In high-volume copper wire and cable manufacturing, the rod breakdown stage is a decisive factor for overall line efficiency, finished wire surface quality, dimensional accuracy, scrap rate, and energy cost per ton. Our Copper Rod Breakdown Machine with Individual Servo Motor Drive is purpose-engineered for this critical process.
It converts single or dual Φ8 mm low-oxygen or oxygen-free copper rods into finished electrical wires ranging from Φ1.2 mm to Φ4.5 mm in one continuous pass. Mechanical speeds reach 30 m/s, supported by independent servo control on every capstan. The result is superior surface finish, stable process parameters across different copper grades, and the operational flexibility required by modern power-cable, building-wire, and magnet-wire producers.
Technological Process
Φ8 mm low-oxygen or oxygen-free copper rod → Precision straightening → Multi-pass straight-line drawing on individual servo-driven Ø450 mm tungsten-carbide coated capstans → Closed-loop tension control → Optional integrated continuous annealing → Full-immersion lubrication & cooling system → Automatic take-up (single/dual bobbin or vertical pay-off) → High-conductivity finished copper wire (Φ1.2–4.5 mm).
The horizontal tandem straight-line arrangement combined with independent servo drives ensures smooth material flow, excellent inter-pass synchronization, minimal vibration, and significantly reduced copper powder generation. Dies can be changed rapidly; bobbins unload automatically without stopping the line, minimizing downtime and labor.
Core Technical Advantages
Individual Servo Motor Drive on Every Capstan Each drawing capstan is powered by its own high-efficiency servo motor with independent control algorithm and dedicated servo controller. This architecture enables precise, stepless adjustment of compression ratios (typical mechanical elongation range 26–50 %) for optimal die matching.
Compared with traditional single-motor gear-drive systems, the individual-motor design delivers:
- Micro-sliding or near non-sliding drawing that reduces surface damage and copper powder, extending both die and capstan service life.
- The ability to switch unused motors off when producing larger diameters, generating energy savings of up to 20 %. Additional savings come from the elimination of gear-mesh losses. Industry comparisons show typical consumption around 110 kWh/t versus approximately 180 kWh/t for conventional gear-driven machines on comparable sizes.
- Lower operational noise and vibration, reduced mechanical stress, and interchangeability of standard motors for easier maintenance.
These features produce consistently superior surface quality and dimensional accuracy across both low-oxygen and oxygen-free copper grades.
High-Speed, High-Efficiency Operation
Mechanical speeds up to 30 m/s with 9, 11 or 13 drawing passes on Ø450 mm capstans. Frequency- or servo-controlled motors deliver high productivity while keeping specific energy consumption low. Dual-rod models effectively double output within nearly the same footprint.
Rapid Die Change & Automatic Bobbin Handling
Quick-die-change system and automatic bobbin unloading without line stoppage minimize changeover time and labor requirements, supporting frequent specification changes common in modern cable plants.
Optional Online Continuous Annealing
Full integration with a continuous annealing unit produces soft, bright, high-ductility copper wire in a single pass. Proper annealing restores elongation (typically 30–36 % or higher depending on copper type and parameters) and maximizes electrical conductivity, eliminating the need for separate annealing operations and improving overall plant efficiency.
Intelligent Control & Flexible Take-Up
Advanced MMI + PLC system with large touch-screen interface enables real-time monitoring, recipe storage, data logging, and easy parameter adjustment. Multiple take-up options (630/800 mm single or dual bobbin, 820 mm vertical pay-off, automatic spool change, or custom combinations) ensure seamless synchronization with downstream multi-wire drawing, bunching, stranding, or extrusion lines.
Collectively these capabilities deliver higher throughput, lower scrap rates, reduced energy costs, longer tooling life, and consistently high wire quality — key performance indicators for competitive copper conductor production.
Comparison: Individual Servo Drive vs Traditional Gear Drive
| جانب | Individual Servo Motor Drive | Traditional Gear Drive |
|---|
| Compression Ratio Control | Independent & precise per pass | Fixed by mechanical gearing |
| Energy Consumption | 15–20 % lower (motors switchable) | Higher (continuous gear losses) |
| Noise & Vibration | Significantly lower | أعلى |
| Die Life & Surface Quality | Longer die life, better surface (micro-sliding) | Higher copper powder, faster die wear |
| Maintenance | Lower (no gear replacement, standard motors) | Gear wear after ~10 years |
| مرونة | One die set covers wide range of sizes | Limited; more die sets often required |
| Downtime for Size Change | Minimal | أعلى |
This technology is particularly advantageous when processing different copper grades or frequently changing outlet diameters.
