Specification for Φ800 Steel Tape Armoring Machine Production Line

IV. Equipment Introduction of Production Line Components

Φ1600/3150 Gantry-type Passive Pay-off Rack

• Pay-off rack type: Gantry ground rail traveling, magnetic powder tension
• Adaptable reels: PN1600—PN3150
• Reel diameter range: Φ1600～Φ3150mm
• Adaptable reel width: 1300～2300mm
• Adaptable cable diameter: Φ10—Φ120mm
• Travel motor: 2.2kw AC motor + cycloidal pinwheel reducer (1 set)
• Lifting motor: 3kw AC motor + cycloidal pinwheel reducer (2 sets)
• Clamping motor: 0.75kw AC motor + cycloidal pinwheel reducer (1 set)
• Load capacity: 20 tons
• Structure type: Gantry ground rail traveling type, upper sleeve type; gantry frame formed by bending and welding; the two centers of the reel are lifted by lead screws and nuts driven by two motors via cycloidal reducers; each center seat can be lifted individually or simultaneously, with dual mechanical and electrical protection devices; different specifications of center sleeves can be equipped if needed to meet the installation of different reel specifications; reel clamping is achieved via motor-reduction, with clamping overload protection.
• Tension mode: Passive tension by magnetic powder brake, adjustable tension according to cable size.

Aligner

Semi-cut Non-metallic Tape Lapping Main Machine

• Adaptable cable diameter: Φ10～Φ60mm
• Tape thickness: 0.1～0.4mm
• Tape reel specification: Φ630×Φ80×(15～80)mm
• Tray outer diameter: Φ650×14mm
• Number of tape reels: 2
• Lapping head speed: 600rpm
• Lapping head pitch: Steplessly adjustable
• Motor power: 15kw (permanent magnet servo motor)
• Equipment direction: Right-hand machine/Left-hand machine
• Equipment center height: 1000mm
• Tape pay-off tension: Controlled by imported German ZF hysteresis tension control, with automatic adjustment.
• Driven by a separate permanent magnet servo motor, speed regulated by frequency converter; lapping pitch adjusted proportionally to meet the pitch requirements of the lapping process.
• The main machine is equipped with a pneumatic clamp-type brake device (equipped with a compressed air storage tank); brake speed can be adjusted via air pressure to achieve consistent overall braking, inching and other actions.
• Equipped with tape breakage stop function (pulse vector detection) to realize automatic shutdown and compensation.
• Equipped with bearing temperature sensing; pre-alarm and shutdown when temperature is too high.
• Lubrication method: Automatic timed oil injection for spindle bearing seats.
• Safety cover: Axially movable (push-pull type), fully enclosed structure.

Φ800×2 Semi-cut Steel Tape Armoring Machine

• Adaptable cable diameter: Φ10～Φ100mm
• Tape thickness: 0.2～0.8mm
• Tape reel specification: Φ630×Φ200×(20～60)mm

• Number of tape reels: 2 (See Image)
• Steel tape head speed: 600rpm
• Steel tape head pitch: Steplessly adjustable
• Motor power: 22kw (AC servo motor)
• Equipment direction: Right-hand machine/Left-hand machine
• Equipment center height: 1000mm
• Tape pay-off tension: Controlled by imported German ZF hysteresis tension control, with automatic adjustment.
• The steel tape head adopts an integral frame structure: after integral welding to eliminate internal stress, integral machining is performed, and finally dynamic balance verification is conducted, suitable for high-speed operation with low failure rate.
• Driven by a separate AC variable frequency motor, speed regulated by frequency converter; lapping pitch adjusted proportionally to meet the pitch requirements of the lapping process.
• The steel tape armoring machine is equipped with a pneumatic clamp-type brake device; brake speed can be adjusted via air pressure to achieve consistent overall braking, inching and other actions.
• The discharged steel tape passes through multiple guide rollers, which play the role of tape stabilizing and leveling.
• Equipped with tape breakage stop function (pulse vector detection) to realize automatic shutdown and compensation.
• Safety cover: Axially movable (push-pull type), fully enclosed structure.

