Low-voltage cable cabling production line and production method thereof

Abstract

The application relates to a low-voltage cable cabling production line and a production method thereof, and belongs to the technical field of cable production equipment. The low-voltage cable cabling production line comprises a tension release pay-off unit, a filling unit, a forming module unit, a wrapping isolation unit, a rotating traction unit and a single-strand cabling unit. The tension release pay-off unit is used for constant tension pay-off of multiple cable cores. The filling unit is used for conveying filling medium. The forming module unit is used for step-by-step roundness preforming of the gathered cable cores and the filling medium. The wrapping isolation unit is used for wrapping isolation protection tape on the outer periphery of the cable cores. The rotating traction unit is used for uniform-speed rotating traction conveying of the wrapped cable cores. The single-strand cabling unit is used for cabling multiple preformed cable cores at a set pitch. Through the setting of the tension release pay-off unit, the rotating traction unit and the single-strand cabling unit, the traditional cage type cabling machine is replaced, the insulation cable core tension can be kept constant in real time during the production process, and the problems of cable core stretching and deviation caused by tension fluctuation are eliminated.

Description

Technical Field

[0001] This application relates to the technical field of cable production equipment, and in particular to a low-voltage cable cabling production line and its production method. Background Technology

[0002] The cabling process for low-voltage small wires (usually referring to power cables of 70mm² and below) is a key step in the production of multi-core cables. The core process involves regularly twisting multiple insulated cable cores and adding filling, wrapping and other processes to form a cable core with a stable structure, round shape and good electrical and mechanical properties.

[0003] Currently, for cabling low-voltage wires of 70mm² and below, production lines generally use cage-type cabling machines as the core equipment. While this technology is mature, it suffers from a series of inherent drawbacks that severely restrict production efficiency, product quality, and cost control. 1. High equipment inertia: The cage of the cage-type cable forming machine needs to drive multiple heavy-duty reels to rotate as a whole. The rotational inertia is large, which makes the equipment start and stop slowly, difficult to adjust the speed, and difficult to increase the production line speed, resulting in low production efficiency.

[0004] 2. Residual internal stress in the cable core: As the cable reel rotates with the winch, significant internal torque is generated in the core wires during the stranding process. This internal torque causes the cable core to spring back and deform after forming, affecting the roundness, flexibility, and structural stability of the cable core.

[0005] 3. Complex Process: Due to the inherent characteristics of the cage winding process and the limitations of traditional traction and meter-counting methods, the measurement of the cable core length after cable formation is inaccurate. To accurately count the length and control costs and material consumption, the finished cable core must undergo an additional independent rewinding process. This not only increases equipment investment, factory space, and energy consumption, but also significantly extends the production cycle and increases labor costs.

[0006] 4. Limited Functionality: Traditional cage stranding production lines typically cannot be efficiently integrated with high-speed steel strip armoring machines. If armored cables need to be produced, the semi-finished products after cable formation must be transferred to another independent armoring production line, resulting in a broken production process, low efficiency, and increased damage and quality risks in intermediate stages.

[0007] In recent years, the industry has begun to try to introduce single-strand winches to replace traditional cage winches in order to improve speed. However, simply replacing the main machine does not solve the fundamental problem: on the one hand, the high-speed rotating take-up part of the single-strand winch cannot directly achieve high-precision meter counting; on the other hand, high-speed twisting may aggravate the torque and internal stress of the cable core, making it impossible to guarantee the quality of cable core forming.

[0008] In view of the shortcomings of the aforementioned related technologies, how to achieve internal stress relief, high-precision online meter counting, simplified process flow, and online integration of cable forming and armoring processes has become a key technical problem that urgently needs to be solved by those skilled in the art. Summary of the Invention

[0009] To address the above issues, this application provides a low-voltage cable cabling production line and its production method.

[0010] To achieve the above objectives, the present invention adopts the following technical solution: Firstly, this application provides a low-voltage cable assembly line.

[0011] A low-voltage cable production line includes a de-twisting and laying unit, a filling unit, a forming module unit, a wrapping and isolation unit, a rotary traction unit, and a single-twisted cable forming unit arranged sequentially along the production line. The de-twisting and laying unit is used for laying multiple cable cores under constant tension. The filling unit is used for conveying filling medium towards the cable cores. The forming module unit is used for pre-forming the assembled cable cores and filling medium into a circular shape step by step. The wrapping and isolation unit is used for wrapping an isolation and protective strip around the cable cores. The rotary traction unit is used for uniformly rotating and traction conveying the wrapped cable cores. The single-twisted cable forming unit is used for twisting the pre-formed multiple cable cores into a single cable core according to a set pitch.

[0012] By adopting the above technical solution, a new architecture consisting of a de-twisting cable laying unit, a rotary traction unit, and a single-twisting cable forming unit is used to replace the traditional cage-type cable forming machine. The high-speed rotation of the single-twisting main arm, combined with the cable laying frame with de-twisting function, achieves a production efficiency that is twice that of a conventional cage-type cable forming machine, with some products seeing a capacity increase of over 30%. Compared to the 6-7 times speed advantage of the cage-type cable forming machine, the production cycle of a single cable is significantly shortened, and the output per unit time is significantly increased.

