In the modern wire and cable industry, demand for high-performance multi-strand conductors continues to accelerate, driven by growth in electronics, electric vehicles, renewable energy systems, data centers and industrial automation. Precise, high-speed bunching of fine wires is essential to achieve the flexibility, conductivity, mechanical strength and surface quality required by these demanding applications.
ال آلة تجميع مزدوجة اللف series (Models 315E to 1250) is a high-speed, high-precision industrial solution specifically engineered for stranding multi-stranded copper wires, tinned copper wires, enameled wires and copper-clad aluminum (CCA) wires. Unlike conventional single-twist systems, the true double-twist mechanism applies two twists with every single rotation of the bow. This doubles productivity while preserving conductor integrity, delivering uniform lay length and a bright, compact surface finish ready for extrusion, laying-up or final cable assembly.
This technology is particularly valuable for cable manufacturers in Saudi Arabia and the wider GCC region who must increase output to support Vision 2030 localization, mega-projects (NEOM, Red Sea, Qiddiya), EV charging infrastructure, solar farms and expanding data-center capacity — without compromising quality or raising scrap rates.
How the Double Twist Process Works
Incoming single wires from pay-off racks (in-line or multi-head) enter the high-speed double-twist bunching head. The rotating bow imparts two twists per revolution (100% back-twist capability available). An advanced constant-tension system maintains stable force from full to empty bobbin. PLC control sets and locks lay pitch and direction. The finished multi-strand conductor is wound onto the take-up bobbin with excellent concentricity and minimal internal stress.
The result is a conductor that combines high flexibility with superior electrical performance and a clean, bright surface — critical for downstream processes and end-product reliability.
Technological Process
Incoming single wires from pay-off racks (in-line or multi-head) → High-speed double-twist bunching head with 100% back-twist capability → Advanced constant-tension control system → PLC-controlled lay pitch and direction setting → Finished compact, bright, high-quality multi-strand bunched conductor wound onto take-up bobbins.
The double-twist principle applies two twists during each full rotation of the bow, significantly increasing linear output compared with single-twist machines while maintaining the mechanical and electrical properties of the finished conductor.
Core Technical Advantages
True Double-Twist Technology – Up to 2× Productivity
Two twists per revolution deliver significantly higher linear output than single-twist machines at the same rotational speed. Industry comparisons show double-twist systems can more than double throughput on fine-to-medium conductors while reducing cost per meter of finished conductor.
Full-Automatic PLC + HMI Intelligent Control
Operators preset lay pitch, direction and tension via an intuitive touchscreen. Recipe storage enables rapid, error-free changeovers. Real-time monitoring and automatic stop functions (wire break, length reached, door open) minimize downtime and operator intervention.
Precision Constant Tension Control
Stable tension from full to empty bobbin dramatically reduces wire breakage and surface defects. Lay-length consistency typically reaches ±1% or better, producing uniform, high-quality bunched conductors with bright surfaces.
Carbon-Fiber Composite Bows (Selected Models)
Lightweight, high-strength carbon-fiber bows lower centrifugal force, reduce vibration and energy consumption, and allow higher sustained speeds with improved service life and lower noise.
Wide Application Range & Flexible Integration
Covers ultra-fine wires from Φ0.04 mm up to Φ3.2 mm across eight models. Supports both in-line pay-off racks (Φ100–300 mm bobbins) and double-bobbin multi-head pay-off systems (Φ500–800 mm), enabling seamless integration with existing drawing lines or standalone operation.
Robust, Safe & Low-Maintenance Design
Closed safety enclosure with noise isolation (industry benchmarks ≤75 dB), electromagnetic braking, and durable construction for continuous 24-hour industrial duty. Low maintenance requirements support long-term operational reliability.