Unit Synchronous Control System + Console-type Operation Platform

• The entire machine is operated via a 10.7-inch touch screen, controlled by Siemens PLC; the operating system is reasonably and reliably designed, with Ethernet interface and support for MES system data interface.
• The touch screen displays the speed, current, frequency signals of each motor, as well as line speed, length counting and other information.
• The control panel is equipped with separate control buttons for operation; the speed of the main lapping head and traction is given via communication, with single-action and linkage control functions.
• During the linkage speed-up process of the entire machine, synchronous control is well implemented; the lapping pitch can be automatically tracked with closed-loop control to accurately control the steel tape overlap rate and save materials.
• Length counting mode: Internal length counting, displayed on the touch screen;
• Controller type: Servo and frequency conversion control
• Separate power cabinet + operation control platform

Mechanical Length Counter

• Components: Mechanical bracket, left-right double wheels, 5-digit length counter, encoder, etc.;
• Type: Double-wheel (horizontal structure); two pressure wheels are equipped with buffer springs, with automatic centering function; wire guide rollers are provided for both wire inlet and outlet;
• Length counter wheel diameter: 159.15mm;
• Length counting range: 9999m;
• Length counter wheel circumference: 500mm;
• Length counting accuracy: 0.3%;
• Material: Aluminum alloy wheel circumference;
• Counting method: Dual length counting via 5-digit length meter combined with encoder;
• Length counter wheel surface: Electroplated.

2000kg Crawler-type Traction Machine

• Cable passing outer diameter: φ130mm
• Maximum traction force: 2000kg
• Traction speed: 2.3-80m/min
• Crawler contact length: 2395mm
• Number of cylinder pairs: 7 pairs
• Equipment center height: 1000mm
• Main motor: 15kw permanent magnet servo motor
• Pneumatic emergency stop brake

Aligner

Φ1600/3150 Gantry-type Take-up Rack

• Adaptable reels: PN1600—PN3150
• Reel diameter range: Φ1600～Φ3500mm
• Adaptable reel width: 1300～2300mm
• Adaptable cable diameter: Φ10—Φ120mm
• Main take-up motor: 11kw/1450rpm AC variable frequency
• Take-up speed: 60m/min (max)
• Lifting power: 3Kw AC motor + cycloidal pinwheel reducer (2 sets)
• Clamping motor: 0.75kw AC motor + cycloidal pinwheel reducer (1 set)
• Cable arrangement motor: 2.2kw/1500rpm (AC variable frequency motor)
• Transmission method: 2.2Kw AC variable frequency motor + cycloidal pinwheel reducer
• Load capacity: 20T (max)
• Structure type: Gantry ground rail traveling type, upper sleeve type; gantry frame formed by bending and welding; the two centers of the reel are lifted by lead screws and nuts driven by two motors via cycloidal reducers; each center seat can be lifted individually or simultaneously, with dual mechanical and electrical protection devices; different specifications of center sleeves can be equipped if needed to meet the installation of different reel specifications; reel clamping is achieved via motor-reduction, with clamping overload protection; the take-up motor is a variable frequency motor, and the transmission method is that the motor drives the reel spindle to rotate via a 3-speed gearbox. The take-up motor is driven by a Siemens frequency converter. The cable arrangement adopts a high-speed ratio cycloidal reducer, driven by a 2.2kw AC variable frequency motor and frequency converter; when the cable arrangement reverses, the take-up rack stops for 3/4 of a circle before starting to move again; the cable arrangement pitch is set on the TD-400 display screen, and the cable arrangement pitch and tension can be set on the TD-400; the cable arrangement speed automatically tracks the take-up line speed; there are jog buttons for forward and reverse take-up; tension display and cable arrangement pitch display are provided.

Molding Die

Spare Tools