Automatic Wire Rope Cutting Machine

The combination of PLC, rotary encoder, and hydraulic drive ensures each cut piece meets the programmed length within documented tolerances. For production runs under 10m, deviation stays within 0–10mm; for longer lengths, accuracy scales proportionally to one-thousandth of the total measurement. This repeatability eliminates the need for post-cut sorting or trimming.

The dedicated pay-off stand uses a frequency converter linked to the main machine’s electronic ruler, automatically adjusting spool rotation speed to match the feeding cycle. This prevents slack buildup, over-tensioning, and uneven wear on the wire rope — problems that commonly cause downtime on manual or semi-automatic systems. The stand accommodates I-shaped spools from Ф300 to Ф700 and loads up to 500kg, covering the most common supply coil sizes.

All cutting parameters — length, quantity, speed — are entered through the LCD touch screen. The PLC handles sequencing, feeding, cutting, and blanking without continuous operator intervention. A single worker can monitor the entire line, freeing labor for other tasks on the shop floor.

The hydraulic cutting system delivers consistent shearing force across the 2–6mm diameter range, producing uniform cut faces that reduce the need for secondary end-finishing. Compared to abrasive or manual shearing methods, hydraulic action also generates lower noise during operation.

The three-section design — pay-off, main machine, and blanking rack — can be arranged to suit available floor space. The pneumatic blanking rack is built in 1.5m modules, and the total system weight of 1.5 tons allows installation on standard industrial flooring without reinforcement.