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Cutting Technology for Control Cables used in the Automotive and associated industries with the 6000 series Conduit Cutting Machines

6000 series Conduit Cutting Machines

ImageClick to Enlarge

Control Cable Assemblies eg push-pull cables, comprise the following component parts

  • A steel outer conduit, plastic covered and sometimes with a Teflon liner
  • A inner stranded wire sometimes with a central king wire
  • Termination fittings for the outer conduit so that the control cable can be assembled

We are concerned here with cutting the outer conduit

  • The outer conduit is cut using an abrasive cutting wheel to give a high quality cut surface onto which terminations can be fitted
  • The cutting can be done with coolant or dry
  • Cut Length measurement is made either (i)using an end stop or (ii) using an encoder measuring system
  • Length accuracy is becoming important and needs to be known

6000 series cutting machines for cutting the outer conduit have 2 basic length measuring systems

  • Standard & heavy duty abrasive cutting machines
  • Length measurement- cable drive to end stop or encoder measuring system

6000 series Cutting Machine range of models

Specification / Model 6000 6100 6200 6300
Std machine X X    
Heavy Duty machine       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

Cable feed +pneumatic vice + cutting head + ejection system

PLC control for end stop system (1) / or control system for encoder measuring system (2)

Models 6000/6200 end stop machines for cutting the outer conduit

ImageClick to Enlarge Cable drive showing upper & lower rollers & variable speed control
ImageClick to Enlarge Pneumatic vice area, showing cutting wheel & first part of ejection flap. Wheel wear compensation is built into the system

Specification of Models 6000/6200 Conduit Cutting Machines

General

Floor standing cabinet with clear view canopy.
Hinged front access panel with time delay safety interlock switch.
Access side ports for cable drive and ejection flap.
Front Control panel for operation

Cutting Head

Model 6000
Wheel spindle diameter 12.7mm
Indirectly driven by 2.2KW /3HP, 3 phase motor
Cutting discs up to 230mm/9in can be used
Pneumatic raise/lower of cutting head
Adjustable feed rate.

Model 6200 
Wheel spindle diameter 32mm/1.25in
Indirectly driven by 3.6KW/ 5HP, 3 phase motor
Cutting discs up to 250mm/10in can be used
Pneumatic raise/lower of cutting head
Adjustable feed rate.

PLC

Programmable logic controller to control automatic cutting cycle

Programmed with ladder logic from laptop computer

Wheel Wear

Wheel wear compensation system consisting of optical fibres for wheel edge detection and a detector for sensing movement of the cutting head linkage

Vice

pneumatic vice with front jaw holding of both sides of the cut cable. Front jaw carbide tipped for longer life
Encoder Measuring & Feeding System

Conduit Feed System

Precision feed rollers with upper roller pneumatically powered. Precision cable guide and intermediate guide

Ejection Flap

Cut pieces of cable eject through flap into collector
Cut lengths up to 3m standard.
Longer flap length available as an option
Adjustable End Stop with integrated sensor
Inclined collector fitted under flap

Coolant Circulation

External 10gal Coolant Tank model 6000
External 20 gal Coolant Tank model 6200
Circulation pump 55 lit/min capacity

Safety features

As per CE requirements

Services:

Power: 3phase 3.5KVA

Airline: dry air at 5bar/80psi

Additional Options

600-610 2.2KW Inverter for wheel speed variation 2000 to 6000 rpm
620-610 4KW Inverter for wheel speed variation 2000 to 6000 rpm
600-615 Constant Peripheral Speed Control (600/620-610 Inverter must be fitted)
600-640 Remote Control Pan
600-260 Set of hardened Profile Rollers with cable guide
600-290 Pneumatic clamp on Cable Drive for use with flexible conduit
600-293 Adjustable pressure control on drive rollers

600-230 LH + RH Pneumatic vices for improved grip on the offcut side. Adjustable pressure control (deduct standard Pneumatic Vice)

600-700 Extraction spark chute for dry cutting

600-720 DRO Readout of End Stop Position (3m flap)

600-330 Conveyor for short length ejection

600-740 Lifting End Stop for use with Compressible Conduit

600-770 2 Stage Optical End Stop for use with conduit which cannot be compressed

600-328 Additional length of Ejection Flap per 1 m (up to 5m maximum length)

