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1、Adaptable wire diameter range: 5-10mm
2、Speed: max200m/min
3、Meter counting accuracy: ±0.5%.
1、Adaptable wire diameter range: 5-10mm
2、Speed: max200m/min
3、Meter counting accuracy: ±0.5%.
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See DetailsWhat are the main working principles of a Cable Mesh Winding Machine?
Working Principles of a Cable Mesh Winding Machine:
1. Drive and Rotation: A high-efficiency motor (AC induction or DC) directly drives the drum, achieving fast and smooth rotation.
2. Tension and Speed Closed-Loop Control: Through a tension sensor and PLC/PLC-HMI closed-loop adjustment, constant tension and synchronized rotation speed are maintained to prevent wire breakage or over-tightening.
3. Mesh Winding: The metal mesh (or multiple cables) enters a dedicated clamping-guide element under gravity. The element is stacked layer by layer with the help of the winding device, forming a dense and intersecting mesh structure, significantly reducing the risk of tangling and knotting.
4. Layer and Pattern Programming: The CNC/servo system can preset the number of layers and laying patterns (crossing, diagonal, etc.) to achieve precise winding of multiple specifications of LAN cables (Cat5e-Cat8).
What are the key differences between a Cable Mesh Winding Machine and a regular Cable Winding Machine?
| Cable Mesh Winding Machine (mesh‑type winding) | Conventional Cable Winding Machine (traditional winding) | |
| Winding Structure | Uses a mesh‑style cross‑winding; cables pass between multiple guide arms and are stacked in an interlaced grid, greatly reducing tangles and knots. | Single guide arm or fixed track; cables are wound directly onto the drum in successive layers, prone to entanglement. |
| Tension Control | Multiple tension sensors monitor in real time; closed‑loop algorithm keeps tension within ±0.5 % accuracy. | Single‑point tension control; relatively lower precision. |
| Automation Level | Fully automatic: automatic feeding, cutting, loading/unloading, metering, and leakage detection are integrated. | Often semi‑automatic or manual; requires human intervention for loading, metering, or cutting. |
| Capacity & Efficiency | Up to 200 m/min, suitable for 5‑10 mm wire diameters; a single machine can produce over 100,000 m per day. | Speed is limited; overall capacity is lower. |
| Applicable Range | Designed for high‑speed network cables (Cat5e‑Cat8) where packaging quality is critical. | Primarily for general power or low‑speed cables in bulk production. |
| Equipment Structure | Modular mechanical design allows quick replacement of mesh guide units, simplifying maintenance. | More monolithic structure; modifications are difficult. |
How are automatic winding, metering, and leak detection achieved? Technical Solutions for Automated Winding, Metering, and Leak Detection
1. Automated Winding
Multi-axis Drive: The main motor drives the drum to rotate, while the transverse guide motor moves synchronously, achieving uniform layering.
Robot/Pneumatic Arm: Working in conjunction with a PLC, it enables automated wire arrangement, automatic wire cutting, and automatic loading and unloading, truly allowing for "one-person monitoring."
2. High-Precision Metering
Track-type Counter: A track counting device is installed on the side of the drum, using photoelectric or magnetic induction methods, achieving a metering accuracy of ±0.5% (0.5‰).
Length Setting and Automatic Stop: The system can preset a target length; once the target length is reached, winding automatically stops to prevent overwinding.
3. Leakage (Electrical Leakage) Detection
Leakage Spark Detector: High-sensitivity detectors are placed along the winding path to monitor cable insulation leakage in real time. Once an abnormality is detected, the system immediately stops and returns to the leakage point for re-inspection.
Closed-Loop Safety Control: The detection signal is directly fed back to the PLC, triggering an emergency stop and alarm to ensure operational safety.
4. Intelligent Optimization
AI/Big Data Analysis: Collects operational data such as tension, speed, and power, and uses machine learning models to dynamically optimize parameters, further improving finished product quality and reducing scrap rate.
Frequently Asked Questions (FAQ)
Q1:What are the technological advantages of the Cable Mesh Winding Machine?
A:It adopts a fully domestically produced control system, possessing high-speed, precise cable winding and tension control; it has a compact structure and short cable changeover time; it supports dual monitoring by PLC and host computer, achieving flexible automation.
Q2:What is the annual output value and scale of Dachen Machinery?
A:The modern factory covers an area of approximately 10,000 m², and its annual output value has exceeded 50 million RMB.
Q3:What are the core competitive advantages of Dachen Machinery?
A:① A complete independent R&D chain (mechanical-electrical-software)
② A high proportion of senior engineers in the team
③ Rapid delivery and flexible customization capabilities
④ National High-tech Enterprise qualification and ISO quality system certification
Q4:Do Dachen Machinery's machines support automated control?
A:All new equipment adopts PLC/IPC control, equipped with HMI/SCADA interfaces, enabling fully automated production and data acquisition.
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