[0013] Preferably, the unwinding and unwinding unit includes a first unwinding group and several second unwinding groups. The first unwinding group and the second unwinding group have the same structure, and the several second unwinding groups are symmetrically arranged on both sides of the first unwinding group. The first unwinding group includes an unwinding mechanism and a wire guide mechanism. The unwinding mechanism includes a lifting platform, on which a support base is fixedly installed. A unwinding reel is rotatably mounted inside the support base, and a first motor for driving the unwinding reel to rotate is fixedly mounted on the outside of the support base. A second motor is mounted below the lifting platform, and the output shaft of the second motor is fixedly connected to a drive pulley. A driven pulley is mounted at the bottom of the lifting platform, and a transmission synchronous belt is sleeved between the drive pulley and the driven pulley. The wire guide mechanism includes... The system includes a column, on which a first crossbeam and a second crossbeam are vertically fixed. The first crossbeam is positioned close to the pay-off reel, and the second crossbeam is positioned away from the pay-off reel. A first pay-off wheel is rotatably mounted on the first crossbeam, and a second pay-off wheel is rotatably mounted on the second crossbeam. The axes of the first and second pay-off wheels are parallel to each other to ensure smooth, linear feeding of the cable cores. The axis of the pay-off reel of the second pay-off group is parallel to the axis of the pay-off reel of the first pay-off group. The conductor mechanism of the first pay-off group is aligned with the pay-off mechanism of the first pay-off group. The conductor mechanism of the second pay-off group is located to one side of the pay-off mechanism of the second pay-off group and is used to gather the cable cores fed out by the second pay-off group towards the center, allowing multiple groups of cable cores to converge at the same axis.

[0014] By adopting the above technical solution, the first motor directly drives the pay-off reel to rotate, providing the basic pay-off force to overcome the inertia of the pay-off reel; the second motor drives the lifting platform and the pay-off reel to rotate as a whole through synchronous belt transmission, so as to actively compensate for the reverse torque transmitted back by the downstream rotation traction unit, thereby achieving active torque reduction. The conductor mechanism is used to guide the cable cores to output in a straight and smooth manner; the conductor mechanism, which is inclinedly arranged in the second pay-off group, can accurately and orderly guide and gather the cable cores from both sides to the central axis of the production line, ensuring that all cable cores have a highly consistent spatial position when entering the forming module unit.

[0015] Preferably, the rotary traction unit includes a support frame, a main rotating body, a rotary motor, a traction motor, a traction transmission assembly, a cable core traction mechanism, and a cable core clamping mechanism. The rotary motor is fixed on the support frame, and the main rotating body has hollow central spindles at both ends. The central spindles at both ends of the main rotating body are rotatably mounted on the support frame. The output shaft of the rotary motor drives the main rotating body to rotate around the support frame via belt drive. The traction motor and the traction transmission assembly driven by it are both located outside the main rotating body. The cable core traction mechanism and the cable core clamping mechanism are both located on the main rotating body. A traction shaft is coaxially fixedly sleeved on the outside of the central spindle. The traction motor drives the traction transmission assembly to rotate via a reducer, thereby driving the cable core traction mechanism to rotate. The cable core clamping mechanism presses against the track of the cable core traction mechanism to clamp the cable core and achieve traction transport.

[0016] By adopting the above technical solution, the rotary traction unit is driven by an external traction motor. Compared with the traditional built-in motor structure, this effectively reduces the internal space occupied by the main rotating body, facilitating equipment maintenance and repair. The main rotating body achieves overall rotation through a central spindle in conjunction with a rotary motor, enabling the cable core to rotate synchronously during traction. It undertakes the dual functions of rotational shaping and active traction, ensuring that the pitch and shape of the cable core are highly stable before entering the single-twisted cabling unit.

[0017] Preferably, a traction drive pulley is fixed on the output shaft of the traction motor, a traction driven pulley is fixed on the traction shaft, and a traction master timing belt is sleeved between the traction drive pulley and the traction driven pulley.

[0018] By adopting the above technical solution, and through the transmission structure of the traction drive pulley, the traction driven pulley and the traction master synchronous belt, the efficient transmission of traction motor power to the traction shaft is achieved.

[0019] Preferably, the cable core traction mechanism includes an upper traction module and a lower traction module arranged symmetrically vertically; the traction transmission assembly includes an upper traction transmission group and a lower traction transmission group; the upper traction transmission group includes an upper traction main pulley, an upper traction driven pulley, and an upper traction synchronous belt, the upper traction main pulley is fixed on the traction shaft, the upper traction driven pulley is fixed on the upper traction module, and the upper traction synchronous belt is sleeved between the upper traction main pulley and the upper traction driven pulley; the lower traction transmission group includes a lower traction main pulley, a lower traction driven pulley, and a lower traction synchronous belt, the lower traction main pulley is fixed on the traction shaft, the lower traction driven pulley is fixed on the lower traction module, and the lower traction synchronous belt is sleeved between the lower traction main pulley and the lower traction driven pulley.

