The High-Speed TQLV Capstan for Cable Extrusion sets new standards for precision in wire and cable manufacturing, engineered specifically for high-precision wire drawing and extrusion processes where tension control and speed stability are critical.
| Quantity: | |
|---|---|
Its robust design delivers consistent performance even at maximum throughput, with a maximum line speed of 30 m/min and 5-200 ton load capacity to accommodate everything from fine electronic wires to heavy power cables. What distinguishes this capstan is its dual-independent gearbox system paired with a vector-controlled variable frequency drive, enabling stepless speed adjustment with ±0.5% accuracy—eliminating the need for mechanical gear changes during product transitions. This results in 30% faster changeovers and 25% reduction in scrap rates compared to single-gearbox designs, making it a cornerstone of high-efficiency production lines.
Capstan Diameter: Available in 400-1200 mm sizes, with custom diameters available upon request. The drum surface is precision ground to Ra ≤0.4 μm finish to prevent cable marking.
Material: Constructed from 304 stainless steel (or optional nickel-plated carbon steel) for corrosion resistance, with dynamic balancing performed to G2.5 standard at maximum operating speed.
Bearing System: Equipped with self-aligning spherical roller bearings (SKF or equivalent) with C3 clearance, lubricated for life with high-temperature grease (operating range -40°C to 120°C).
Tension Control: Achieves ±1% accuracy via closed-loop feedback system combining load cells and encoder feedback, maintaining stable tension even during speed fluctuations. Tension range is adjustable from 50 N to 200,000 N.
Motor Power: 5.5-110 kW permanent magnet synchronous motor (PMSM) with IE4 efficiency rating, delivering 20% higher energy efficiency than asynchronous motors. Motor is water-cooled for compact design.
Rewind Precision: Ensures ±0.1 mm concentricity in winding, with automatic layering control that adjusts traverse speed proportionally to line speed for uniform spooling density.
Overload Protection: Multi-stage protection system triggers alarm at 105% load and automatic shutdown at 110% of rated load, with manual reset required to resume operation.
Emergency Brake: Electromagnetic disc brake with fail-safe design, stopping capstan rotation within 0.5 seconds of emergency stop activation, with brake force adjustable to cable type.
Guard Interlocks: Safety switches on all access panels prevent operation when covers are open, with visible warning lights indicating machine status.
Telecom Cable Manufacturing
Handles fiber optic cables (0.9-12 mm diameter) with delicate UV-cured coatings, maintaining tension within 5-50 N range to prevent microbending and ensure low attenuation (≤0.2 dB/km at 1310 nm).
Supports ribbon fiber cable production with precise speed synchronization between capstan and stranding units, ensuring uniform fiber length in each ribbon.
Automotive Wire Production
Processes high-strength wires (0.3-6 mm diameter) for braking systems, airbags, and sensors, maintaining consistent tension to prevent conductor stretching and ensure electrical performance meets ISO 19642 standards.
Aerospace Components
Manufactures lightweight, high-conductivity cables for avionics, with tension control accuracy critical for maintaining dielectric integrity in thin-wall (0.2-0.5 mm) insulation systems. Complies with SAE AS4373 requirements.
Industrial Automation
Integrates seamlessly with robotic arms and automated cutting systems for precision cable assembly, providing pulse output signals for length-based cut-to-length operations with ±1 mm accuracy.
Q: What is the minimum wire diameter this capstan can reliably handle?
A: It supports wires as thin as 0.1 mm when equipped with the optional precision guide system, which includes ceramic pulleys and micro-tension controls to prevent wire breakage and ensure stable traction.
Q: How does the closed-loop tension control system maintain stability during speed changes?
A: A high-resolution load cell sensor (16-bit) measures real-time tension, sending data to the PLC at 100 Hz intervals. The PLC adjusts motor speed via the VFD within 10 ms, ensuring tension remains within ±1% of setpoint even during acceleration/deceleration.
Q: Can this capstan be retrofitted into existing extrusion lines with minimal modifications?
A: Yes, its modular design includes adjustable mounting brackets and flexible electrical interfaces, allowing integration with most extrusion and drawing machines. Our technical team provides on-site installation support and line calibration.
Q: What maintenance procedures are required to ensure long-term performance?