المواصفات الفنية
| نموذج | Drive Type | Inlet Diameter | No. of Wires | Outlet Diameter | Max. Speed | تمريرات رسم | Capstan Diameter | السعة المركبة |
|---|
| LWHD-450/9 | Individual (Shunt) | Φ8 mm | 1 | Φ2.1–4.2 mm | 25 m/s | 9 | Φ450 mm | 400 kVA |
| LWHD-450/11 | Individual (Shunt) | Φ8 mm | 1 | Φ1.7–4.2 mm | 28 m/s | 11 | Φ450 mm | 450 kVA |
| LWHD-450/13 | Individual (Shunt) | Φ8 mm | 1 | Φ1.2–4.5 mm | 30 m/s | 13 | Φ450 mm | 500 kVA |
| LWHD-450/9(2) | Individual (Double) | 2×Φ8 mm | 2 | 2×Φ2.05–3.2 mm | 25 m/s | 9 | Φ450 mm | 900 kVA |
| LHD-450/9 | Linear Single Motor | Φ8 mm | 1 | Φ2.1–4.2 mm | 25 m/s | 9 | Φ450 mm | 400 kVA |
| LHD-450/11 | Linear Single Motor | Φ8 mm | 1 | Φ1.7–4.2 mm | 28 m/s | 11 | Φ450 mm | 450 kVA |
| LHD-450/13 | Linear Single Motor | Φ8 mm | 1 | Φ1.2–4.5 mm | 30 m/s | 13 | Φ450 mm | 500 kVA |
| LHD-450/9(2) | Linear Single Motor (Double) | 2×Φ8 mm | 2 | 2×Φ2.05–3.2 mm | 25 m/s | 9 | Φ450 mm | 900 kVA |
Take-up Options: 630/800 mm single or dual bobbin, 820 mm vertical pay-off, or custom combinations.
الأجزاء الرئيسية وتكامل النظام
- Individual servo motor drive system for each capstan
- High-precision tungsten carbide drawing cones and capstans (Ø450 mm)
- Straight-line drawing path with advanced tension control
- Intelligent MMI + PLC control system with touch-screen interface
- Lubrication and cooling system with optional high-efficiency filtration
- Optional integrated continuous annealing unit
- Complete turnkey accessories (threading machine, cold welder, heat exchanger, oil filtration system)
التطبيقات الأساسية
- High-speed production of electrical copper wires (Φ1.2–4.5 mm)
- Single and double rod breakdown for power cables, building wire, and magnet wire
- Online annealing for soft annealed copper wire in one continuous process
- Integration with multi-wire drawing, bunching, or extrusion lines
This machine is especially suitable for complete copper conductor production plants in Saudi Arabia and the GCC.
Why Choose Our Copper Rod Breakdown Machine with Individual Motors?
- Superior Wire Quality & Flexibility: Independent motor drive provides precise control and excellent results across different copper grades.
- High Productivity: Speeds up to 30 m/s with single or double-rod configurations.
- Energy Efficient & Reliable: Lower energy consumption and reduced mechanical stress for long-term operation.
- Full Local Support in Saudi Arabia: Turnkey installation, operator training, 24/7 remote diagnostics, and spare parts stock in the Eastern Province.
- Vision 2030 Aligned: Supports local manufacturing and quality requirements for copper conductors in power infrastructure and industrial projects.
استفسر الآن
تواصل مع فريقنا التقني اليوم. في غضون 48 ساعة، سنقدم اقتراح تكوين مفصل، وحساب عائد الاستثمار، ورسومات تخطيطية، وحالات مرجعية من مشاريع مماثلة في دول مجلس التعاون الخليجي.
Ready to upgrade your copper wire production with high-speed, high-precision individual motor drive technology?
استفسر الآن — Let us deliver the reliable solution that powers your success in the Saudi and GCC copper conductor market.
Copper Rod Breakdown Machine with Individual Motor
High-speed Copper Rod Breakdown Machine with Individual Motors (LWHD-450 / LHD-450 Series). Draws single or double Φ8 mm copper rods into Φ1.2–4.5 mm wires at up to 30 m/s with online annealing option. Individual servo motor drive per capstan for precise control.
رمز تعريف SKU للمنتج.:
LWHD-450/11(2) / LHD-450/13
العلامة التجارية للمنتج:
شركة آر إل بي للآلات
عملة المنتج:
دولار أمريكي
سعر المنتج:
اتصل بنا للحصول على عرض سعر
المنتج متوفر في المخزون:
في الأوراق المالية
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