A Wire Twisting Machine (wire stranding machine) is specialized automation equipment used to twist single or multiple strands of wire into a unified, structured strand. It is widely applied in the wire and cable, electronics, automotive, and electrical manufacturing industries, playing a key role in improving wire conductivity, mechanical strength, and stability.
Its primary function is to twist discrete wires (such as copper, aluminum, tinned copper, enameled wire, or fiber optic conductors) into a single, integrated strand. The twisted structure enhances the wire’s performance—for example, reducing signal interference in communication cables or increasing load-bearing capacity in power cables.
- 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.
The operation of a wire twisting machine follows a "unified tension supply → synchronous twisting → stable traction → precise winding" workflow, driven by mechanical transmission and automated control. The core steps are as follows:
- 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.
This is the key link, and the twisting method varies by machine type (see Section 3 for classifications). The core principle is to use a rotating mechanism to drive the wires to spiral around a central axis:
- 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.
- 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.
The twisted wire is evenly wound onto a take-up spool via a "traverse guide" (a reciprocating component that ensures the wire is neatly arranged without overlapping). The take-up spool is driven by a torque motor or servo motor, with speed adjusted to match the traction speed for stable winding.
- 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.
Machines are classified by structure and twisting method, each suited to different wire specifications and production needs:
Parameters directly affect the machine’s performance and applicable wire range. When selecting a machine, focus on the following:
Compared to manual twisting or semi-automatic equipment, automatic wire twisting machines offer significant benefits:
- 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.
To ensure stable operation, regular maintenance and timely troubleshooting are essential:
- 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.
- 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.
In summary, wire twisting machines are indispensable in modern wire processing. Their performance directly determines the quality of downstream products (e.g., cables, motors). Selecting the right machine type and maintaining it properly are critical for improving production efficiency and product competitiveness.
| Corrugated Sizes | Flange Diameter (mm) | Outer Width (mm) | Barrel Diameter (mm) | Inner Width (mm) | Load Capacity (kg) |
| 2000X1200X1000 | 2000 | 1210 | 1200 | 1000 | 5000 |
| 2250X1050X1400 | 2250 | 1650 | 1050 | 1400 | 5300 |
| 2800X1800X1400 | 2800 | 1650 | 1800 | 1400 | 13000 |
| 3000X1800X1400 | 3000 | 1650 | 1800 | 1400 | 15000 |
| 355X178X200 | 355 | 256 | 178 | 200 | 150 |
| 630X350X412 | 630 | 450 | 350 | 412 | 1000 |
| 1200X600X800 | 1200 | 1000 | 600 | 800 | 1500 |
| 1400X700X1000 | 1400 | 1210 | 700 | 1000 | 2500 |
| 1600X800X1000 | 1600 | 1210 | 800 | 1000 | 3700 |
| 1800X900X900 | 1800 | 1100 | 900 | 900 | 4200 |
| 2000*1400*1000 | 2000 | 1210 | 1400 | 1000 | 4600 |
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.
