basic knowledge, installation and maintenance, common problems and solutions of cable forming machine

Generally, the cable forming machine can be divided into cage type cable forming machine and high-speed cage type cable forming machine. The high-speed cage cable forming machine is used for the stranding of copper core aluminum stranded wire and bare aluminum wire. At the same time, it can also be used for the cable forming of plastic cable, rubber sheathed cable and other products.

Purpose of cable forming machine

Cable forming machine is a necessary equipment for cable production. It has many varieties, complete specifications and wide application. Users can choose the corresponding cable forming equipment according to their own production needs. The equipment has the functions of untwisting and non untwisting. The untwisting modes include untwisting ring untwisting, star gear system untwisting and sprocket untwisting. The form of pre twisting is divided into manual pre twisting and electric pre twisting. The coil clamping is divided into dynamic clamping and electric clamping, and the take-up is divided into the form with shaft and without shaft.

Equipment composition

Pay off frame, stranding cage, wire mold base, wrapping machine, armor loader, meter counter, traction device, take-up and arrangement frame, transmission system and electrical system.

Main technical parameters

1. Cable section 2, winch speed 3, cable pitch 4, winding head speed 5, winding pitch 6, traction wheel diameter 7, outgoing line speed.

Types of cable formers

There are two types of cable forming machines: ordinary type and reel type. There are two types of ordinary cable forming machines, cage type and disc type, and the cable forming speed is generally less than 10m / min.

The large-scale cable forming mechanism is disc type, which can form three core, four core and five core cables. For example, for 1 + 3 / 1600, 1 + 3 / 2400, 1 + 4 / 1600 and 1 + 4 / 2400 cable formers, the maximum pay off reel is 1600mm and 2400mm respectively. The medium and small-sized cable forming machines are cage type, and the stranding part is like the stranding cage of the stranding machine, which has 1 + 6 / 1000 and 1 + 6 / 400 specifications.

The reel type cable forming machine is a relatively new cable forming equipment, with high production efficiency, speed generally above 30m / min and wide application range. It can be used for the cable forming of various power cables, communication cables, control cables and split conductors of large section EHV cables.

Installation and maintenance of cable former

>>>>install

Before installing the machine, the foundation and anchor screw holes shall be reserved according to the dimensions of the foundation drawing, and can be installed only after the foundation is solidified (the anchor hole position of each component shall be positioned on site according to the actual size, and then poured with cement for fixation).

First, determine two standard points on the foundation, pop up an ink line with an ink bucket, and lead out the center line of the machine. Then, according to the size and position of the drawing, arrange the main engine gearbox, support seat, winch, paper Baotou, steel Baotou, traction wheel and other components in order according to the general drawing.

At the same time, set up two one meter high posts at both ends of the ink line, and tighten a thin line to make it on the same axis through the hollow shaft. Then install the main engine gear box, winch cage, wrapping head, steel strip head, universal coupling and 27 stage gearbox.

>>>>lubrication

Local lubrication is adopted for each unit of the machine. The gear reducer shall be filled with 30-40 oil, and the oil level shall be observed from the oil sight hole frequently. The oil in the box shall be replaced. Calcium based grease shall be added to each transmission shaft bearing. The equipment requiring lubricating oil in the box include:

① Winch gearbox ② corner gearbox ③ reducer ④ winding head gearbox ⑤ steel belt head gearbox ⑥ traction gearbox ⑦ wire arrangement gearbox ⑧ lifting worm gear box after 1000 hours of production, each gearbox shall be cleaned and replaced with new oil, and then replaced with new oil every 12 months.

The parts with relative movement (slideway, screw rod, open gear pair, etc.) shall be refueled once before production. Grease parts shall be filled once a year.

>>>>maintain

Check the oil level of the gearbox once a month. If the oil level is lower than the oil line, add new oil. Before each shift of production, check whether the fastening screws of the wireframe gland are loose and tightened.

One month after production, check whether the anchor and screws are loose. Once found, tighten them in time, whether the moving parts are abnormal, and whether the operation of the winch is stable. Check and adjust the supporting wheel to ensure the operation of the winch.

Precautions and operation of cable forming machine

>>>>Preparation before startup

The operator shall first check the lubrication of all rotating parts of the machine, whether the position of the speed change handle is in place, whether all parts of the machine are normal, whether the turnover of the winch cage is flexible, whether the back twist bolt is correctly placed, whether the cradle bolts are tightened, and whether all safety devices are in good condition. After checking properly, operate at a slow speed first.

According to the product process requirements, make preparations before cable forming, hoist the cable core required to be twisted onto the frame, and choose to use back twisting or non back twisting, then lead the cable core from the reel to the front end of the distribution reel, pass through the wire mold base after manual twisting, and lead out the cable head with the help of a traction cable. At this time, start the machine to run slowly to make the outgoing cable have sufficient length, and after winding several times on the traction wheel, Start the machine again. After a certain period of operation, the twisted cable can be wound onto the reel.

>>>>Operation of hoisting reel and brake

Make the winch cage frame at the top horizontal position, tighten the brake, open the bearing bush, hoist the reel into the frame with a crane, close the bearing bush, tighten the bolts, release the brake, adjust the hoisted reel to the bottom, tighten the brake, and then hoist other reels according to the above methods

>>>>matters needing attention

Make the winch cage frame at the top horizontal position, tighten the brake, open the bearing bush, hoist the reel into the frame with a crane, close the bearing bush, tighten the bolts, release the brake, adjust the hoisted reel to the bottom, tighten the brake, and then hoist other reels according to the above methods

Common problems and Solutions

>>>>After cable forming, the cable is serpentine

Cause analysis:

1. The cable tension is uneven.

2. The cable pitch does not meet the requirements.

3. The winding arrangement is pressed into a snake shape.

Solution:

1. Adjust the setting out tension.

2. Adjust the pitch.

3. Pay attention to the tight and neat arrangement of wires.

>>>>Fan shaped insulated core turning over

Cause analysis:

1. Improper pre torsion angle.

2. The wire core on the pay off reel turns over, and the wire core turns back when it is separated to lower the reel, resulting in turning over.

Solution:

1. adjust the distance between the pre twist angle or the press die and the guide wheel of the wire core.

2. Properly adjust the pre twist angle. When the wire core is placed on the plates on both sides of the coil, pay special attention to the angle of the wire core entering the die.

>>>>Core insulation damage

Cause analysis:

1. The insulating core is damaged during transportation and storage after the footwall.

2. The insulation of the insulated core coil is damaged by the ferrule during the cable forming process.

3. The wire core insulation is twisted due to improper operation during cable forming.

Solution:

1. Do not damage the insulation during storage and handling.

2. Timely handle the snare found in the insulation winding and arranging of wire core.

3. Pre torque shall be appropriate.