WCA September 2013

Custom-made manufacturing lines

❍ ❍ DSI pairing line consisiting of an ARD 630 double twist backtwist pay-off, an ALB longitudinal tape pay-off and a type DSI 631 double twist stranding machine

With DSI lines all types of the above mentioned cables – and even cables of future categories – can be manufactured with high speeds and the utmost precision and quality. Because of the modular concept, DSI stranding lines can be modified and adapted to increasingly changing cable designs and specifications. The user benefit of DSI stranding lines is even further enhanced by the fact that they can be adapted flexibly to manufacturing scheduling and planning: If a line is not fully utilised with the stranding of data cables, it can be used to manufacture other cables. It is also possible to realise completely new manufacturing processes and to test the production of new products.

Cable design is continually becoming more and more complex because cables must meet ever more demanding tasks. In order to keep up with these developments, the manufacturers of such high quality cables need refined equipment which operates economically and can be used to produce reliably and efficiently today’s and tomorrow’s cables. The DSI stranding system developed by Maschinenfabrik Niehoff meets these requirements. The already field-proven double twist stranding machines DSI 631 and DSI 1001 are designed to manufacture insulated conductors into pairs or quads or to strand conductor pairs into special cables with or without foils. Compared to conventional cable stranding machines, energy consumption and noise emission of the DSI machines are significantly reduced due to their one-bow design and a state-of-the-art energy saving drive technology. A further characteristic is the contactless machine data transfer system which minimises maintenance and operational and material costs. The DSI machines are built for a wide conductor cross-section range and a maximum strand diameter of 8.5mm or 15mm, respectively. The lay length can be freely adjusted over a wide range within a very narrow tolerance band. The machines can be combined in a modular system with double twist backtwist pay-offs, longitudinal tape pay-offs, pre-twisters and other ancillary equipment. In this way complete lines can be configured, perfectly adapted to the requirements of each user. Such user-specific complete lines can be used to manufacture cables such as bus, data, sensor, signal, instrumentation and LAN cables. Depending on the configuration, a DSI stranding line can apply up to three foils inline on a cable under controlled foil tension in the multi-taping process. Also backtwisting of single insulated conductors with a diameter of up to 3mm as well as pairs and quads can be achieved. The back twist ratio can be regulated from 0-100 per cent or even higher if required. The number of twists is infinitely variable up to 3,200 twists/min. The tension is on-line controlled during the operation; the production speed is up to 300m/min. Optionally the double twist backtwist pay-offs can be used to enable a triple twist stranding mode. In this configuration the stranding speed and therefore the production capacity can be increased considerably and – as a consequence – production costs can be reduced further.

In this manner, the DSI lines enable a maximum efficiency and productivity. Another advantage for the users of these and other Niehoff systems is that Niehoff supports customers with comprehensive process knowledge, professional after sales services and expedient customer services. The users of Niehoff technology therefore have the ideal tools at hand to benefit from the further development in the cable sector. Maschinenfabrik Niehoff GmbH & Co KG – Germany Website : www.niehoff.de ❍ ❍ Interior of a DSI 1001 type double twist stranding machine

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Wire & Cable ASIA – September/October 2013