In the cable manufacturing industry, stranding and armouring lines are essential for producing robust and reliable cables. One of the key machines used in this process is the Drum Twister, which plays a pivotal role in twisting, armouring, and protecting cable cores. This article will provide a comprehensive guide on drum twisters, their operation, key equipment involved, and the advantages of modern armouring and stranding technology.
Drum Twister: What Is It?
A Drum Twister is a specialized machine designed to handle high-speed twisting and armouring of cables. It can process different types of cables, including power cables, optical fibers, and subsea cables. Drum Twisters are preferred for their versatility, allowing for the efficient production of both single-core and multi-core cables.
Drum Twister 1 and Drum Twister 2
There are various configurations of drum twisters, often labeled as Drum Twister 1 and Drum Twister 2, based on the application and complexity of the cabling operation:
- Drum Twister 1: Typically used for basic twisting operations involving single-core cables.
- Drum Twister 2: An advanced version that can handle multi-core cables, providing enhanced control and precision during the stranding process.
Both types of drum twisters ensure the proper formation of cables while minimizing stress on the materials, enhancing the durability of the final product.
Assembling and Armouring Line
The Assembling and Armouring Line is an integrated system that combines multiple stages of cable manufacturing. After the stranding process, cables are often armoured to provide additional protection, especially for cables used in harsh environments like underwater or underground.
Key Components of the Assembling and Armouring Line
- Core Assembling Unit: This unit ensures that all core components of the cable are correctly positioned before the armouring process begins.
- Armouring Unit: In this stage, steel wires or tapes are applied to the cable to enhance its strength and resistance to external factors.
Line Equipments in a Drum Twister System
The efficiency of a drum twister largely depends on the equipment that supports its operations. Here are some critical components:
2500 / 1600 mm Rotating Pay-Off
The Rotating Pay-Off is responsible for unwinding the cable during the manufacturing process. The dimensions of the pay-off are critical, as larger sizes, such as the 2500/1600 mm configurations, are better suited for high-capacity operations where long cable lengths are involved.
2500 mm Rotating Take-Up
Similarly, the Rotating Take-Up winds the cable onto a drum after it has been processed by the drum twister. Like the pay-off, a larger take-up unit ensures smooth handling of extensive cable lengths, preventing tangling and damage during winding.
Rotating Caterpillar (1800 kgF)
The Rotating Caterpillar provides the necessary traction force to move the cable through the drum twister system. With a force of 1800 kgF, this component ensures that the cable is smoothly and steadily fed through the twisting and armouring process, minimizing the risk of breaks or interruptions.
Die Stand and Length Counter
- Die Stand: This device shapes the cable as it passes through the system, ensuring uniformity in diameter and structure.
- Length Counter: Ensures precise measurements, allowing manufacturers to track the exact length of the cable being produced, essential for meeting specific customer requirements.
Guide Rollers
Guide Rollers are used to direct the cable throughout the manufacturing process. They maintain the correct tension and alignment, preventing the cable from veering off course and ensuring that the twisting and armouring process remains consistent.
Sector Core Deflecting Unit
For cables with sector-shaped cores, the Sector Core Deflecting Unit helps position the core correctly before armouring. This ensures that the unique shape of the core is maintained throughout the stranding and armouring processes, providing optimal performance in the finished cable.
Steel Taping Machine
Steel Taping Machines are critical for armouring cables. This equipment applies a layer of steel tape around the cable, offering enhanced mechanical protection and resistance to external damage.
Paper Taping Machine
The Paper Taping Machine adds another layer of insulation or protection, depending on the cable’s design. Paper taping is commonly used for specific types of cables, especially those used in telecommunication and high-voltage applications.
Electrical Control Cabinet
The Electrical Control Cabinet is the brain of the operation, controlling all the systems in the drum twister. It ensures synchronization between different components, maintaining precision and consistency during the stranding and armouring process.
Alternatives to Standard Equipment
For larger or more complex cable operations, alternatives to standard equipment are available:
3000/3600 mm Rotating Pay-Off / Take-Up
These larger Rotating Pay-Off and Take-Up machines handle even longer and heavier cables, making them suitable for large-scale industrial projects such as subsea or high-voltage power cables.
Benefits of Drum Twister Technology
- Efficiency: Drum twisters offer high-speed operation, enabling manufacturers to produce large quantities of cables in a shorter amount of time.
- Precision: The advanced controls and components in drum twisters ensure that each cable is produced with exact specifications.
- Versatility: Drum twisters can be used for a wide range of cable types, making them essential for cable manufacturers working with various industries.
Frequently Asked Questions (FAQs)
1. What is a drum twister used for?
A drum twister is used for twisting and armouring cables, ensuring their durability and mechanical protection, especially for industrial and telecommunication applications.
2. How does a drum twister work?
A drum twister works by rotating the cable around its axis while it is twisted and armoured, creating a uniform, durable product.
3. What is the difference between Drum Twister 1 and Drum Twister 2?
Drum Twister 1 is used for simpler, single-core cables, while Drum Twister 2 is designed for more complex, multi-core cables.
4. Why is armouring important in cable manufacturing?
Armouring provides additional mechanical protection to the cable, making it suitable for harsh environments like underwater or underground.
5. What is the function of the Rotating Pay-Off and Take-Up?
The Rotating Pay-Off unwinds the cable, while the Take-Up winds it onto a drum after processing, both playing crucial roles in cable handling.
6. Can drum twisters handle large-scale cable production?
Yes, with equipment alternatives like the 3000/3600 mm Rotating Pay-Off/Take-Up, drum twisters are capable of handling large-scale, high-capacity cable production.
Conclusion
The drum twister and armouring line represent a critical aspect of modern cable manufacturing, enabling the production of strong, reliable, and durable cables. With advancements in technology and equipment, these systems continue to improve in efficiency, precision, and versatility, serving a wide range of industries worldwide.
[…] A Drum Twister is a specialized machine designed to handle high-speed twisting and armouring of cables. It can process different types of cables, including power cables, optical fibers, and subsea cables. Drum Twisters are preferred for their versatility, allowing for the efficient production of both single-core and multi-core cables. […]