The industrial cable processing sector demands increasingly high efficiency and precision. XYZ Machinery’s BSGC-2 Winding Machine and F.IDL-1600 Independent Pay-Off and Take-Up Rack stand out with their innovative designs. This article addresses common customer queries, covering technical specifications, operational scenarios, and maintenance tips to help you maximize product performance.
1. What Are the Core Advantages of the BSGC-2 Winding Machine?
Dual-Head Parallel Winding System: Enables two-thread synchronous operation, significantly boosting productivity.
1800 RPM High-Speed Winding: Ideal for high-intensity, large-volume cable processing, shortening production cycles.
Smooth Rod Cable Arrangement Technology: Ensures uniform cable winding through precise tension control, minimizing breakage risks.
Time-Based Length Calculation: Simplifies setup with intuitive time settings, eliminating complex programming.
Applications: Automotive wiring harnesses, communication cables, motor windings, and other industries requiring high-precision winding.
2. How Does the F.IDL-1600 Rack Ensure Stable Pay-Off and Take-Up?
4NM Torque Take-Up Motor: Delivers consistent tension for heavy-duty cable processing.
Passive Pay-Off Design: Prevents over-stretching to maintain cable integrity.
1600x1180mm Large Wire Reel: Supports high-capacity spools, reducing downtime for continuous production.
380V 1.1KW Lifting Motor: Adjusts reel height swiftly for diverse production needs.
Compatibility: Seamlessly integrates with the BSGC-2 to form an automated production line solution.
3. What Makes the "Smooth Rod Cable Arrangement" Technology Unique?
This technology combines precision guide rails and tension sensors to ensure uniform cable distribution during winding. Compared to traditional gear-driven systems, the smooth rod design reduces mechanical wear, lowers maintenance costs, and enhances winding accuracy (error rate <0.5%).
4. What Spool or Frame Sizes Are Supported by the Winding Machine?
The BSGC-2 is compatible with the following separable frames:
Φ66mm x 82.5mm: For small cables or short-length winding.
Φ66mm x 116mm: Ideal for medium-to-large cables, such as power cables or custom harnesses.Users can switch between sizes using quick-change fixtures (setup time <3 minutes).
5. Key Maintenance Tips for the Equipment
Lubrication Intervals: Apply high-temperature-resistant grease to guide rails and bearings every 500 hours.
Motor Inspection: Regularly clean the take-up motor’s ventilation ports to prevent dust buildup affecting torque output.
Spool Calibration: Perform tension calibration via the control panel after each spool change to ensure winding consistency.
6. Troubleshooting Common Operational Issues
Issue
Possible Cause
Solution
Wire misalignment
Tension sensor imbalance
Recalibrate the tension system
Speed fluctuations
Unstable power supply
Check 380V/220V voltage stability
Motor overheating
Poor ventilation or overload
Pause operation and clean cooling components
7. Are Custom Configurations Available?
XYZ Machinery offers the following customization services:
Extended Spool Sizes: Supports frames up to Φ100mm x 200mm.
Multi-Thread Upgrades: BSGC-2 can be expanded to 4-head parallel winding (pre-order required).
Smart Control Systems: Optional PLC + touchscreen interface for remote monitoring and data logging.
Industrial cable braiding demands precision and adaptability. XYZ Machinery’s 24-85BW and 86-85BW High-Speed Cable Braiders address these needs with cutting-edge technology. Below, we answer critical questions to help users maximize performance.
1. What Differentiates the 24-85BW and 86-85BW Models?
Spindle Configuration: The 24-85BW has 24 spindles, optimized for speeds up to 85 RPM, while the 86-85BW’s 38 spindles prioritize larger diameters (up to φ80mm) at 55 RPM max.
Production Speed: The 24-85BW achieves 1050m/h, ideal for high-volume orders, whereas the 86-85BW offers 821m/h for thicker cables.
Pitch Adjustment: The 86-85BW supports finer adjustments (20–90mm) for complex braiding patterns.
2. How Does the Electronic Meter Recording Device Enhance Accuracy?
This feature tracks braiding length and speed in real time, ensuring consistent quality and reducing material waste. Data can be exported for compliance reporting or process optimization.
3. What Materials Can These Braiders Process?
Both models handle:
Conductive Wires: Soft copper, aluminum-magnesium alloy.
Protective/Decorative Wires: Stainless steel, polyester, cotton.Adjust spindle wire counts based on thickness (e.g., 1–12 wires/spindle for φ0.30mm).
4. How to Maintain Optimal Spindle Performance?
Lubrication: Apply industrial grease to spindles every 300 hours.
Motor Care: Clean the 380V 7.5KW host motor vents monthly to prevent overheating.
Traction System Checks: Inspect crawler/tractor wheels for wear weekly.
5. Troubleshooting Common Issues
Issue
Cause
Solution
Uneven braiding
Loose spindle tension
Re-tension wires and recalibrate
Meter device errors
Sensor misalignment
Clean sensors and reset calibration
Speed drops
Voltage fluctuations
Stabilize 380V power supply
6. Can These Braiders Be Customized?
Yes! XYZ Machinery offers:
Extended Spool Sizes: Up to 2000mm diameter.
Automated Take-Up Systems: Integrate with existing production lines.