[0020] By adopting the above technical solution, the symmetrical upper and lower traction modules, together with the corresponding upper and lower traction transmission groups, realize bidirectional synchronous traction of the cable core, ensuring that the speed of the upper and lower tracks is completely synchronized, and eliminating the problems of wire twisting, abrasion and wrapping layer damage caused by speed difference from the root.

[0021] Preferably, the output shaft of the traction motor is equipped with a rotary encoder for real-time detection of the traction motor speed and for preliminary cumulative calculation of the traction length.

[0022] By adopting the above technical solution, the control system calculates and accumulates the traction length of the cable core in real time based on the encoder pulse count, the total reduction ratio of the transmission system, and the effective circumference of the traction wheel, thus achieving preliminary online meter counting.

[0023] Preferably, a non-contact laser meter is also provided on the cable core path between the rotating traction unit and the single-twisted cabling unit for high-precision measurement of the actual running length of the cable core.

[0024] By adopting the above technical solution, the laser meter directly measures the length passing through the cable core surface. The measurement result is unaffected by mechanical slippage, wear, or elastic deformation, providing an absolute length reference for the system. The control system uses this reference to dynamically calibrate and compensate for errors in the encoder metering system.

[0025] Preferably, it also includes a steel strip armoring unit located between the rotary traction unit and the single-strand cable forming unit, for performing online steel strip armoring processing on the cable core after traction and transportation.

[0026] By adopting the above technical solution and adding optional steel tape armored units, this production line can be flexibly used to produce unarmored or armored cables, making it highly versatile.

[0027] Secondly, this application provides a low-voltage cable cabling production method, which utilizes the aforementioned low-voltage cable cabling production line, and includes the following steps: S1. Constant tension cable release: Multiple cable cores are released synchronously by the first and second cable release groups in the un-twist cable release unit. The inclined conductor mechanism in the second cable release group is used to gather the cable cores on both sides towards the middle and transport them to the forming module unit. S2, Filling: The filling medium is delivered to the molding module unit; S3. Pre-forming round: The cable core and filling medium are extruded and shaped step by step through multi-stage die holes to form a cable core blank; S4. Isolation Wrapping: The pre-formed cable core blank enters the wrapping and isolation unit, and the isolation and protective tape is evenly wrapped around the outer surface of the cable core to achieve tightening and shaping, and insulation protection. S5. Rotary traction conveying: After the cable core is wrapped, it is sent into the rotary traction unit. The rotary motor drives the main rotating body to rotate, and the external traction motor drives the upper and lower traction modules to operate synchronously. Together with the cable core clamping mechanism, the track clamping and traction are realized, and the cable core can rotate and twist while moving. At the same time, the rotary encoder on the traction motor completes the preliminary length measurement. S6. High-precision secondary meter counting: The cable core passes through a laser meter counter, which uses a non-contact detection method to accurately verify the actual delivery length of the cable core, eliminating slippage errors and achieving high-precision online meter counting; S7. Online Armoring Processing: If armored cables are being produced, the cable core continues to be fed into the steel tape armoring unit to complete the steel tape covering and armoring; if it is not an armored cable, it directly proceeds to the next process. S8. Single-strand cabling: The pre-formed multiple insulated cable cores are twisted together at a set pitch to form the final cable core, completing the cabling process of the low-voltage cable.

[0028] In summary, this application includes at least one of the following beneficial technical effects: 1. By incorporating a de-twisting and laying unit, a rotary traction unit, and a single-twisting cabling unit, the traditional cage-type cabling machine is replaced. This allows for real-time maintenance of constant tension in the insulated cable core during production, eliminating cable core stretching and misalignment caused by tension fluctuations. Simultaneously, the de-twisting and laying unit actively eliminates torsional stress generated during cable core twisting, further improving the roundness and flexibility of the formed cable core. The pre-positioning of the rotary traction unit ensures that the cable core pitch is stabilized before entering the final single-twisting unit, guaranteeing stability and preventing slippage at subsequent measurement points. The single-twisting cabling machine ensures that the measured results for each meter are consistent.

[0029] 2. By integrating a rotary encoder and laser meter into the rotary traction unit, the length of the cable core can be measured and controlled in real time and with precision during the cabling process to achieve the required length, thus completely eliminating the need for a separate rewinding and length-fixing process. This directly reduces equipment investment, site occupation, energy consumption, and material turnover, significantly improving production efficiency and lowering production costs.

