Tension Control Solutions for the Wire and Cable Industry
Precise tension control at every stage of wire and cable manufacturing ensures product quality, meets customer specifications and reduces waste. At Carotron, our application engineers communicate directly with you and your team to deliver advanced solutions tailored to your production challenges.
Our Tension Control Solutions
Whether you’re producing data cables or another product, every stage from wire drawing to spooling requires precise control. At Carotron, we have solutions for different needs:
- Wire drawing: Precise speed and tension control feed wire spools evenly, ensuring a smooth surface and uniform lay lengths and wire diameter. Our drives safeguard your product consistency, even with very fine wires, by offering steady pull and wire tension control, preventing breakage or other quality defects.
- Stranding and bunching: Protect individual wires while combining multiple wires into cables, protecting the integrity of the final cable.
- Spooling: Winding finished wire onto reels requires stable tension to ensure uniform twists, preventing too-tight reels that stress cables. Even twists also prevent loose reels that can expose the cable to damage and stress during transportation.
Carotron’s tension control systems use advanced sensors and algorithms or interface with existing plant sensors to maintain uniform tension and speed for optimal cable quality and energy efficiency.
Regenerative Drives for the Wire and Cable Industry
Used across multiple processes, including wire drawing, stranding and spooling, this technology ensures precise control and recovers energy, reducing waste. These drives capture energy from braking and return it to your process, improving efficiency and cutting waste.
Regenerative drives can also reduce energy losses associated with the frequent starting and stopping of machinery. These smart systems give you an advantage in a competitive industry.
Our regenerative control solutions can support drawing very thin wires with consistent tension, minimizing snapped wires and frequent stoppages. Our Elite Series of DC drives is one solution for regenerative and nonregenerative needs.
Maintain constant pull at high speeds. In cable bundling, our regenerative drives can help you reduce customer rejections by reliably meeting strict specs. Since the winding process is energy-intensive, the energy savings from our regenerative drives can help you manage project costs.
Why Choose Carotron?
When you need extremely tight tolerances for high-performance or other products, older wire-drawing machines and older tension-control machinery may impact quality and customer perception.
You can integrate our advanced tension control systems into existing wire drawing and stranding lines, preventing costly rework and waste. We design our systems for accuracy and reliability.
For operations with legacy drives, Carotron offers custom integration solutions. Where possible, we work with you to reduce the need for major retrofits. Our engineers can consult directly with you to find solutions that support a more reliable and profitable manufacturing system.
When you contact Carotron, you reach a person — not endless voicemails. With our high-quality products and exceptional service from a team that cares, you get systems that enhance your product quality and help control production costs.
Contact Carotron for Higher Cable and Wire Quality
High breakage rates, returned orders, high electrical bills and material waste may result from inadequate tension or motor control. Contact us to get recommendations from an application engineer or call us at 888-286-8614.