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Category

cable

Cable Machinery

By | installation engineering, portfolio, portfolio

Machinery and Production Lines for Cable Production and Cable Manufacture

KHU Sondermaschinen develops, designs and fabricates stock and custom machinery and production plants for the cable and wire industry. Our customers value the quality and performance of our cable production plants and automated cable harness plants. Among complete cable production plants we offer a comprehensive supply of components, such as pay-off, take-up, caterpuller and capstans, stranding machinery, twisters and much more. If you can not find what you are searching for please contact us for we are happy to make machinery that does not exist yet. We concentrate on innovative designs to supply our customers with revolutionary products giving them the key competitive advantage.

Cable Manufacture

By | Uncategorized
We provide machines and equipment for automated cable preparation and manufacture, ranging from stations for manual operation to fully automatic cable harnessing lines. Our systems are built in linear or round table transfer designs and perfectly tailored for processing your product. It is also possible to integrate more stations at a later point for processing a variety of products with one single automatic cable manufacturing line. As an experienced system integrator we can provide you the best suited system to realize fully automated cable harness production.

De-Reeler

We provide different kinds of Pay Off’s and Take-Up’s depending on your purpose.

Dancer

For optimal de-reeling and stable cable processing down the line we provide custom designed dancer systems.

Cutting to length

We have developed processes for automatic de-reeling, measuring, feeding and cutting cables to length for a broad variety of cables, e.g. energy cables, data cables, wires, coax cables…

Stripping

For stripping cable jackets we have developed specific processes for best repeatability results and therefor maximized process safety.

Stripping Outer Conductor

For safe stripping of coax- and antenna cables we have designed a system for valley and peak detection in order to precisely cut and strip outer conductors.

Dielektrikum Einschneiden und Abziehen

Equipment for cutting and removing of dielectric without residues.

Inspection & QM

We measure cable prep and stripping levels prior to applying connectors to make sure that all specifications are within tolerance for cables with best electrical conductivity und pristine cable quality.

Connector assembly

Thanks to a lot of different cable manufacturing machines that we have delivered to our customers, we have gained much experience also with handling connectors and processing them by soldering, welding, crimping and pressing.

Inline Overmould

For our automatic cable manufacturing lines we have developed an overmould process for over moulding cables automatically and within the cable processing line.

Cut to length and strip

For partial automatisation of cable harness we provide compact machines, which produce cables that are cut to length, stripped and conveniently presented to the operator.

Soldering

With our innovative solder feed measuring we provide soldering stations for induction brazing and resistance soldering with dual monitoring. By that we make sure that the soldered contacts are a 100% within the specification and your cables perform at their best.

Crimping

Automated stations for cable crimping.

Concentric Tape Binder

By | fo, fo, fo, fo, fo, fo, fo

Concentric Tape Binder BW560

Kupferbandwickler

This tape binder provides an automatic reel take-up via pneumatic pintles, facilitating high rotational speeds with heavy reels. The tape is pulled tangentially from the reel by a driven flyer ring and then wound helically around the cable to the stranding die core by a guiding system. The BW 560 is equipped with a pneumatic brake for a quick stop.

BW560 TECHNICAL DATA (also available for other products)

Reel dimensions
Outside diameter………………… 560mm
Max. weight …………………………. 450kg
CU-Tapes
Tape thickness apr. ………. 0.1-0.2mm
Tape width ………………… 5.0-12.0mm

General machine data
Cable passage…………….. max. 65mm
Lay length……………………. adjustable
Flyer …………………………… 750 min-1
Drive…………………. AC – servo motor

capstans

By | Uncategorized

catterpullers, belt-type capstans, wheel-capstans, multiple wire capstans

In the field of catterpullers and capstans KHU Sondermaschinen offers a broad range of equipment tailored to your specific need. Whether big or small – we build them all.

This machine consists of a solid construction which can be bolted to the floor and therefore is easy to integrate into your existing production line.

The belts can be individually adjusted according to your requirements. Pressing and tensioning can be done mechanically and pneumatically. The desired pressure can be steplessly adjusted. The high number of reels results in less wear and tear of the belts and a soft handling of the product (e.g. cable). According to your requirements the capstan can also be equipped with a three-phase motor and a gear box.

Wheel-capstans for almost all requirements: cable, ribbon, sheathed pellets. In addition to our stock capstans we provide individually designed capstans for your purpose.

