The High-performance Portal Type Payoff & Takeup for Wire and Cable represents the pinnacle of wire handling technology, combining dual-axis tension control with advanced motion systems to deliver unmatched precision in manufacturing and recycling processes.
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Designed to eliminate common challenges like wire tangling, uneven winding, and tension fluctuations, this system features heavy-duty linear rail-guided pillars that enable synchronized movement across reel diameters, ensuring consistent wire path alignment regardless of reel size. Its intuitive PLC+HMI interface puts real-time control of tension, speed, and winding patterns at operators’ fingertips, while built-in data logging captures key performance metrics for process optimization. With a reputation for reliability in 24/7 production environments, it reduces material waste by 25% and increases throughput by 20% compared to conventional payoff/takeup systems.
Reel Capacity: Accommodates reels from 36-120 inches in diameter, with maximum payload of 40,000 lbs (20 tons) per reel. Reel shafts are available in 3", 6", and 8" diameters with quick-change adapters.
Tension Control: Utilizes magnetic powder brakes/clutches with proportional control, achieving ±0.5% tension accuracy across a range of 10 N to 5,000 N. Tension is adjustable in 0.1 N increments via HMI.
Traversing System: Servo-driven ball screw traverser with backlash ≤0.01 mm, ensuring consistent layering with programmable pitch settings (0.5-50 mm). Traverse speed is dynamically adjusted to match line speed for uniform winding.
Line Speed: Supports production speeds up to 170 m/min with smooth acceleration/deceleration profiles (0.5-5 m/s²) to prevent wire shock loading. Speed regulation is ±0.2% of set value.
Winding Precision: Achieves ±0.2 mm pitch control and ±0.5 mm flange alignment, with automatic taper control for neat reel edges and reduced end-of-reel waste.
Energy Consumption: 5.5-22 kW power rating with regenerative braking system that feeds excess energy back to the grid, reducing overall power consumption by 18%.
Recipe Storage: Capacity to save and recall 50+ production profiles, each storing parameters for tension, speed, pitch, and acceleration rates for quick product changeovers.
Remote Monitoring: Equipped with IoT-enabled dashboard that provides real-time machine status, production counts, and maintenance alerts accessible via web browser or mobile app.
Data Logging: Automatically records process data at 1 Hz interval, storing up to 1 year of production history for quality traceability and process optimization.
Power Cable Recycling
Efficiently unwinds and rewinds scrap cables (10-180 mm diameter) for copper/aluminum recovery, with adjustable tension to prevent insulation damage while ensuring complete unwinding of tangled reels.
Integrates with cable stripping machines to maintain synchronized speed, reducing bottlenecks in recycling lines.
Automotive Wiring Harnesses
Ensures kink-free unwinding of automotive wires (0.3-6 mm diameter) during harness assembly, with constant tension control critical for accurate crimping and terminal attachment.
Supports multi-reel operations with automatic reel changeover, reducing downtime in high-volume production.
Construction Industry
Handles large reels of steel cables (8-50 mm diameter) for crane and elevator manufacturing, with precise winding tension ensuring uniform load distribution during storage and transportation.
Features heavy-duty reel locks and safety interlocks for secure handling of large payloads.
Research Laboratories
Provides ultra-precise tension control (±0.1 N) for wire testing and prototyping applications, supporting research into new materials and cable designs with detailed process data logging.
Q: How quickly can the system switch between different reel sizes during production changeovers?
A: The motorized linear rail pillars adjust position automatically in <30 seconds upon recipe selection, with built-in laser sensors verifying reel diameter and position to ensure accurate alignment—eliminating manual measurements and adjustments.
Q: What safety measures are implemented to protect operators during reel loading and operation?
A: The system includes safety light curtains (Type 4, SIL 3) around the reel area that stop all motion when breached, emergency stop buttons at multiple locations, and interlocked guard doors with keyed access. Reel lifting mechanisms feature overload protection and anti-drop devices.
Q: Can the payoff/takeup integrate with third-party manufacturing execution systems (MES)?
