SCREENING MACHINE For HV / MV CABLES

I - PURPOSE

The machine should be suitable to apply screening process with wires and tapes over insulated conductors made of ( Cu or AL), from CCV insulation line for cable (6 -110) KV

according to the following steps:

1-semi-conducting tapes have to be applied over the insulation screen.

2-wires screening have to be applied over the  semi-conducting tapes.

3- Metallic screen (Copper / Aluminum) tape.

4-Swelling tape above the metallic screen (spiral)

5- Longitudinal  (polyester, swelling ) tape.

6- Longitudinal Aluminum tape. 

7- Cable passage diameter range : (up to 150) mm approx.

8-The screening machine should have high productivity.

A - PAY-OFF STAND:

1- Portal type self-aligning pay-off stand type with strong-structure and advanced design suitable for bobbin as per DIN 46395 and DIN 46391.

     Bobbin size as the following:

    -Flange dia: (1400-3200) mm approx.

    - Width: (700 - 2000) mm approx.

    -Gross weight (bobbin plus material) : (16) tons approx.

2- The stand is composed of two vertical frames can be moved one towards the other to take the bobbin between interchangeable pintles directly on the correct position on the floor.

3- The whole structure of the bobbin can move laterally to obtain the correct alignment of the stand by an automatic control to keep the cable in the center   line with the possibility of controlling the cable unwinding constant tension, during the operation without any bad effect on the cable.

4- The stand should have easy loading / unloading of bobbins and equipped with set of adaptors for pintles suitable for sizes of the required bobbin.

B- GUIDING UNIT

     suitable for maintaining the cable in the right line during operation toward tapping units.

C- NO (1) TANGENTIAL TAPING HEAD

1- The taping head suitable for accommodating two pad side by side and driven by independent motor synchronized in the production line . the fitted pads as per the following sizes:

 - Pad outer dia : (600)mm  approx.

 - Pad width : (15 � 80)mm  approx.

 - pad hole dia : (75) mm approx

 - Material tape : textile , plastic polyester, copper ,aluminum, steel

 - Gross pad weight (100) kg approx.

2- The  Taping Head equipped with a system operation for controlling:

 Tape Tension

 Tape break detection.

 Tape end detection.

 Rotor brake for taping head.

 Guiding rollers and equipment suitable to lead the tape to  the taping point according to tape angle and  overlapping tape.

3- The Taping Head suitable for cable passage diameter (150)mm equipped with safety guard and monitoring.

D- Rigid cage with 54 Bobbins 500mm Diameter for wire screening. The main components of the unit :

1- 54 bobbin rigid cage for screening bobbins � 500mm as (DIN46397) in 6 lines of 9 bobbins each which there are mechanical and electrical safety devices to prevent incorrect operations which could damage the machine or put the operate in danger.  

 The cage must Designed for the automatic loading / unloading .

 The wire tension is kept constant during the unwiding from full to empty bobbin.

 Wire break detection.

 Wire passages on the rotating cage made of tungsten carbide fair leads.

 Three interchangeable noses must be supplied for 54 wires and for (36, 48) wires .

2- Automatic unloading-loading device platform Type. The device can load and unload bobbins from rigid cage able to load also a reduced number of bobbin if required and with safety electrical and mechanical devices.

3- Sound proof GUARD.

     Cover of rotating body of 54 Bobbins

4- Screening Die-holder stand

*) BOBBIN SPECIFICATION FOR CAGE:

OD= 500 mm as DIN 46397

ID = 315 mm

BORE = 127 mm

OW = 375 mm

MAX weight : 300 kg ( copper wire)

Wire material : annealed copper or Aluminum.

Wire size : 0.70 � 2.2 mm copper  approx .

                  1.6 � 2.6 mm Aluminum  approx .

* Number of Bobbins= max 54  

Dia  of cable  = 20 � 100 mm approx.

Lay range = 300 � 1500 mm approx.

E- No (2) TANGENTIL TAPING HEAD POSITIONING IN TANDEM LINE OPERATION.

1-Each Taping head suitable for accommodating two pad side by side and driven by independent motor synchronized in the production line.

The fitted pads as per the following size:

 Pad outer Dia (600) mm approx.

 Pad width (15-80) mm approx.

 Pad hole Dia (75) mm approx.

 Material tape : textile, plastic, polyester, copper , Aluminum and steel .

 Gross pad weight : (100) kg Approx.

 Taping pitch length : (10-120) mm Approx.

2- Each taping head equipped with a system operation for controlling :

 Tape tension.

 Tape break detection

 Tape end detection

 Rotor brake for taping head .

 Guiding rollers and equipment suitable to lead the tape to taping point according to tape angle and overlapping tape.

3- Each taping head suitable for cable passage diameter (150) mm equipped with a safety guard and monitoring .

F- LONGITUDINAL ( SWELLING AND ALUMINUM )TAPING UNIT

The unit is composed of :

1- Double pay off for swilling Aluminum tape  application

a- main frame and pads supports

b- Tape centering system

c- Tape pad changing

d- Tape tensioning.

e- low tape pad warning / End tape.

  OD = 1000 mm

  ID  = 100 mm 

Maximum tape pad width  (330 mm), Max pad weight 400 kg with loading system.

2- cutting and welding table for al tape thickness    =   0.1� 0.5 mm ,

                                                               width max = 330 mm

3-Aluminum strip smoothing  device

4- INTEGRAL TABLE :

This unit is basically a table adjustable in height where the cone forming  tooling to close the Aluminum is disposed , with a device to keep the Aluminum Tape closed all the time.

Note :the table can be removed by wheel from the line when don't need Aluminum Application

G- COUNTERMETER  DEVICE  FOR CABLE LENGTH  (Belt Type)

 Suitable for the machine with accuracy of 0.1 % approx.

 Equipped with a Monitoring Display with 4 digits.

 Meter counter can be pre-set according to the desired production length.

H-  HAULOFF UNIT( BELT -TYPE  CATERPILLER)

 I-      TAKE-UP STAND: