Power Cable Steel Wire Armoring Machine PLC+HMI​ With Recipe Storage

Power Cable Steel Wire Armoring Machine PLC+HMI​ With Recipe Storage

Steel Wire Armouring Machine Overview​
A steel wire armouring machine wraps high‑strength steel wires around a cable core (single or double helix) to provide mechanical protection for power and control cables in harsh environments. It is widely used in ​construction, mining, maritime, and heavy‑lifting​ applications where resistance to impact, abrasion, and tensile load is critical. The process ensures the cable maintains integrity under bending, compression, and environmental stress, forming the outermost protective layer before final jacketing and coiling.
​Key Components and Working Principle​

Line composition: ​central pay‑off, ​armouring cage (stranding cage)​, ​die holder, ​taping head​ (for pre‑wrapping/taping), ​traction system, ​capstan, ​meter counter, ​take‑up with traversing, ​drive system, and ​electric/PLC‑HMI control.
Process flow: feed the core → pre‑wrap/tape if required → feed steel wire from bobbins → planetary/rotary stranding with controlled ​lay length​ and ​tension​ → form/compact with dies → pull through capstan → take‑up and coil.
Drive and control: planetary or gear‑driven cages with ​servo/PLC​ closed‑loop control for pitch and tension; emergency stop, broken‑wire detection, and safety interlocks are standard.

​Typical Specifications and Configurations​

Wire diameter scope: commonly handles ​0.8–4.0 mm​ steel wire (models available for ​1–2.5 mm​ as well), suitable for single‑ or double‑wire armouring.
Max. armour OD: typically up to ​70 mm​ across popular models.
Cage and bobbins: ​24/36/42/48​ bobbin configurations; bobbin sizes ​315–630 mm; center pay‑off up to ​PN3150; capstan diameters ​1600–2500 mm.
Speed and line pull: cage speeds roughly ​28–100 r/min​ (depending on bobbin count and model), maximum line speed ​25–45 m/min, maximum haul‑off force ​10–20 T.
Drive options: planetary gearboxes (e.g., ​36‑stage), quenched helical gears; PLC+HMI with touch screen for recipe setup and monitoring.
Special builds: dual‑cage ​48+48​ high‑productivity lines and configurations for ​DIN 400​ processes are available.

​Process Control and Quality Assurance​

Tension control: multi‑zone tensioning across pay‑off, cage, and take‑up maintains uniform lay and prevents wire breakage or looseness; closed‑loop systems improve consistency.
Pitch and geometry: planetary motion with precise lay‑length programming; die selection and pre‑forming ensure roundness, compactness, and correct helix geometry.
Defect prevention: real‑time monitoring for ​broken wire, ​mis‑lay, and ​tension spikes; proper guide alignment and wire straightening minimize ​protrusion, gaps, and overlaps.
Materials handling: preheating/tensioning of wires, clean and deburred dies, and consistent lubrication protect surface finish and die life.

​Selection Criteria and Safety​

Match the machine to your product: target ​OD, ​wire gauge, single/double armour, desired ​lay length/range, and required ​output (m/min)​.
Capacity planning: select cage size and bobbin count (e.g., ​24–48​ bobbins) based on target productivity and changeover needs; ensure sufficient capstan pull (10–20 T) for your core weight and lay.
Control and integration: prefer ​PLC+HMI​ with recipe storage, remote diagnostics, and integration to upstream/downstream equipment (pay‑off, take‑up, spooling).
Safety and uptime: ensure ​emergency stop, broken‑wire trip, guarding, and lubrication systems; verify electrical classification and earthing for the operating environment.
Application guidance: choose single‑wire for standard mechanical protection and double‑wire for higher transverse strength; align wire grade and coating (e.g., galvanized) with corrosion and conductivity requirements