[0030] 3. By integrating wrapping, rotary traction, forming, wrapping, high-precision metering, and steel tape armoring into a continuous production line, intermediate turnovers and joints are reduced. Simultaneously, the modular design allows the production line to flexibly adapt to the production of both unarmored and armored cables, greatly enhancing the equipment's versatility and market competitiveness. Attached Figure Description

[0031] Figure 1 This is a schematic diagram of the structure of a low-voltage cable production line as shown in Embodiment 1 of this application.

[0032] Figure 2This is a schematic diagram illustrating the connection relationship between the first and second wire-laying groups in Embodiment 1 of this application.

[0033] Figure 3 This is a schematic diagram illustrating the connection relationship between the wire feeding mechanism and the conductor mechanism in Embodiment 1 of this application.

[0034] Figure 4 This is a schematic diagram of the well-type conductor frame used in Embodiment 1 of this application.

[0035] Figure 5 This is a schematic diagram illustrating the structure of the rotary traction unit in Embodiment 1 of this application.

[0036] Figure 6 yes Figure 5 The enlarged view in section A shows the connection relationship between the upper and lower traction drive groups.

[0037] Figure 7 yes Figure 5 The enlarged view of section B shows the structural schematic of the upper clamping unit.

[0038] Explanation of reference numerals in the attached drawings: 1. Unwinding and unwinding unit; 11. First winding group; 111. Winding mechanism; 1111. Lifting platform; 1112. Support base; 1113. Winding reel; 1114. First motor; 1115. Second motor; 1116. Drive pulley; 1117. Driven pulley; 1118. Synchronous belt; 112. Conductor mechanism; 1121. Column; 1122. First crossbeam; 11221. First pay-off reel; 1123, Second crossbeam; 11231, Second pay-off reel; 12, Second pay-off group; 2, Filling unit; 3, Forming module unit; 4, Wrapping isolation unit; 41, Concentric wrapping device; 5, Rotary traction unit; 51, Support frame; 52, Main rotating body; 521, Central main shaft; 522, Traction shaft; 523, Rotary motor; 53, Traction motor; 531, Traction driving pulley; 532, Traction driven pulley; 533, Traction main synchronous belt; 54, Traction transmission assembly; 541, Upper traction transmission group; 5411, Upper traction main pulley; 5412, Upper traction driven pulley; 5413, Upper traction synchronous belt; 542, Lower traction transmission group; 5421, Lower traction main pulley; 5422, Lower traction driven pulley; 5423, Lower traction synchronous belt; 55, Cable core traction mechanism; 551, Upper traction module; 55 11. Upper traction drive roller; 5512. Upper traction driven roller; 5513. Upper traction track; 552. Lower traction module; 56. Cable core clamping mechanism; 561. Upper clamping unit; 5611. Upper clamping cylinder; 5612. Mounting plate; 5613. Clamping roller shaft; 562. Lower clamping unit; 6. Single stranded cable forming unit; 7. Well-type conductor frame; 71. Adjusting guide roller; 8. Steel strip armor unit; 9. Laser meter counter. Detailed Implementation

[0039] The following is in conjunction with the appendix Figure 1-7 This application will be described in further detail. Example

[0040] This application discloses a low-voltage cable assembly line, referring to... Figure 1 The production line includes, in sequence, a untwisting and unwinding unit 1, a filling unit 2, a forming module unit 3, a wrapping and isolation unit 4, a rotary traction unit 5, and a single-twisted cabling unit 6. An external electrical control cabinet is installed on the outside of the production line, integrating a PLC controller. A touchscreen display is embedded on the surface of the cabinet, allowing operators to input processing parameters such as stranding pitch, production line speed, metering threshold, and clamping pressure.

[0041] Reference Figure 1 , Figure 3 The un-twist and pay-off unit 1 is used for constant tension pay-off of multiple cable cores. The un-twist and pay-off unit 1 includes a first pay-off group 11 and several second pay-off groups 12. The first pay-off group 11 and the second pay-off groups 12 have the same structure, and the several second pay-off groups 12 are symmetrically arranged on both sides of the first pay-off group 11. The first pay-off group 11 includes a pay-off mechanism 111 and a conductor mechanism 112. The lifting platform 1111 of the pay-off mechanism 111 can be finely adjusted in height using an electric screw to adapt to different working heights. A support base 1112 is fixed on the lifting platform 1111. A pay-off reel 1113 is rotatably mounted inside the support base 1112. A first motor 1114 is provided on the outside of the support base 1112. The output shaft of the first motor 1114 is coaxially and fixedly connected to the pay-off reel 1113 to drive the pay-off reel 1113 to rotate, thereby locking the tension of the pay-off reel 1113. A second motor 1115 is installed below the lifting platform 1111. A drive pulley 1116 is fixedly connected to the output shaft of the second motor 1115. A driven pulley 1117 is rotatably installed at the bottom of the lifting platform 1111. A synchronous belt 1118 is sleeved between the drive pulley 1116 and the driven pulley 1117.

