Operation and process boundary
Combine individual conductor wires into a defined bunch or strand structure.
| Incoming material | Machine operation | Output |
|---|---|---|
| Individual conductor wires | Conductor formation | A conductor prepared for insulation |
Conductor bunching works with individual wires. Pair twisting works with insulated cores, and cabling assembles cores or pairs. Define the incoming material before choosing the machine family.
First selection check: Individual wire diameter, strand count and finished cross-section
Start with the conductor structure.
Flexible bunches and specified strand layers need different equipment reviews. Choose the operation before comparing models.
Double-twist bunching
Flexible conductor preparation
| Input | Operation | Output |
|---|---|---|
| Drawn or annealed individual wires | Double-twist bunching | Flexible bunched conductor |
Review for flexible conductor preparation; check individual wire size and total cross-section together.
Selection inputs: Wire count, single-wire diameter, finished cross-section and take-up reel.
The four PY reference models apply to bunching. Reel diameter alone does not confirm a match.
Reference tables: High-speed bunching: reference model comparison.
Arch-type stranding
Bunching and cable assembly
| Input | Operation | Output |
|---|---|---|
| Wires or elements specified in the drawing | Arch-type stranding | Specified bunch or cable assembly |
Review when the construction calls for an arch-type bunching or assembly arrangement.
Selection inputs: Assembly diameter, pitch range, reel loading and downstream process.
Assembly size, lay and reel loading need type-specific confirmation; the double-twist bunching table is not its specification.
Planetary stranding
Structures requiring controlled element orientation
| Input | Operation | Output |
|---|---|---|
| Elements with an orientation requirement | Planetary stranding | Assembly with the specified element orientation |
Review when the cable construction requires controlled element orientation or a defined back-twist arrangement.
Selection inputs: Core construction, back-twist requirement and bobbin arrangement.
Confirm the bobbin arrangement and orientation requirement. No planetary model table is published here.
Rigid-frame & tubular stranding
Specified stranded conductor structures
| Input | Operation | Output |
|---|---|---|
| Wire for a specified strand structure | Rigid-frame or tubular stranding | Conductor with the required strand layers |
Review the layer arrangement, wire material and reel handling to distinguish these two machine types.
Selection inputs: Wire layers, conductor material, reel sizes and required configuration.
Rigid-frame and tubular configurations need separate technical review. Bunching model values do not cover either type.
Wire count, lay and tension control
| Selection priority | What to review |
|---|---|
| Check two size limits | Individual wire diameter and total conductor cross-section are separate selection inputs. A suitable finished area does not by itself establish that every wire size is compatible. |
| Define the conductor construction | Flexible bunches and specified concentric strand layers require different process reviews. Share the strand arrangement, lay and material before choosing a stranding method. |
| Include reel handling | Take-up diameter affects loading and the next operation. Confirm reel dimensions, loading weight and transfer to insulation extrusion as part of the equipment selection. |
Double-twist bunching: compare PY reference models
These PY reference values apply to the listed bunching models. Do not use this table to size planetary, rigid-frame or tubular stranding equipment.
High-speed bunching: reference model comparison
| Model | Single wire Ø (mm) | Max. area (mm²) | Lay length (mm) | Take-up Ø (mm) |
|---|---|---|---|---|
| PY-Φ500 | 0.06–0.45 | 2.5 | 4.22–100 | 500 |
| PY-Φ630 | 0.10–1.05 | 10 | 8.54–140 | 630 |
| PY-Φ800 | 0.2–1.5 | 16 | 22.51–152.32 | 800 |
| PY-Φ1000 | 0.3–3.0 | 25 | 35–200 | 1000 |
Values apply to the listed bunching models, not the entire stranding range. Material, strand construction and lay must be reviewed together.
Configuration sequence
| Stage | What to confirm |
|---|---|
| Prepare the input | Confirm wire diameter, material, temper and the supply reel format. |
| Define the construction | Agree the wire count, lay direction, pitch and finished conductor size. |
| Configure the machine | Match the stranding method, pay-off arrangement and take-up to the product. |
| Connect the next stage | Plan reel handling and the interface with insulation extrusion. |
Choose the purchase situation
Making a flexible conductor
The drawing specifies a bunch of individual fine wires.
Review double-twist bunching against single-wire size, strand count, finished cross-section, lay and take-up reel.