A: Lubricate bearing housings with specified grease every 200 operating hours, inspect brake pads for wear monthly (replace when thickness <3 mm), and calibrate tension sensors quarterly using certified weights. The system includes predictive maintenance alerts for critical components.
Its robust design delivers consistent performance even at maximum throughput, with a maximum line speed of 30 m/min and 5-200 ton load capacity to accommodate everything from fine electronic wires to heavy power cables. What distinguishes this capstan is its dual-independent gearbox system paired with a vector-controlled variable frequency drive, enabling stepless speed adjustment with ±0.5% accuracy—eliminating the need for mechanical gear changes during product transitions. This results in 30% faster changeovers and 25% reduction in scrap rates compared to single-gearbox designs, making it a cornerstone of high-efficiency production lines.
Capstan Diameter: Available in 400-1200 mm sizes, with custom diameters available upon request. The drum surface is precision ground to Ra ≤0.4 μm finish to prevent cable marking.
Material: Constructed from 304 stainless steel (or optional nickel-plated carbon steel) for corrosion resistance, with dynamic balancing performed to G2.5 standard at maximum operating speed.
Bearing System: Equipped with self-aligning spherical roller bearings (SKF or equivalent) with C3 clearance, lubricated for life with high-temperature grease (operating range -40°C to 120°C).
Tension Control: Achieves ±1% accuracy via closed-loop feedback system combining load cells and encoder feedback, maintaining stable tension even during speed fluctuations. Tension range is adjustable from 50 N to 200,000 N.
Motor Power: 5.5-110 kW permanent magnet synchronous motor (PMSM) with IE4 efficiency rating, delivering 20% higher energy efficiency than asynchronous motors. Motor is water-cooled for compact design.
Rewind Precision: Ensures ±0.1 mm concentricity in winding, with automatic layering control that adjusts traverse speed proportionally to line speed for uniform spooling density.
Overload Protection: Multi-stage protection system triggers alarm at 105% load and automatic shutdown at 110% of rated load, with manual reset required to resume operation.
Emergency Brake: Electromagnetic disc brake with fail-safe design, stopping capstan rotation within 0.5 seconds of emergency stop activation, with brake force adjustable to cable type.
Guard Interlocks: Safety switches on all access panels prevent operation when covers are open, with visible warning lights indicating machine status.
Telecom Cable Manufacturing
Handles fiber optic cables (0.9-12 mm diameter) with delicate UV-cured coatings, maintaining tension within 5-50 N range to prevent microbending and ensure low attenuation (≤0.2 dB/km at 1310 nm).
Supports ribbon fiber cable production with precise speed synchronization between capstan and stranding units, ensuring uniform fiber length in each ribbon.
Automotive Wire Production
Processes high-strength wires (0.3-6 mm diameter) for braking systems, airbags, and sensors, maintaining consistent tension to prevent conductor stretching and ensure electrical performance meets ISO 19642 standards.
Aerospace Components
Manufactures lightweight, high-conductivity cables for avionics, with tension control accuracy critical for maintaining dielectric integrity in thin-wall (0.2-0.5 mm) insulation systems. Complies with SAE AS4373 requirements.
Industrial Automation
Integrates seamlessly with robotic arms and automated cutting systems for precision cable assembly, providing pulse output signals for length-based cut-to-length operations with ±1 mm accuracy.
Q: What is the minimum wire diameter this capstan can reliably handle?
A: It supports wires as thin as 0.1 mm when equipped with the optional precision guide system, which includes ceramic pulleys and micro-tension controls to prevent wire breakage and ensure stable traction.
Q: How does the closed-loop tension control system maintain stability during speed changes?
A: A high-resolution load cell sensor (16-bit) measures real-time tension, sending data to the PLC at 100 Hz intervals. The PLC adjusts motor speed via the VFD within 10 ms, ensuring tension remains within ±1% of setpoint even during acceleration/deceleration.
Q: Can this capstan be retrofitted into existing extrusion lines with minimal modifications?
A: Yes, its modular design includes adjustable mounting brackets and flexible electrical interfaces, allowing integration with most extrusion and drawing machines. Our technical team provides on-site installation support and line calibration.
Q: What maintenance procedures are required to ensure long-term performance?
A: Lubricate bearing housings with specified grease every 200 operating hours, inspect brake pads for wear monthly (replace when thickness <3 mm), and calibrate tension sensors quarterly using certified weights. The system includes predictive maintenance alerts for critical components.
