Tubular stranding machine for the production of wires and cables in aluminum, in multiple configurations. The industrial plant is located in Keila, Estonia.
Made for the Prysmian Group – Draka Kelia Cables, world leader in the production of electrical cables and fiber optic cables in collaboration with Tezal Lavorazioni Meccaniche.
The purpose of the tubular stranding machine is to obtain cables of braided wires, starting from the individual coils with single conductor diameter up to 4 mm. The line consists of two groups: a 6-coil tubular and a 12-coil tubular.
Each of the two tubulars can work in single mode:
- 6 + 1 reel tubular with its own haul-off and a portal winder
- 12 coil tubular with its own unwinder and a portal winder
In addition, the tubular stranding machines can work in coupled mode, thus becoming a single line capable of producing, in a single pass, a cable consisting of 1 + 6 conductors in the center, then covered with another braided layer, consisting of 12 further wires.
Intech took care of the design of the electrical schematics and the whole automation of the system, as well as the construction of the electrical equipment, divided into 3 cabinets.
Our supervision of the on-board wiring, and preliminary tests at a workshop in Italy have led to the successful quick and effective commissioning of the entire line in Estonian plant.
The two main sections of the tubular stranding machine had to be independent from each other, therefore it was decided to divide the system into two separate electrical cabinets, adding a third one which is positioned on board the main winder machine.
These units are connected via Profinet fieldbus, which allows both the low-priority signals necessary for the operation and synchronism of the machine, and the Profisafe protocol for the management of emergencies and safety protections of the entire line flow. The net was designed to have low latency and high performances.
There are two main control stations, each consisting of a human-machine interface with a 15″ touch-screen panel. These stations allow the operators to manage production parameters, control the process of the equipment involved, by displaying the variables involved, in real time, and any detailed alarms / messages that may come from the machine status.
We have been committed on various fronts, but thanks to our ability to understand the actual needs of the customer and the attention in carrying out the analysis of the machine, we managed to find the optimal solutions that included all the different possibilities of project development.
We have put in place all our know-how of the technologies used: Safety plc with safety protocols, hmi interface panels, vectorial inverters and Profinet control systems.
The design times took us for 1 month, as well as the time for the implementation and commissioning.