Specialized Wire Guides: For niche materials like Kevlar®.
ConclusionThe 24-85BW and 86-85BW braiders combine speed, precision, and flexibility. For technical support or customization, contact XYZ Machinery’s engineering team today!
Enhancing Precision in Cable Braiding: Technical Insights for 16 & 24 Spindles Machines
Modern cable braiding demands cutting-edge technology to balance speed and accuracy. The newly launched 16-180Q-HDE and 24-1200Q-ME models address these challenges through innovations like the electronic meter recording device and AC variable frequency control. Below, we explore their technical advantages and operational best practices.
Technical Breakdown:
1. Why Choose 16 or 24 Spindles?
The 16 Spindles model prioritizes mid-volume production with a 604m/h output, while the 24 Spindles variant maximizes throughput at 723m/h for thicker cables.
2. Precision via Electronic Meter Recording Device
Monitor braiding length and RPM in real time to minimize deviations. Export data for quality audits or process optimization.
3. Leveraging AC Variable Frequency Control
Maintain consistent spindle speeds even under fluctuating loads, reducing energy waste and downtime.
4. Multi-Material Compatibility in Action
Switch seamlessly between conductive (copper, aluminum alloy) and protective (polyester, stainless steel) wires without recalibration.
5. Optimizing the Adjustable Pitch Range
Fine-tune braid density for specialized applications, from fine electronics to heavy-duty industrial cables.
Maintenance Tips:
Lubricate spindles every 200 operating hours to prevent friction-related wear.
Clean the electronic meter recording device sensors weekly to ensure accurate data capture.
Inspect AC variable frequency control systems monthly for voltage stability.
Troubleshooting Guide:
Issue
Solution
Uneven braiding
Re-tension spindles and recalibrate pitch
Meter data discrepancies
Reset the electronic recording device
Speed fluctuations
Verify AC power supply stability
For custom configurations like extended spool capacities or automated take-up systems, contact our engineering team to tailor these high-speed cable braiders to your production needs.
Q1: Why Choose Vertical CNC Braiding Machines Over Horizontal Models?
The Vertical CNC Braiding Machine design is tailored for high-pressure hose production and large-diameter cables. Its vertical orientation allows efficient handling of heavy materials like steel wire, while the oil bath lubrication system ensures smooth operation under high tension.
Q2: How Does the Oil Bath Lubrication System Enhance Durability?
This system immerses critical components (e.g., horn gears, carriers) in lubricant, reducing friction and heat generation. Combined with the fully enclosed low-noise design, it extends machine lifespan and minimizes maintenance intervals.
Q3: What Materials Can the BFB-200L Series Process?
These machines support:
Metallic Wires: Stainless steel, alloy steel.
Composite Yarns: Aramid fiber, carbon fiber, cotton.
Industrial Hoses: Rubber, thermoplastic, or corrugated cores.
Q4: How to Maintain Peak Performance?
Clean the oil bath lubrication system reservoir every 300 hours.
Inspect carrier tension (0.4–5.0kg) weekly for consistent braiding quality.
Replace worn bobbins promptly to avoid downtime.
Q5: Are Custom Configurations Supported?
Our Company offers:
ODM Customization: Adjust carrier counts, bobbin dimensions (e.g., 93x30x210mm), and control interfaces.
IoT Integration: Add smart sensors for real-time monitoring of large bobbin capacity usage and predictive maintenance.
What industries benefit from the BFHG-255C wire winding machine?The BFHG-255C is widely used in steel wire production, hydraulic hose braiding, cable manufacturing, and stainless steel wire processing. In these sectors, the machine’s high throughput and precision significantly improve production efficiency by providing reliable, high-speed winding for various wire products.
How does the machine maintain consistent wire tension?Each wire is managed by an independent control unit with a dedicated precision sensor, ensuring that tension remains constant throughout the winding process. This steady tension control results in uniformly wound coils with minimal variation, minimizing inconsistencies and reducing errors during operation.
What safety features does the BFHG-255C include?The machine automatically stops whenever it detects a broken wire, an out-of-wire situation, or an air pressure defect. Additionally, it features a metering system with an error margin of less than 10 m per bobbin to maintain winding accuracy. These safety measures protect the equipment and ensure product quality by preventing errors from going unchecked.
Can the machine accommodate different wire types and sizes?Yes. The BFHG-255C has a customizable pay-off system that supports various wire diameters and types. It can wind up to 16 strands per bobbin, providing the flexibility to meet different manufacturing needs and easily adapt to a range of wire specifications.
What are the power and operating requirements?The machine operates on a 380V/220V 50 Hz power supply, driven by either a 3 kW or 3.5 kW motor depending on the model. It also includes frequency conversion technology for improved energy efficiency. This allows integration into standard factory power setups while optimizing energy consumption during operation.
How does the smart compensation mechanism improve efficiency?The built-in smart compensation mechanism actively adjusts the winding process by sorting and guiding wires evenly onto the spool. This helps prevent wire overlap and tangling during high-speed operation. By reducing the risk of wire breakage and avoiding interruptions for untangling, the machine ensures continuous, uninterrupted productivity and consistent winding quality. This results in a smoother winding process and optimized overall performance.