[0042] The conductor mechanism 112 includes a column 1121, on which a first crossbeam 1122 and a second crossbeam 1123 are vertically fixed. The first crossbeam 1122 is located at the upper end of the column 1121 and faces the wire feeding mechanism 111; the second crossbeam 1123 is located below the first crossbeam 1122 and away from the wire feeding mechanism 111. A first wire feeding wheel 11221 is rotatably mounted on the first crossbeam 1122, and a second wire feeding wheel 11231 is rotatably mounted on the second crossbeam 1123, with the axis of the first wire feeding wheel 11221 parallel to the axis of the second wire feeding wheel 11231. The conductor mechanism 112 of the first wire feeding group 11 is aligned with the wire feeding mechanism 111 of the first wire feeding group 11. The conductor mechanism 112 of the second wire feeding group 12 is located on one side of the wire feeding mechanism 111 of the second wire feeding group 12, converging the cable cores on the side towards the central axis, so that multiple groups of cable cores converge at the same axis.

[0043] Reference Figure 4 The filling unit 2 includes two symmetrically arranged filling devices, which are close to the second pay-off group 12. The forming module unit 3, wrapping isolation unit 4, rotating traction unit 5, and single-twisted cabling unit 6 are all in a straight line. A well-type conductor frame 7 is provided between the filling unit 2 and the forming module unit 3. The core function of the well-type conductor frame 7 is to ensure that multiple cable cores can travel strictly along the preset centerline before entering the forming module. Its "well"-shaped structure consists of two horizontal adjusting guide rollers 71 and two vertical adjustable guide rollers 71. The horizontal adjusting guide rollers 71 guide and position the filling medium conveyed on the filling device, and the vertical adjusting guide rollers 71 guide and position the cable cores. This precise positioning ensures that the force direction and angle of all cable cores are uniform, avoiding positional deviation caused by uneven pay-off tension or equipment vibration, thereby ensuring that the pitch and outer diameter of the stranded product are always consistent. It prevents loosening and skipping, and prevents the cable cores from unconstrained and jumping out, ensuring that the stranded layer is tight and the structure is stable. The well-type conductor frame 7 uses a rolling guide roller, and the contact with the cable core and filling medium is rolling friction, which greatly reduces the wear on the cable core insulation layer or conductor surface.

[0044] The wrapping isolation unit 4 includes two concentric wrapping devices 41 arranged in sequence. After multiple core wires pass through the forming module, a cylinder with precise dimensions, a smooth surface, and a regular shape is obtained. It then enters the two concentric wrapping devices 41 in sequence, which can complete the double-layer wrapping that originally required two separate processes in one go. This directly saves the time and labor costs of intermediate wire take-up and secondary winding, and greatly improves production efficiency.

[0045] Reference Figure 5The rotating traction unit 5 includes a support frame 51, a main rotating body 52, a rotating motor 523, a traction motor 53, a traction transmission assembly 54, a cable core traction mechanism 55, and a cable core clamping mechanism 56. The rotating motor 523 is fixed on the support frame 51. The two ends of the main rotating body 52 are provided with hollow central spindles 521. The two ends of the central spindles 521 of the main rotating body 52 are rotatably mounted on the support frame 51. The output shaft of the rotating motor 523 drives the main rotating body 52 to rotate around the support frame 51 through belt drive, so as to realize the twisting and torsional matching of the cable core.

[0046] Both the traction motor 53 and the traction transmission assembly 54 are located outside the main rotating body 52. ​​The traction shaft 522 is coaxially fixed to the outside of the central main shaft 521. The output shaft of the traction motor 53 is fixed with a traction drive pulley 531, and the traction driven pulley 532 is fixed to the traction shaft 522. A traction master timing belt 533 is sleeved between the traction drive pulley 531 and the traction driven pulley 532.

[0047] Reference Figure 5 , Figure 6 Both the cable core traction mechanism 55 and the cable core clamping mechanism 56 are mounted on the main rotating body 52. ​​The traction transmission assembly 54 includes an upper traction transmission group 541 and a lower traction transmission group 542. The upper traction transmission group 541 includes an upper traction main pulley 5411, an upper traction driven pulley 5412, and an upper traction synchronous belt 5413. The upper traction main pulley 54111 is fixed to the traction shaft 522, and the upper traction driven pulley 54122 is mounted on the main rotating body 52 and connected to the worm shaft of the upper worm gear transmission assembly via a coupling. The upper traction synchronous belt 5413 is sleeved between the upper traction main pulley 5411 and the upper traction driven pulley 5412. The lower traction transmission assembly 542 includes a lower traction main pulley 5421, a lower traction driven pulley 5422, and a lower traction synchronous belt 5423. The lower traction main pulley 5421 is fixed on the traction shaft 522. The lower traction driven pulley 5422 is mounted on the main rotating body 52 and connected to the lower worm shaft of the lower worm gear transmission assembly through a coupling. The lower traction synchronous belt 5423 is sleeved between the lower traction main pulley 5421 and the lower traction driven pulley 5422.