A: Yes, it supports OPC UA and Modbus TCP communication protocols for seamless data exchange with MES, ERP, and SCADA systems. Custom API integration is available for proprietary software platforms.
Designed to eliminate common challenges like wire tangling, uneven winding, and tension fluctuations, this system features heavy-duty linear rail-guided pillars that enable synchronized movement across reel diameters, ensuring consistent wire path alignment regardless of reel size. Its intuitive PLC+HMI interface puts real-time control of tension, speed, and winding patterns at operators’ fingertips, while built-in data logging captures key performance metrics for process optimization. With a reputation for reliability in 24/7 production environments, it reduces material waste by 25% and increases throughput by 20% compared to conventional payoff/takeup systems.
Reel Capacity: Accommodates reels from 36-120 inches in diameter, with maximum payload of 40,000 lbs (20 tons) per reel. Reel shafts are available in 3", 6", and 8" diameters with quick-change adapters.
Tension Control: Utilizes magnetic powder brakes/clutches with proportional control, achieving ±0.5% tension accuracy across a range of 10 N to 5,000 N. Tension is adjustable in 0.1 N increments via HMI.
Traversing System: Servo-driven ball screw traverser with backlash ≤0.01 mm, ensuring consistent layering with programmable pitch settings (0.5-50 mm). Traverse speed is dynamically adjusted to match line speed for uniform winding.
Line Speed: Supports production speeds up to 170 m/min with smooth acceleration/deceleration profiles (0.5-5 m/s²) to prevent wire shock loading. Speed regulation is ±0.2% of set value.
Winding Precision: Achieves ±0.2 mm pitch control and ±0.5 mm flange alignment, with automatic taper control for neat reel edges and reduced end-of-reel waste.
Energy Consumption: 5.5-22 kW power rating with regenerative braking system that feeds excess energy back to the grid, reducing overall power consumption by 18%.
Recipe Storage: Capacity to save and recall 50+ production profiles, each storing parameters for tension, speed, pitch, and acceleration rates for quick product changeovers.
Remote Monitoring: Equipped with IoT-enabled dashboard that provides real-time machine status, production counts, and maintenance alerts accessible via web browser or mobile app.
Data Logging: Automatically records process data at 1 Hz interval, storing up to 1 year of production history for quality traceability and process optimization.
Power Cable Recycling
Efficiently unwinds and rewinds scrap cables (10-180 mm diameter) for copper/aluminum recovery, with adjustable tension to prevent insulation damage while ensuring complete unwinding of tangled reels.
Integrates with cable stripping machines to maintain synchronized speed, reducing bottlenecks in recycling lines.
Automotive Wiring Harnesses
Ensures kink-free unwinding of automotive wires (0.3-6 mm diameter) during harness assembly, with constant tension control critical for accurate crimping and terminal attachment.
Supports multi-reel operations with automatic reel changeover, reducing downtime in high-volume production.
Construction Industry
Handles large reels of steel cables (8-50 mm diameter) for crane and elevator manufacturing, with precise winding tension ensuring uniform load distribution during storage and transportation.
Features heavy-duty reel locks and safety interlocks for secure handling of large payloads.
Research Laboratories
Provides ultra-precise tension control (±0.1 N) for wire testing and prototyping applications, supporting research into new materials and cable designs with detailed process data logging.
Q: How quickly can the system switch between different reel sizes during production changeovers?
A: The motorized linear rail pillars adjust position automatically in <30 seconds upon recipe selection, with built-in laser sensors verifying reel diameter and position to ensure accurate alignment—eliminating manual measurements and adjustments.
Q: What safety measures are implemented to protect operators during reel loading and operation?
A: The system includes safety light curtains (Type 4, SIL 3) around the reel area that stop all motion when breached, emergency stop buttons at multiple locations, and interlocked guard doors with keyed access. Reel lifting mechanisms feature overload protection and anti-drop devices.
Q: Can the payoff/takeup integrate with third-party manufacturing execution systems (MES)?
A: Yes, it supports OPC UA and Modbus TCP communication protocols for seamless data exchange with MES, ERP, and SCADA systems. Custom API integration is available for proprietary software platforms.
