Tapered Head Wire Rope Melting & Cutting Machine

The electric resistance welding head melts each cut point into a solid cone whose outer diameter is smaller than the wire rope itself. Ends stay consolidated — no wrapping tape, no dipping solder, no secondary finishing. Adjustable cone length and flat-head size let you match the exact end profile your downstream assembly requires.

A step-motor feeding system paired with PLC-governed positioning delivers ±2‰ length tolerance across a working range of 170 mm to 30 m. Operators set the target length on the touch screen; the controller handles acceleration, deceleration, and stop point automatically, removing human measurement error from every cut.

Switching between rope diameters (2.0–5.0 mm), cut lengths, and taper profiles requires only touch-screen parameter changes — no mechanical tooling swaps. This makes short production runs and mixed-order batches economically viable.

Air-driven clamps grip the rope at 0.4–0.6 MPa during the melting and cutting stroke, ensuring the workpiece cannot shift. The pneumatic draw system then indexes the rope forward for the next cycle. Together, they keep the operator’s hands away from the cutting zone while maintaining consistent feed force.

A bright yellow guard encloses the melting and cutting area, and a clearly positioned emergency stop button provides immediate shutdown. Warning labels for electrical and pinch-point hazards are factory-applied. The full-color touch screen displays live process data so even new operators can monitor and adjust runs with minimal training.