[0048] Reference Figure 5 The cable core traction mechanism 55 includes an upper traction module 551 and a lower traction module 552 arranged symmetrically. The upper traction transmission group 541 is connected to the upper traction module 551 via an upper worm gear transmission assembly; the lower traction transmission group 542 is connected to the lower traction module 552 via a lower worm gear transmission assembly. The upper and lower worm gear transmission assemblies are used for reversing direction.

[0049] The upper traction module 551 includes an upper traction drive roller 5511, an upper traction driven roller 5512, and an upper traction track 5513. The upper traction drive roller 5511 is coaxially and fixedly connected to the worm wheel of the upper worm gear transmission assembly. The upper traction driven roller 5512 is rotatably mounted on the main rotating body 52, and the upper traction track 5513 is sleeved between the upper traction drive roller 5511 and the upper traction driven roller 5512. Since the lower traction module 552 is completely symmetrical to the upper traction module 551 and operates on the same principle, it will not be described in detail here for the sake of simplicity. With this design, a fixed traction motor 53 can drive the rotating upper traction module 551 and lower traction module 552 to achieve precise mechanical synchronous traction.

[0050] Reference Figure 5 , Figure 7 The cable core clamping mechanism 56 includes an upper clamping module and a lower clamping module arranged symmetrically. The upper clamping module is located inside the upper traction track 5513 and includes multiple upper clamping units 561 arranged along the length of the main rotating body 52. ​​Each upper clamping unit 561 includes a mounting plate 5612 horizontally fixed on the main rotating body 52. ​​An upper clamping cylinder 5611 is vertically mounted on the mounting plate 5612, with its piston rod extending downward and connected to a mounting frame. Several freely rotatable clamping roller shafts 5613 are mounted side by side in the mounting frame, and the axis of the clamping roller shafts 5613 is perpendicular to the axis of the upper clamping cylinder 5611. During operation, the upper clamping cylinder 5611 pushes the clamping roller shafts 5613 downward, pressing the inner side of the upper traction track 5513 against the cable core. The lower clamping unit 562 is symmetrical to the upper clamping unit 561. Its clamping cylinders lift upwards to provide support from below, which, together with the pressure of the upper clamping roller 5613, forms a clamping force. By adjusting the pressure of each upper clamping cylinder 5611, the clamping force on the cable core can be controlled to prevent slippage or damage.

[0051] Reference Figure 1 To measure the length of the single-stranded cable, a rotary encoder electrically connected to the PLC controller is installed on the output shaft of the traction motor 53. To further improve the accuracy of the measurement, a non-contact laser meter 9, also electrically connected to the PLC controller, is installed between the rotary traction unit 5 and the single-stranded cable unit 6 to perform high-precision measurement of the actual running length of the cable core. The PLC controller uses the data recorded by the laser meter 9 as a reference to dynamically calibrate and compensate for errors in the rotary encoder measurement system.

[0052] Reference Figure 1Traditional single-strand cable production lines cannot be used in conjunction with steel tape machines. In this application, a steel tape armoring unit 8 can be placed between the rotary traction unit 5 and the single-strand cable forming unit 6 as needed. When steel tape armoring is required, the cable core enters the high-speed concentric steel tape armoring machine to complete the armoring. The purpose is to immediately apply a robust metal armor layer online after the cable core has undergone necessary inner layer covering (such as insulation, flame retardancy, and binding), thereby producing a cable with resistance to mechanical damage in a single operation. The steel tape armoring machine is placed between the rotary traction unit 5 and the single-strand cable forming unit because: when the cable enters the rotary traction unit, most of the pitch has already been formed; entering the high-speed concentric steel tape armoring machine after rotary traction prevents cable twisting. Example

