Cutting Stranded Wire Rope for Control Cable Assemblies and other applications
The inner stranded wire is cut using an flash cutter in which the stranded wire is clamped by copper electrodes on either side of the break point. A high current is passed to heat the wire. The clamps move apart and the wire breaks and at the same time welds the wire ends together. Length measurement is set either (i)using an end stop or (ii) using an encoder measuring system. Length accuracy is important and needs to be known.
Cut & Weld (flash cutter) Machines
Range of Cut & Weld (flash cutter) Machines
| Specification / Model | 6500 | 6510 | 6501 | 6511 |
|---|---|---|---|---|
| Std machine | X | X | ||
| Heavy Duty machine | X | X | ||
| End stop | X | X | ||
| Encoder Measuring | X | X | ||
| Close tolerance | X | X | ||
| Keypad data entry | X | X |
- Advantages of end stop system: close tolerance cutting, suited for large production runs, more economical pricing
- Advantages of encoder measuring system: long lengths (10m+), keypad entry for length and quantity, ease of frequent length changes and smaller footprint
- Choice of (i) End stop system or (ii) Encoder measuring system for setting cut & weld length
- Quality Welded ends ensure stranded wires can be inserted into the termination
- Stranded wires up to 6mm diameter can be handled
- Choice of (i) End stop system or (ii) Encoder measuring system for setting cut & weld length
- Quality Welded ends ensure stranded wires can be inserted into the termination
- Stranded wires up to 6mm diameter can be handled
Cut & weld electrodes for ‘flash cutting’ the inner wire
- The heart of the flash cutter; a set of 4 electrodes for clamping and carrying current to the wire.
- The electrodes move pneumatically during heating of the wire to ensure a welded end of diameter similar to the wire diameter.
- The electrode gap can be adjusted for different wire diameters
- Wire feed system for flash cutter consists of upper and lower drive rollers with adjustable pressure control according to the wire diameter to be cut. The roller system drives the wire to an end stop
- For models with encoder measuring systems an rotary encoder is incorporated into the drive roller assembly and measures the preset length of wire.
- Ejection system for expelling the cut pieces of stranded wire. The wire rope is expelled into a collector by an upper powered roller and lower roller
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Specification models 6500/6501 with end stop
Model 6500/01 Cut and Weld machine for wires up to 4 / 6mm dia.
Omron PLC to control electrical sequence Transformer 5KW/ 7KW provides power through 4 profile copper electrodes. There is adjustment for stretch with a coarse and fine tuning of power to control weld. Powered Rollers to feed cable during cutting. Retracting end stop to allow cut pieces to be ejected to the collector. Included is batch counter and emergency stop. Minimum Cut length 200mm , Maximum Cut length 2800mm. Length is set by moving the end stop along a gauge bar using a rule to measure length.
Specification models 6510/6511 with encoder measuring system
Model 6510/11 Cut and Weld machine for stranded wires up to 4 / 6mm dia.
Omron PLC to control electrical sequence Transformer 5KW/ 7KW provides power through 4 profile copper electrodes. There is adjustment for stretch with a coarse and fine tuning of power to control weld. Powered Rollers to feed cable during cutting. Retracting end stop to allow cut pieces to be ejected to the collector. Included is batch counter and emergency stop. Minimum Cut length 200mm , Maximum Cut length 9999mm. Length is measured by encoder on the wire feed system.
6600 Series De-reeler
Particularly useful when using the encoder measuring system. The power de-reeler ensures the take-up of the wire by the machine is free from tension, ensuring accurate length measurement