High speed twisting machine is a key equipment used in industries such as wire and cable, communication cable, etc. to twist multiple single wires (such as copper wire, aluminum wire, optical fiber, enameled wire, etc.) into stranded wires (or cable cores) according to certain rules. Its core feature is "high-speed twisting" (usually twisting speed ≥ 3000r/min, some models can reach 10000r/min or more). To achieve stable twisting and high-quality products at high speeds, its technical characteristics are mainly reflected in speed control, twisting accuracy, tension balance, automation adaptation, etc., as follows:

1. High speed and dynamic stability, suitable for high-speed production needs
The core advantage of high-speed wire twisting machine is "high speed", but high speed will be accompanied by problems such as vibration and increased centrifugal force. Therefore, its design needs to break through the physical limitations of traditional equipment:
High rigidity drive system: using high-precision servo motors (such as permanent magnet synchronous servo motors) in conjunction with precision planetary gearboxes to achieve high torque output and low speed fluctuations (speed error ≤± 0.1%), ensuring stable power during the twisting process. Meanwhile, the connection between the motor and the spindle adopts an elastic coupling to reduce vibration transmission during high-speed rotation.
Dynamic balance design: Rotating components such as hinge plates and pay off racks need to undergo precise dynamic balance correction (balance accuracy ≤ G2.5 level) to avoid resonance caused by center of gravity deviation during high-speed rotation and prevent uneven twisting caused by single wire shaking. The frame adopts thick walled cast iron or welded steel structure to enhance overall rigidity and further suppress vibration.
Cooling system: During high-speed operation, components such as motors and bearings generate severe heat, requiring forced air cooling (fan+cooling fins) or water cooling system to ensure that the temperature of the equipment remains stable below 60 ℃ during long-term high-speed operation (such as 24-hour continuous production), avoiding performance degradation caused by overheating.

2. High precision twisting parameter control to ensure twisting quality
The quality of twisting directly affects the electrical performance (such as impedance consistency) and mechanical performance (such as tensile and bending resistance) of the cable, and precision control at high speeds is a technical difficulty:
Pitch accuracy control: Pitch (the distance traveled by a single wire rotating around the twisting axis for one revolution) is the core parameter of twisting. The high-speed twisting machine achieves precise control through "electronic gear synchronization technology": the spindle speed and traction speed (cable forward speed) are linked in real time through PLC, and the pitch error can be controlled within ± 0.5% (traditional low-speed equipment usually has ± 2%). For example, for communication cables, a stable pitch can ensure impedance matching and reduce signal transmission losses.
Twisting direction and number of layers adjustable: supports switching between "left twisting" and "right twisting", adapted to different cable standards (such as power cables often using right twisting, communication cables may need to alternate directions); At the same time, multi-layer twisting can be achieved (such as 2 or 3 layers), and the twisting angle can be controlled layer by layer (such as 15 °~45 ° adjustable) to ensure uniform force distribution of multi-layer single wires and avoid excessive stretching of inner single wires.
Consistency of single line arrangement: By using precision guiding mechanisms (such as porous positioning plates and guide wheel sets), multiple single lines are ensured to be evenly distributed before entering the twisting point, avoiding crossing and overlapping, and ensuring that the cross-section of the twisted strands is regular (such as circular or fan-shaped), especially for multi-core cables (such as control cables), which can reduce the thickness deviation of the insulation layer.

3. Multi line tension coordinated control to prevent single line damage and loose twisting
When high-speed twisting, the tension of multiple single wires (usually 3-24) needs to be strictly consistent: if the tension is uneven, the single wire with excessive tension will be stretched (causing a decrease in cross-sectional area and an increase in resistance), and the single wire with insufficient tension will relax (causing loose twisting and poor roundness of the strands). The characteristics of tension control technology for high-speed stranding machines are as follows:
Independent tension adjustment: Each single line is equipped with an independent tensioner (such as magnetic powder tensioner, servo tensioner), which detects the tension of the single line in real time through a tension sensor (accuracy ± 0.1N), and is independently adjusted by the PLC (such as increasing or decreasing the current of the magnetic powder brake, fine-tuning the speed of the servo motor) to ensure that the tension deviation of multiple lines is ≤ 5%.
Dynamic tension compensation: During the twisting process, as the diameter of the single wire decreases (during the unwinding process), the tension will naturally fluctuate. The equipment calculates the remaining wire length in real time through a diameter detection device (encoder), compensates for the tension in advance (such as reducing the braking force appropriately when the diameter decreases), and avoids single wire breakage caused by sudden changes in tension.

4. Integration of automation and intelligence to improve production efficiency
The high-speed wire twisting machine needs to match the fast-paced modern production line, and automation function is the core competitiveness:
Automatic wire changing and docking: When the single wire coil is about to run out, the equipment triggers a warning through a wire breakage detection sensor (such as a photoelectric sensor), automatically docking the wire end of the new coil with the old wire end (hot melt docking or mechanical crimping), reducing downtime for wire changing (increasing wire changing efficiency by more than 60%).
Online defect detection: Integrated vision system (high-speed camera) or tension mutation monitoring, real-time detection of single wire breakage, missed twisting, abnormal pitch and other defects in the twisted strands. If any problems are found, the machine will be stopped immediately and an alarm will be triggered to avoid the production of batches of non-conforming products.
Parameterized programming and storage: Through the human-machine interface (HMI), different product twisting parameters (pitch, speed, tension, twisting layers, etc.) can be preset, and more than 100 sets of formulas can be stored, which can be directly called during production changes, reducing debugging time (increasing production efficiency by 50%).

5. Structural optimization and adaptive design to meet diverse needs
Cables from different industries, such as power cables, RF cables, and fiber optic cables, have varying requirements for twisting. High speed twisting machines need to have a wide range of adaptability:
Modular design: The core components such as the pay off frame, twisting head, and traction mechanism are assembled modularly and can be flexibly replaced according to the number of single wires (3-24 pieces) and wire diameter range (0.05mm~2mm), adapting to the twisting requirements from thin diameter enameled wires (electronic wires) to medium and thick diameter copper wires (power cables).
Scratch resistant and clean design: For insulated single wires (such as PVC insulated wires) or precision materials (such as optical fibers), guide wheels and twisting heads are made of ceramic or polytetrafluoroethylene materials (low friction, high wear resistance) to avoid scratching the surface of the single wire; Simultaneously equipped with an air blowing device to remove dust generated during the twisting process (such as debris from metal wire twisting) and prevent pollution.
Security protection upgrade: High speed rotating components (such as hinges) are equipped with fully enclosed protective covers and built-in safety interlock devices (the machine will stop immediately when the protective cover is opened); Simultaneously set up an emergency braking system with a response time of ≤ 0.1 seconds to prevent safety accidents during high-speed operation.