[0053] Reference Figure 1 A method for producing low-voltage cable cabling, using the low-voltage cable cabling production line in Example 1, includes the following steps: S1. Constant tension wire feeding: The first motor 1114 of the first wire feeding group 11 and the second motor of the second wire feeding group 12 are controlled in coordination by the PLC controller to drive the corresponding wire feeding reel 1113 to rotate, ensuring that multiple cable cores are released synchronously with constant tension; the first wire feeding wheel 11221 and the second wire feeding wheel 11231 in the conductor mechanism 112 of the second wire feeding group 12 sequentially gather the cable cores toward the central axis, realizing the precise convergence of multiple wire cores in space, avoiding deviation or tangling, and providing stable input for subsequent processes. The converged cable cores enter the well-type conductor frame 7. S2, Filling: Filling unit 2 delivers the filling medium, such as PP rope, to the well-type conductor frame 7; S3, Pre-forming a circle: The well-type conductor frame 7 feeds the filling medium and the cable core into the forming module unit 3 respectively. The cable core is extruded and shaped step by step through multi-stage die holes to eliminate the random deviation of the cable core and pre-form the cable core cross section into a standard circle. S4. Isolation Wrapping: The pre-formed cable core enters two concentric wrapping devices 41 in sequence, and two layers of isolation protective tape are evenly wrapped around the outer surface of the cable core to achieve tightening and shaping, and insulation protection. S5. Rotary traction conveying: After the cable core is wrapped, it is sent into the rotary traction unit 5. The rotary motor 523 drives the main rotating body 52 to rotate. The external traction motor 53 drives the upper and lower traction modules 552 to operate synchronously. Together with the cable core clamping mechanism 56, the track clamping traction is realized. The cable core can rotate and twist at the same time while moving. At the same time, the rotary encoder on the traction motor 53 completes the preliminary length measurement. S6. High-precision secondary meter counting: A non-contact laser meter counter 9 is installed after rotational traction to detect the actual running length of the cable core in real time and upload the data to the PLC controller. The PLC controller compares the laser meter counting value with the preliminary measurement value of the rotary encoder, dynamically calibrates the meter counting parameters of the traction system, and compensates for errors caused by slippage, compression, and other factors. S7. Online armoring process: If armored cables are to be produced, the cable core continues to be fed into the steel tape armoring unit 8 to complete the steel tape covering and armoring; if it is not an armored cable, it directly enters the next process. S8. Single-strand cabling: The final cable core is fed into the single-strand cabling unit 6, where a high-speed rotating single-strand machine twists multiple insulated cores into a cable according to a preset pitch. This process, combined with the untwisting function at the pay-off end, eliminates internal stress, ensuring tight twisting, uniform pitch, and a stable and flexible finished cable core structure.

[0054] The above are all preferred embodiments of this application, and are not intended to limit the scope of protection of this application. Therefore, all equivalent changes made in accordance with the structure, shape and principle of this application should be covered within the scope of protection of this application.

Claims

1. A low-voltage cable forming production line, characterized in that: It includes a untwisting and unwinding unit (1), a filling unit (2), a forming module unit (3), a wrapping and isolation unit (4), a rotating traction unit (5), and a single-twisted cable forming unit (6) arranged sequentially along the production line; The untwisting and laying unit (1) is used for laying multiple cable cores under constant tension. The filling unit (2) is used to deliver the filling medium in the direction of the cable core; The forming module unit (3) is used to perform step-by-step pre-forming of the assembled cable core and filling medium into a round shape; The wrapping isolation unit (4) is used to wrap an isolation protective strip around the outer periphery of the cable core; The rotating traction unit (5) is used to rotate and transport the wrapped cable core at a uniform speed. The single-twisted cabling unit (6) is used to twist multiple pre-formed cable cores into a cable core according to a set pitch.

2. The low-voltage cable forming production line according to claim 1, characterized in that: The untwisting and unwinding unit (1) includes a first unwinding group (11) and several second unwinding groups (12). The first unwinding group (11) and the second unwinding group (12) have the same structure, and several second unwinding groups (12) are symmetrically arranged on both sides of the first unwinding group (11). The first wire feeding group (11) includes a wire feeding mechanism (111) and a wire feeding mechanism (112); The wire feeding mechanism (111) includes a lifting platform (1111), a support base (1112) fixedly installed on the lifting platform (1111), a wire feeding reel (1113) rotatably mounted inside the support base (1112), and a first motor (1114) for driving the wire feeding reel (1113) to rotate fixedly on the outside of the support base (1112); a second motor (1115) is mounted below the lifting platform (1111), the output shaft of the second motor is fixedly connected to a drive pulley (1116), a driven pulley (1117) is mounted at the bottom of the lifting platform (1111), and a transmission synchronous belt (1118) is sleeved between the drive pulley (1116) and the driven pulley (1117); The conductor mechanism (112) includes a column (1121), on which a first crossbeam (1122) and a second crossbeam (1123) are vertically fixed. The first crossbeam (1122) is located close to the pay-off reel (1113), and the second crossbeam (1123) is located away from the pay-off reel (1113). A first pay-off wheel (11221) is rotatably mounted on the first crossbeam (1122), and a second pay-off wheel (11231) is rotatably mounted on the second crossbeam (1123). The axis of the first pay-off wheel (11221) is parallel to the axis of the second pay-off wheel (11231) so that the cable core is smoothly transported in a straight line. The axis of the pay-off reel (1113) of the second pay-off group (12) is parallel to the axis of the pay-off reel (1113) of the first pay-off group (11). The conductor mechanism (112) of the first pay-off group (11) is on the same straight line as the pay-off mechanism (111) of the first pay-off group (11). The conductor mechanism (112) of the second pay-off group (12) is located on one side of the pay-off mechanism (111) of the second pay-off group (12), and is used to gather the cable cores released by the second pay-off group (12) towards the middle, so that multiple groups of cable cores converge at the same axis to complete the convergence.