Provide the conductor drawing and individual-wire specification.
Making a specified strand structure
The conductor requires a defined layer arrangement or element orientation.
Review planetary, rigid-frame or tubular stranding against the construction and any back-twist requirement.
Provide the strand arrangement, material and required lay direction.
Replacing an existing buncher
A current machine limits your product range or workflow.
Compare the required conductor range with pay-off capacity, lay, take-up and the surrounding process.
Share current machine details, the limitation and the products you want to add.
Interfaces with the surrounding process
| Interface | Review requirement |
|---|---|
| Drawing to pay-off | Confirm wire dimensions, condition, supply-bobbin count, reel dimensions and loading arrangements. |
| Conductor to insulation | Agree finished construction, diameter or cross-section, take-up package and transfer to extrusion. |
| Target output to the process | Use the actual conductor and lay when reviewing output; match working hours and handling assumptions across stages. |
Equipment package and responsibilities
Agree in the equipment package
- Bunching or stranding machine for the conductor design
- Pay-off count and wire tension arrangement
- Lay range, direction and take-up reel
- Wire-break detection and machine control requirements
Confirm separately
- Supply reels, loading weights and handling equipment
- Upstream drawing or annealing equipment
- Conductor acceptance requirements and sample run
Review the technical proposal
Is the proposed conductor construction demonstrated at your required working conditions?
| Review item | Compare on the same basis | Requested evidence |
|---|---|---|
| Conductor construction | Compare the same individual wire size, strand count, total cross-section and lay. Different constructions can require different machine types. | A conductor schedule mapped to the proposed bunching or stranding configuration. |
| Finished conductor | Agree the checks for lay, finished dimensions, surface condition and reel winding on the selected product. | Representative wire requirements and a recorded trial/inspection plan. |
| Pay-off & take-up | Confirm the number of wire sources, input reels, take-up format and tension-control responsibilities. | An itemised handling package and reel compatibility drawings. |
| Output comparison | Evaluate the agreed conductor at a defined production condition. Rotational speed alone is not finished metres per shift. | Output assumptions including loading, reel changes and product changeovers. |
What changes the quotation scope?
Conductor construction, working range, pay-off count, tension control, reel loading and the selected stranding method change the package.
Cable production applications
Solar Cable
Form the specified flexible conductor before solar-cable insulation.
Confirm individual-wire diameter, strand count, cross-section and transfer reel.
Power & Building Cable
Form the stranded conductor required by the power-cable drawing.
The strand arrangement determines the stranding method; the illustration is an equipment example.
Power & Building Cable production line
Power Cord
Build flexible conductors for the individual power-cord cores.
This stage produces conductors; plug molding and termination are outside this equipment selection.
USB & Data Cable
Combine fine wires where the data cable specifies stranded conductors.
Confirm the fine-wire range and tension needs against the selected model.
USB & Data Cable production line
Additional equipment views
Inside the bunching machine
Frequently asked questions
Bunching or stranding: where do we start?
Start with the conductor drawing and the intended cable. The construction, individual wire size, required lay and reel arrangement guide the equipment discussion.
Can this be part of a complete line?
Yes. The catalog covers drawing, conductor formation, insulation, cabling and sheathing. We can discuss the equipment combination around your product.
Can an existing conductor process be upgraded?
Share the current machine details, product range and the bottleneck you want to address. Compatibility with upstream reels and downstream equipment should be reviewed before selection.
Can I select a buncher by reel diameter alone?
No. Reel diameter is only one limit. Compare individual wire diameter, strand count, total cross-section, material, lay length and take-up requirements.
Does maximum rotating speed equal production output?
No. Lay length, conductor construction, setup and operating conditions affect achievable output. Agree the production requirement for your actual conductor rather than treating maximum rpm as a daily capacity.
Prepare the equipment requirements
| Requirement | Information to provide |
|---|---|
| Conductor | Material, single-wire diameter, strand count and finished cross-section. |
| Lay & tension | Required pitch, direction and handling needs for the wire construction. |
| Reels & workflow | Pay-off bobbins, take-up reel dimensions and loading arrangements. |
| Production plan | Product mix, required output, changeovers and available floor space. |
For a single machine, a line upgrade or a new production line, prepare the cable drawing, input and output requirements, reels and process interfaces.
The current project form prepares a local downloadable brief; it does not send an inquiry.