Stranding Machine Wireless Replaces Slip Ring

In cable production, so-called stranding machines are used to combine several individual strands or wires into communication cables through controlled twisting. The machines consist of a spool carrier around which a rotor moves at high speed, drawing the individual elements from pay-off stands. Precise detection and control of the movement sequences are essential to ensure consistently high product quality.

At Kabel Sterner GmbH, a stranding machine was modernised to make signal transmission between the rotating and stationary machine components more reliable.

In the original machine configuration, signals were transmitted via slip rings. However, in continuous industrial operation, this technology is prone to wear and interference.

The switch to radio technology presented specific technical challenges. The radio link had to function reliably in an extremely confined, metallic environment. At the same time, the rotor and the coil carrier move towards each other at high speed, which placed additional demands on the stability of the data transmission.

As part of the modernisation, the slip ring technology was replaced by wireless signal transmission using DATAEAGLE radio modules. The DATAEAGLE 3715 X-treme with an omnidirectional antenna and Bluetooth technology was used.

The 2.4 GHz Bluetooth technology used is characterised by high robustness and frequency hopping. This ensures a stable connection even in challenging industrial environments.

As part of the modernisation, the machine was also converted to fieldbus communication using PROFIBUS DP. This also allowed the use of the patented filter technology integrated into the DATAEAGLE, which was specifically developed to ensure particularly reliable transmission of PROFIBUS signals.

• DATAEAGLE 3715 X-treme wireless module
• Omnidirectional antenna
• Bluetooth-based wireless communication (2.4 GHz)
• Fieldbus integration via PROFIBUS DP
• Patented DATAEAGLE filter technology

Replacing the slip ring technology has significantly improved the reliability of signal transmission. Since the conversion, the machine has been operating smoothly and reliably, even under the demanding conditions of the rotating mechanism and the metallic environment.

Ralph Püschel from the technical maintenance department at Kabel Sterner GmbH describes the project as follows:

“We were initially somewhat sceptical about switching from slip ring to radio technology given the specific requirements. However, the prospect of greater operational reliability ultimately persuaded us to take this step – and we were not disappointed.”

The use of industrial radio technology has thus proven to be an efficient and low-maintenance alternative to slip ring technology.