The Double-Column Payoff/Takeup for Cable Handling is engineered to meet the demands of high-capacity cable processing in heavy-industry applications, where reliability, throughput, and safety are paramount.
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Its distinctive dual independent columns design enables simultaneous unwinding and rewinding of multiple cables—doubling processing efficiency compared to single-column systems while maintaining precise tension control. With a robust 5-15 ton load capacity per column and PLC-controlled tension regulation, this system excels in handling large-diameter, heavy-weight cables that challenge conventional handling equipment. Field-proven in demanding environments from submarine cable factories to offshore wind farms, it reduces manual labor requirements by 50% and increases production throughput by 30% through parallel processing capabilities.
Columns: Heavy-duty welded steel frame construction with stress-relieved joints, featuring anti-vibration mounts that reduce operational noise to ≤85 dB(A). Column height is adjustable from 2.5-4.5 meters to accommodate tall reels.
Reel Handling: Equipped with hydraulic lifting systems (16 MPa working pressure) for safe reel loading/unloading, with lifting speed adjustable from 0.5-2 m/min. Includes reel centering guides and automatic locking pins.
Tension Control: Utilizes mechanical disc brakes with pneumatic actuation, providing ±1.5% tension accuracy across a range of 500-10,000 N. Tension is adjustable via HMI with 10 N resolution.
Line Speed: Supports stable operation at up to 150 m/min with programmable acceleration/deceleration (0.2-2 m/s²) to prevent cable damage from sudden speed changes. Speed synchronization between columns is ±0.5%.
Rewind Uniformity: Achieves ±0.3 mm layer alignment through servo-controlled traversing systems, with adjustable layering patterns (parallel, cross-wound) selectable via HMI.
Power Requirements: 5.5-11 kW total power consumption (depending on load), with 380-480V AC, 3-phase, 50/60 Hz input. Includes power factor correction for energy efficiency.
Overload Alarms: Multi-stage protection system triggers audible and visual warnings when tension exceeds 105% of rated load, with automatic tension reduction at 110% load to prevent cable failure.
Emergency Clamps: Spring-loaded mechanical clamps instantly secure reels during power outages or emergency stops, preventing uncontrolled reel rotation and cable payoff.
Operator Protection: Reinforced safety cages around reel areas, emergency stop buttons at all access points, and interlocked maintenance doors with zero-speed verification.
Submarine Cable Manufacturing
Handles large-diameter submarine cables (50-150 mm diameter) weighing over 10 tons per reel, with constant tension control critical for maintaining armor integrity during layering and jacketing processes.
Features corrosion-resistant components and sealed electrical enclosures to withstand humid factory environments.
Wind Turbine Cables
Processes heavy-duty medium-voltage cables (10-35 kV) for offshore wind farms, with precise tension control ensuring minimal conductor elongation (<0.1%) during extrusion and armoring.
Supports long-length production runs (up to 5,000 meters) with consistent winding tension for stable cable performance in dynamic wind turbine applications.
Construction Equipment
Manages hauling cables (12-30 mm diameter) for excavators, cranes, and mining machinery, with rugged design handling the thick, abrasive insulation common in construction-grade cables.
Enables efficient reel-to-reel transfer with minimal cable damage, reducing waste in heavy equipment manufacturing.
Telecom Infrastructure
Supports high-speed production of coaxial cables (6-25 mm diameter) and fiber optic loose tubes, with dual-column design allowing parallel processing of different cable types for just-in-time delivery.
Q: Can both columns operate independently with different cable types and processing parameters?
A: Yes, each column features independent drive systems, tension controls, and programmable parameters, allowing parallel processing of two different cable types or sizes simultaneously. The HMI provides separate control screens for each column with synchronized status monitoring.
Q: What is the typical installation process and required facility preparations?
A: Installation requires a reinforced concrete foundation (minimum 200 mm thickness, 30 MPa compressive strength) with anchor bolts embedded per provided drawings. The system arrives pre-assembled in major components, with on-site setup including hydraulic connection, electrical wiring, and calibration—typically completed within 5 working days.
Q: What maintenance procedures are necessary to ensure reliable operation in heavy-duty environments?
A: Grease hydraulic lifting mechanisms monthly with NLGI 2 lithium complex grease, inspect brake pads for wear every 500 hours (replace when thickness <5 mm), and clean tension sensor rollers weekly to prevent debris buildup. Annual preventative maintenance includes hydraulic fluid analysis and replacement, and calibration of tension controls.