KHU Sondermaschinen also fabricates take-off caterpillars, drum pull-offs, multiple wire capstans. There are no limits regarding size and design. Contact us today for your quote.

Belt Type Capstan

By | cable manufacture, cable manufacture, cable manufacture, cable manufacture, extrusion, manufacturing equipment
This machine consists of a solid construction which can be bolted to the floor and thereby easily integrated into your existing production line.

The belts can be individually adjusted according to your requirements. Pressing and tensioning can be done mechanically and pneumatically. The desired pressure can be steplessly adjusted. The high number of reels results in less wear and tear of the belts and a soft handling of the product (e.g. cable). According to your requirements the capstan could be equipped also with a three-phase motor and a gear box.

QSVM

By | general, innovation

The first tubeless tubular strander – the Q-SVM.

Our all new prototype of a high-speed strander – a paradigm shift in cable production.

This new high-speed cable strander is lighter, safer and faster then conventional tubular stranding machines, incorporating many more interesting features.

April 7th – April 11th WIRE Düsseldorf

Austria Pavillion – Hall 10A56-07.

If you have further questions please contact us for more information.

Tensile Strength Test

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Q-TTS 50

The cable sample is put into the testing device and clamped at the designed places.
The desired tensile force has to be defined.
An automatic STOP is possible after the expiry of the programmed time.

Technical Data

Pulling force pneumatic: 100 – 5.000 N
Testing length approx. 600 m

Pulling force hydraulic: 4.000 – 30.000 N
Testing length approx. 600 m

Pulling force hydraulic: 4.000 – 50.000 N
Testing length approx. 360 m

Cable diameter: 5 – 40 mm

Zugfestigkeitstest

Crush Test

By | Uncategorized
Q-TCT 600

According to IEC-794-1-E3-Crush

The cable sample is tightened into the testing device, then pinched between a stationary flat steel plate and a movable 100 mm (length) steel plate whereupon transverse pressure is applied on the cable sample.

The desired pressure has to be defined.

An automatic STOP is possible after the expiry of the programmed time.

This test can be executed automatically and manually.

Measuring unit for calibration of pressure setting including display.

Technische Daten

Cycle time adjustable 0 – 300 sec
Steel plates 100 x 100 mm
Pressure 20 – 6.000 N
Cable sample length 500 mm
Cable diameter 3 – 40 mm

Querdruck Kabeltest

Makromelt machine

By | Uncategorized
This machine is designed to inject liquid synthetic, so called makromelt onto assembled cable ends.
Up to 24 moulds are mounted on a round table. A servo motor drives a piston pump which injects the hot liquid synthetic by volumetrically metering into the mould.
The water cooled moulds are easy to replace which adds to productivity and efficiency.
With this machine it is also possible to use various moulds at the same time thanks to the individually adjustable amount of makromelt volume per station. This makes cable manufacturing very efficient for cables with different types of plugs.
Above the pump is the heated repository which will refill itself automatically by the means of a suction device.
Production sequence
The desired volume of makromelt is defined on the control panel.
After pre heating, the machine starts the automatic manufacturing process.
The plugs are placed upwards into the moulds while the cable is free-hanging. Longer cables can be attached to the cable holder beneath the mould.
For the alignment of the pins a fitted counter plug is to be mounted. Hence the round table feeds the injection tool with the cable by rotation. The mould with the inserted plug is then pressed pneumatically towards the opening of the injection tool starting the moulding process automatically.
After attaining the volume the mould goes back into the starting position and the round table rotates to the next station.
The round table is designed to hold 10 or 22 stations for cooling of the injected makromelt, depending on the machine type.
When reaching the end position the finished cable is to be removed from the machine.
Technical data

Dimension (LxWxH): approx. 400 x 300 x 250 cm
Weight: approx. 2000 kgs
Injecting volume: up to 150 ccm
Injection speed: up to 3,5 l/min
Cycle time of round table: approx. 0,5 – 1 sec.
No. of stations: up tp 24
Volume of heated repository: approx. 4l
Capacity of suction device: 150kgs/h
Heating capacity of injection device: approx. 4kW
Nominal cooling capacity: approx. 14kW
Electrical supply: 3~400V/50Hz
Pneumatics connection: approx. 5bar, 250l/min