Models 6100/6300 encoder measuring machines for cutting the outer conduit

Specification of Models 6100 /6300 Conduit Cutting Machines

ImageClick to Enlarge Cable drive showing upper & lower rollers, stepper motor, encoder wheel
ImageClick to Enlarge Keypad entry for cut length, quantity and kerf. Sequential batches are possible

General

Floor standing cabinet with clear view canopy.
Hinged front access panel with time delay safety interlock switch.
Access side ports for cable drive and ejection flap.
Remote Control unit for operation

Cutting Head

Model 6100
Wheel spindle diameter 12.7mm
Indirectly driven by 2.2KW /3HP, 3 phase motor
Cutting discs up to 230mm/9in can be used
Pneumatic raise/lower of cutting head
Adjustable feed rate.

Model 6300 
Wheel spindle diameter 32mm/1.25in
Indirectly driven by 3.6KW/ 5HP, 3 phase motor
Cutting discs up to 250mm/10in can be used
Pneumatic raise/lower of cutting head

Adjustable feed rate.

PLC

Programmable logic controller to control automatic cutting cycle
Programmed with ladder logic from laptop computer

Wheel Wear

Wheel wear compensation system consisting of optical fibres for wheel edge detection and a detector for sensing movement of the cutting head linkage

Vice

pneumatic vice with front jaw holding of both sides of the cut cable. Front jaw carbide tipped for longer life
Encoder Measuring & Feeding System

Conduit Feed System

Precision feed rollers with upper roller pneumatically powered. Encoder arm resting on cable. Precision cable guide and intermediate guide

Remote Control Unit & software

Data input for cut length, quantity, and kerf is via a keypad on the remote panel.
Software for successive batches

Coolant Circulation

External 10gal Coolant Tank model 6100
External 20 gal Coolant Tank model 6300
Circulation pump 55 lit/min capacity

Safety features

As per CE requirements

Additional Options

600-610 2.2KW Inverter for wheel speed variation 2000 to 6000 rpm

620-610 4KW Inverter for wheel speed variation 2000 to 6000 rpm

600-615 Constant Peripheral Speed Control (600/620-610 Inverter must be fitted)

600-640 Remote Control Panel - additional

610-260 Set of hardened Profile Rollers with cable guide with precision cable guide

600-290 Pneumatic clamp on Cable Drive for use with flexible conduit

610-293 Adjustable pressure control on drive rollers

600-230 LH + RH Pneumatic vices for improved grip on the offcut side. Adjustable pressure control (deduct standard Pneumatic Vice)

610-700 Extraction spark chute for dry cutting

Ordering Information- all cutting machines

8-600-001-00 Model 6000 Conduit cutting machine, w/end stop 380-415V 3 Ph
8-600-002-00 Model 6000 Conduit cutting machine w/end stop 208-220V- 3 Ph
8-620-001-00 Model 6200 Heavy Duty Conduit cutting machine w/end stop 380-415V 3Ph
8-620-002-00 Model 6200 Heavy Duty Conduit cutting machine, w/end stop 208-220V 3Ph
8-610-001-00 Model 6100 Conduit cutting machine, encoder system 380-415V 3 Ph
8-610-002-00 Model 6100 Conduit cutting machine, encoder system 208-220V 3 Ph
8-630-001-00 Model 6300 Heavy Duty Conduit cutting machine, encoder system 380-415V 3 Ph
8-630-002-00 Model 6300 Heavy Duty Conduit cutting machine, encoder system 208-220V 3 Ph

Accessories
600-610 2.2KW Inverter for wheel speed variation 2000 to 6000 rpm
620-610 4KW Inverter for wheel speed variation 2000 to 6000 rpm
600-615 Constant Peripheral Speed Control (600/620-610 Inverter must be fitted)
600-640 Remote Control Panel - additional
600-260 Set of hardened Profile Rollers with cable guide with precision cable guide
600-290 Pneumatic clamp on Cable Drive for use with flexible conduit
600-293 Adjustable pressure control on drive rollers
600-230 LH + RH Pneumatic vices for improved grip on the offcut side. Adjustable pressure control (deduct standard Pneumatic Vice)
600-700 Extraction spark chute for dry cutting

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