المواصفات الفنية
| نموذج | Max. Bobbin (mm) | Copper Wire Dia. (mm) | Sectional Area (mm²) | Max. OD (mm) | Lay Range (mm) | Max. Speed (rpm) |
|---|
| 315E | Φ300 × 180 | 0.04 – 0.10 | 0.25–1.1 | 5 – 11 | 1.2 – 24 | 3000 |
| 500A-C | Φ500 × 320 | 0.08 – 0.32 | 2–5.3 | 4 – 40 | 0.02 – 300 | 3000 |
| 500E | Φ500 × 320 | 0.06 – 0.26 | 1.5–2.8 | 6 – 44 | 3 – 300 | 3000 |
| 630C | Φ630 × 475 | 0.23 – 0.64 | 1.5 – 6 | 6 – 26 | 19 – 75 | 1570 |
| 630P | Φ630 × 475 | 0.15 – 0.64 | 1.5 – 5 | 5 – 15 | 54 – 73.89 | 2200 |
| 800 | Φ800 × 600 | 0.25 – 0.8 | 2.5 – 16 | ≤ Φ34 | 56 – 181.76 | 1200 |
| 1000 | Φ1000 × 750 | 0.4 – 1.5 | 4 – 20 | ≤ Φ12 | 34.55 – 181.76 | 800 |
| 1250 | Φ1250 × 950 | 1.2 – 3.2 | 70 | ≤ Φ22 | 40 – 500 | 650 |
تتوفر التكوينات المخصصة والطرازات ذات السعات الأعلى عند الطلب.
Expanded Primary Applications
- Multi-stranded copper and tinned wires for electronic cables, USB, headphone and internal device wiring
- Enameled wires for magnet wire and winding applications
- Copper-clad aluminum (CCA) for lightweight conductors
- Automotive and EV wiring harnesses (vibration-resistant, thin-wall and high-flex constructions)
- Data and LAN cables (Cat5e / Cat6 / Cat7 twisted-pair production)
- Renewable-energy cables (solar, wind and EV charging systems)
- Industrial control, instrumentation and automation multi-core cables
- Small-core laying-up for communication and specialty cables
Double Twist vs Single Twist – Key Performance Comparison
| ميزة | آلة تجميع مزدوجة اللف | Single Twist Bunching Machine |
|---|
| Twists per Revolution | 2 | 1 |
| Productivity | Up to 2× higher | Baseline |
| Typical Output Suitability | High-volume fine-to-medium conductors | Precision or lower-volume runs |
| Finished Conductor Stress | Lower internal stress, excellent concentricity | Higher path-induced stress possible |
| Energy & Cost per Meter | Lower at high utilization | Higher for equivalent volume |
| Best Fit | Electronics, automotive EV, data, renewable | Specialized or large rigid sections |
التطبيقات الأساسية
- Multi-stranded copper and tinned wires for electronic cables and harnesses
- Enameled wires for magnet and winding applications
- Copper-clad aluminum wires for lightweight conductors
- Small-core laying-up for data, control, and communication cables
The machine supports various pay-off options — in-line racks for Φ100–300 mm bobbins or multi-head racks for larger Φ500–800 mm bobbins — allowing seamless integration into existing production lines.
Why Leading GCC Manufacturers Choose This Series
- جودة موثوقة: Factory-tested machines designed for consistent long-term performance under continuous industrial duty.
- Customized Technical Solutions: Tailored pay-off systems, layout drawings and process integration matched to your exact factory requirements in Saudi Arabia and the GCC.
- شراكة طويلة الأمد: Complete installation, English-language operator training, spare-parts supply, remote diagnostics and performance maintenance contracts.
- Vision 2030 Alignment: High-efficiency, low-maintenance technology that supports local content, reduced scrap and the Kingdom’s growing demand for multi-strand conductors in energy, mobility and digital infrastructure projects.
Ready to increase your fine-wire and multi-strand bunching efficiency?
استفسر الآن — Contact our technical team today. Within 48 hours you will receive a detailed configuration proposal, ROI calculation based on your target volumes, complete layout drawings and relevant GCC project references.
آلة تجميع مزدوجة اللف
High-speed Double Twist Bunching Machine (315E to 1250 Series) for stranding multi-stranded copper wires, tinned wires, enameled wires and copper-clad aluminum wires. PLC+HMI control, constant tension, and flexible pay-off options.
رمز تعريف SKU للمنتج.:
DTB-630 / DTB-1000 / DTB-1250
العلامة التجارية للمنتج:
آلات موثوقة
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دولار أمريكي
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