3. The low-voltage cable forming production line according to claim 1, characterized in that: The rotary traction unit (5) includes a support frame (51), a main rotating body (52), a rotary motor (53), a traction motor (53), a traction transmission assembly (54), a cable core traction mechanism (55), and a cable core clamping mechanism (56). The rotary motor (53) is fixed on the support frame (51). The two ends of the main rotating body (52) are provided with hollow central spindles (521). The two ends of the main rotating body (52) are rotatably mounted on the support frame (51). The output shaft of the rotary motor (53) drives the main rotating body (52) to rotate around the support frame (51) through belt drive. The traction motor (53) and the traction transmission assembly (54) driven by it are both located outside the main rotating body (52); The cable core traction mechanism (55) and the cable core clamping mechanism (56) are both mounted on the main rotating body (52). The traction shaft (522) is coaxially fixed on the outside of the central main shaft (521). The traction motor (53) drives the traction transmission assembly (54) to rotate through the reducer, thereby driving the cable core traction mechanism (55) to rotate. The cable core clamping mechanism (56) presses against the track of the cable core traction mechanism (55) to clamp the cable core and realize traction and transportation.

4. A low-voltage cable forming production line according to claim 3, characterized in that: A traction drive pulley (531) is fixed on the output shaft of the traction motor (53), and a traction driven pulley (532) is fixed on the traction shaft (522). A traction master timing belt (533) is sleeved between the traction drive pulley (531) and the traction driven pulley (532).

5. A low-voltage cable forming production line according to claim 4, characterized in that: The cable core traction mechanism (55) includes an upper traction module (551) and a lower traction module (552) arranged symmetrically in the upper and lower positions. The traction drive assembly (54) includes an upper traction drive assembly (541) and a lower traction drive assembly (542); The upper traction transmission group (541) includes an upper traction main pulley (5411), an upper traction driven pulley (5412), and an upper traction synchronous belt (5413). The upper traction main pulley (5411) is fixed on the traction shaft (522), the upper traction driven pulley (5412) is fixed on the upper traction module (551), and the upper traction synchronous belt (5413) is sleeved between the upper traction main pulley (5411) and the upper traction driven pulley (5412). The lower traction transmission assembly (542) includes a lower traction main pulley (5421), a lower traction driven pulley (5422), and a lower traction synchronous belt (5423). The lower traction main pulley (5421) is fixed on the traction shaft (522), the lower traction driven pulley (5422) is fixed on the lower traction module (552), and the lower traction synchronous belt (5423) is sleeved between the lower traction main pulley (5421) and the lower traction driven pulley (5422).

6. A low-voltage cable forming production line according to claim 3, characterized in that: The output shaft of the traction motor (53) is equipped with a rotary encoder, which is used to detect the rotational speed of the traction motor (53) in real time and to perform a preliminary cumulative calculation of the traction length.

7. A low-voltage cable forming production line according to claim 6, characterized in that: On the cable core path between the rotating traction unit (5) and the single-twisted cabling unit (6), a non-contact laser meter (9) is also provided for high-precision measurement of the actual running length of the cable core.

8. A low-voltage cable forming production line according to claim 1, characterized in that: It also includes a steel strip armor unit (8) located between the rotary traction unit (5) and the single twisted cabling unit (6), which is used to perform online steel strip armoring processing on the cable core after traction and transportation.

9. A method for producing low-voltage cable cabling, applied to the low-voltage cable cabling production line according to any one of claims 1-8, characterized in that: Includes the following steps: S1, Constant tension cable release: Multiple cable cores are released synchronously by the first cable release group (11) and the second cable release group (12) in the un-twist cable release unit (1). The cable cores on both sides are gathered towards the middle and transported to the forming module unit (3) by the inclined conductor mechanism (112) in the second cable release group (12). S2, Filling: The filling medium is delivered to the molding module unit (3); S3. Pre-forming round: The cable core and filling medium are extruded and shaped step by step through multi-stage die holes to form a cable core blank; S4, Isolation Wrapping: The pre-formed cable core blank enters the wrapping isolation unit (4) and the isolation protection strip is evenly wrapped around the outer surface of the cable core to achieve tightening and shaping, and insulation protection; S5. Rotary traction conveying: After the cable core is wrapped, it is sent into the rotary traction unit (5). The rotary motor (53) drives the main rotating body (52) to rotate. The external traction motor (53) drives the upper and lower traction modules (552) to operate synchronously. Together with the cable core clamping mechanism (56), the track clamping traction is realized. The cable core can rotate and twist at the same time while moving. At the same time, the rotary encoder on the traction motor (53) completes the preliminary length measurement. S6. High-precision secondary meter counting: The cable core passes through a laser meter counter (9), and the actual transmission length of the cable core is accurately checked using a non-contact detection method to eliminate slippage error and achieve high-precision online meter counting. S7. Online armoring process: If armored cables are to be produced, the cable core is to be fed into the steel tape armoring unit (8) to complete the steel tape armoring; if it is not an armored cable, it will directly enter the next process. S8. Single-strand cable forming: The pre-formed multiple insulated cable cores are twisted into the final cable core according to the set pitch to complete the cabling process of low-voltage cables.

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