Its distinctive dual independent columns design enables simultaneous unwinding and rewinding of multiple cables—doubling processing efficiency compared to single-column systems while maintaining precise tension control. With a robust 5-15 ton load capacity per column and PLC-controlled tension regulation, this system excels in handling large-diameter, heavy-weight cables that challenge conventional handling equipment. Field-proven in demanding environments from submarine cable factories to offshore wind farms, it reduces manual labor requirements by 50% and increases production throughput by 30% through parallel processing capabilities.
Columns: Heavy-duty welded steel frame construction with stress-relieved joints, featuring anti-vibration mounts that reduce operational noise to ≤85 dB(A). Column height is adjustable from 2.5-4.5 meters to accommodate tall reels.
Reel Handling: Equipped with hydraulic lifting systems (16 MPa working pressure) for safe reel loading/unloading, with lifting speed adjustable from 0.5-2 m/min. Includes reel centering guides and automatic locking pins.
Tension Control: Utilizes mechanical disc brakes with pneumatic actuation, providing ±1.5% tension accuracy across a range of 500-10,000 N. Tension is adjustable via HMI with 10 N resolution.
Line Speed: Supports stable operation at up to 150 m/min with programmable acceleration/deceleration (0.2-2 m/s²) to prevent cable damage from sudden speed changes. Speed synchronization between columns is ±0.5%.
Rewind Uniformity: Achieves ±0.3 mm layer alignment through servo-controlled traversing systems, with adjustable layering patterns (parallel, cross-wound) selectable via HMI.
Power Requirements: 5.5-11 kW total power consumption (depending on load), with 380-480V AC, 3-phase, 50/60 Hz input. Includes power factor correction for energy efficiency.
Overload Alarms: Multi-stage protection system triggers audible and visual warnings when tension exceeds 105% of rated load, with automatic tension reduction at 110% load to prevent cable failure.
Emergency Clamps: Spring-loaded mechanical clamps instantly secure reels during power outages or emergency stops, preventing uncontrolled reel rotation and cable payoff.
Operator Protection: Reinforced safety cages around reel areas, emergency stop buttons at all access points, and interlocked maintenance doors with zero-speed verification.
Submarine Cable Manufacturing
Handles large-diameter submarine cables (50-150 mm diameter) weighing over 10 tons per reel, with constant tension control critical for maintaining armor integrity during layering and jacketing processes.
Features corrosion-resistant components and sealed electrical enclosures to withstand humid factory environments.
Wind Turbine Cables
Processes heavy-duty medium-voltage cables (10-35 kV) for offshore wind farms, with precise tension control ensuring minimal conductor elongation (<0.1%) during extrusion and armoring.
Supports long-length production runs (up to 5,000 meters) with consistent winding tension for stable cable performance in dynamic wind turbine applications.
Construction Equipment
Manages hauling cables (12-30 mm diameter) for excavators, cranes, and mining machinery, with rugged design handling the thick, abrasive insulation common in construction-grade cables.
Enables efficient reel-to-reel transfer with minimal cable damage, reducing waste in heavy equipment manufacturing.
Telecom Infrastructure
Supports high-speed production of coaxial cables (6-25 mm diameter) and fiber optic loose tubes, with dual-column design allowing parallel processing of different cable types for just-in-time delivery.
Q: Can both columns operate independently with different cable types and processing parameters?
A: Yes, each column features independent drive systems, tension controls, and programmable parameters, allowing parallel processing of two different cable types or sizes simultaneously. The HMI provides separate control screens for each column with synchronized status monitoring.
Q: What is the typical installation process and required facility preparations?
A: Installation requires a reinforced concrete foundation (minimum 200 mm thickness, 30 MPa compressive strength) with anchor bolts embedded per provided drawings. The system arrives pre-assembled in major components, with on-site setup including hydraulic connection, electrical wiring, and calibration—typically completed within 5 working days.
Q: What maintenance procedures are necessary to ensure reliable operation in heavy-duty environments?
A: Grease hydraulic lifting mechanisms monthly with NLGI 2 lithium complex grease, inspect brake pads for wear every 500 hours (replace when thickness <5 mm), and clean tension sensor rollers weekly to prevent debris buildup. Annual preventative maintenance includes hydraulic fluid analysis and replacement, and calibration of tension controls.
