1. Core Functions & Application Scenarios

Typical Application Fields:

• Wire & Cable Manufacturing: Stranding for power cables (0.6/1kV low-voltage to 110kV high-voltage), LAN cables (Cat5e/Cat6), automotive wiring harnesses, and coaxial cables.
• Electronics Industry: Twisting of enameled wire for motors/transformers, and flexible wire for connectors.
• Specialty Wire Processing: Production of braided wire, shielded wire, and medical-grade precision wire.

2. Working Principle

Step 1: Wire Unwinding & Tension Control

• Unwinding Mechanism: Raw wires are wound on multiple pay-off spools (the number depends on the required number of strands, e.g., 7-strand or 19-strand stranding). These spools are mounted on a rotating "pay-off turntable" or fixed pay-off frames.
• Tension Regulation: Each pay-off spool is equipped with a tension control device (e.g., magnetic powder brake, dancer arm, or damping wheel) to ensure consistent tension across all wires. Unstable tension causes uneven twisting or wire breakage.

Step 2: Core Twisting Process

• Twisting Drive: A servo motor or variable-frequency motor drives a "twisting bow" (a U-shaped rotating component) or "twisting cage" (a multi-spindle turntable) via a reducer and synchronous belt.
• Strand Formation: As the twisting bow/cage rotates, the wires from the pay-off spools are pulled into the twisting zone, where they spiral around each other to form a stranded conductor. The rotation speed directly determines the "twist pitch" (distance between adjacent spirals)—higher speed = shorter pitch = tighter twist.

Step 3: Traction & Length Control

• Traction Mechanism: After twisting, the integrated strand is pulled forward by a pair of traction wheels (usually rubber-coated to avoid wire damage). The traction speed is synchronized with the twisting speed to prevent slack or stretching.
• Length Monitoring: An encoder is installed on the traction wheel to count its rotations. The system calculates the actual length of the stranded wire (based on wheel circumference × rotations) and triggers a cut or stop signal when the preset length is reached.

Step 4: Winding & Collection

Step 5: Abnormal Protection

• Sensors (e.g., wire breakage detectors, tension sensors, or overload switches) monitor the process in real time. If a wire breaks, tangles, or tension exceeds the threshold, the system immediately stops the machine and triggers an alarm to avoid equipment damage or defective products.

3. Main Types of Wire Twisting Machines

4. Key Technical Parameters

5. Key Advantages

• High Precision: Servo motor control ensures consistent twist pitch and strand tightness, reducing product defect rates.
• Efficient Production: Continuous operation with speeds 5-10x faster than manual work, suitable for mass production.
• Stable Performance: Tension control and abnormal protection systems minimize wire breakage and tangling.
• Flexibility: Adjustable parameters (twist pitch, number of strands, speed) adapt to diverse wire specifications.

6. Common Troubleshooting & Maintenance

Common Issues & Solutions

• Uneven Twisting: Check if tension devices (magnetic powder brakes) are worn; re-calibrate tension for each pay-off spool.
• Wire Breakage: Reduce twisting speed or traction tension; replace worn traction wheels (if causing excessive friction).
• Irregular Winding: Adjust the traverse guide’s reciprocating speed; ensure the take-up spool is properly balanced.

Routine Maintenance

• Daily: Clean wire chips and dust from the twisting zone; check tension devices for looseness.
• Weekly: Lubricate rotating parts (bearings, gears); inspect belts/chains for wear.
• Monthly: Calibrate encoders and tension sensors; test the alarm system for responsiveness.

Underwind - left to right

Underwind - right to left

Overwind - left to right

Overwind - right to left

The right hand normally are used to determining right-lay wire ropes and the left hand for left lay wire ropes when standing toward the drum. The clenched fingers represent the drum and the extended finger stands for the oncoming rope.

Many crane models also have two sided grooved drums for winding wire ropes as shown in the picture.

Tow side grooved drums-1

Tow side grooved drums-2

When re-reeling steel wire ropes from horizontally supported reel to another drum, make sure that the rope is traveling from the top of the reel to the top of the drum or bottom to bottom to avoid a reverse bend. Look at the following picture about the right and wrong method of re-reeling:

Right method of re-reeling wire ropes

Wrong method of re-reeling wire ropes

Wrong method of re-reeling wire ropes

Note:
When re-reeling steel wire ropes, make sure the surface of the drum is clean, smooth and dry to protect wire ropes from damages by foreign particles.

For reels with vertical shafts, re-reeling is also available but you must to ensure the rope is always taut to avoid accumulation of slack.