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IBR intermittently bonded ribbon SWR spider web ribbon

IBR intermittently bonded ribbon Production Line

 Technical Specifications

 1   Purpose of the Equipment

 This equipment is primarily used to produce12 and 16 fibers rollable IBR ribbons.

 2   Main Technical Specifications

 2.1  Equipment Structure

 Split-type

 2.2  Fiber Diameter

 Ф245 μm ± 10 μm

 2.3  Line construction speed

 600 m/min

 2.4  Fiber Pay-off Tension

 40 – 150 g, accuracy ±2 g

 2.5  Additional attenuation

 1550 nm window: ≤ 0.01 dB/km

 2.7  Pay-off Reel Specifications

 Ф236 mm × Ф25.4 mm × 108 mm (reel for 25.2 km of fiber)

 Ф267 mm × Ф25.4 mm × 180 mm (reel for 50.4 km of fiber)

 2.8  Weight of a Full Reel

 ≤ 10 kg

 2.9  Take-up Reel Specifications

 T-type reel (Ф410mm × Ф50.8mm × 391mm) or fiber optic reel

 2.10  Power Supply

 Three-phase, five-wire system, 380 V ±10%

 2.12  Environmental

 Enclosed, clean environment; draft-free and dry; temperature 15–25°C

 2.13  Relative Humidity

 ≤85%

 2.14  Gas Supply Requirements

 Nitrogen at 7 bar, purity 99.99%; compressed air at 6 bar

3 : Equipment Configuration

 3.1 Fiber pay-off 16 spools

 1 set

 3.2 Fiber gathering and guiding Mechanism

 1 set

 3.3   Online Coloring System

 1 set

 3.4   IBR Mold Platform

 1 set

 3.5   Pressure-fed Dispensing system for resin/glue

 1 set

 3.6   uv-LED Curing System (3 small + 1 big)

 1 set

 3.7   Visual monitoring system

 1 set

 3.8   Capstan

 1 set

 3.9   Take-up unit

 1 set

 3.10   Electrical Control System

 1 set

 

4   Description of Main Production Line Equipment

 4.1 Fiber Pay-off 16 spools with traversing

 4.1.1  Structural Features

  1.  Composition: Active fiber optic pay-off unit; Each column of the pay-off cabinet uses a proportional valve to control fiber pay-off tension; the pay-off tension can be set via the system and ensures that, under the same air pressure, the tension difference between each pay-off unit remains within ±0.05 N; Features fiber pay-off tension setting mode and high-speed production mode, switchable via the computer system
  2.  Aluminum alloy profile cabinet structure with a suspended-shaft reel mounting system and core-shaft lock for quick clamping of reel holders;
  3.  Active pay-off: Driven by a three-phase AC motor equipped with an independent cooling fan, and speed-controlled by a Danfoss variable-frequency drive;
  4.  Swing-arm-type tension synchronization control with PID midpoint adjustment; non-contact analog sensors; Each pay-off tension controlled electro-pneumatically thru HMI setting.
  5.  Each pay-off has an independent switch and digital display;
  6.  Fiber guide rollers feature a U-shaped groove, hard-anodized surface, lightweight design, and dynamic balancing to ensure smooth rotation once the roller assembly is locked in place;
  7.  Equipped with fiber break detection and alarm functions;
  8.  Each pay-off cabinet is equipped with a fan to ensure effective heat dissipation;
  9.  The pay-off stand is equipped with a pneumatic switch; if the compressed air supply is suddenly interrupted or a hose ruptures, the pay-off motor will not start, preventing runaway operation;
  10. Install protective guards between the stringing units to prevent damage caused by fiber breakage and whipping.
  11.  A pneumatic fiber clamping device is provided to facilitate operator use;
  12.  A rod-type electrostatic dust collector is installed at the fiber exit point.

 4.1.2 Technical Specifications

  1.  Structure Speed
  2.  Number of spools

 600 m/min

 16
  1.  Pay-off Tension

 0.4–2 N ± 0.02 N
  1.  Fiber Reel Specifications

25km, 50km, 63km international standard spools
  1.  Maximum Weight of spool

 10 kg
  1.  Pay-off motor power

 550W

4.2 Fiber gathering & guiding Mechanism

 Structural Features

  1.  Multi-groove precision guide rollers for fiber convergence;
  2.  Anti-static devices installed along the entire path
  3.  Equipped with anti-jump devices;

ed section.

 

4.3 Mold Platform

 4.3.1  Structural Features (3 mold sets, each capable of mounting up to 5 Nordson EFD jet valve)

  1.  Dedicated mold set for IBR fiber-optic tape;
  2.  The molds are integrated with a dedicated adjustable platform; a platform is installed beneath each group of dot dispensing valves to precisely secure the fiber position, thereby reducing fiber jitter, effectively minimizing fiber oscillation, and ensuring proper fiber formation after dispensing.
  3.  The molds are arranged in three groups to accommodate various types of IBR fiber optic tapes with up to 16 cores.
  4.  The molds feature a heating function

 4.3.2  Technical Specifications

  1.  Adjustment Range: 0–15 mm (adjustable);
  2.  Mold base temperature control range: 20–60°C (adjustable);

4.4  Glue/Resin Dispensing System

 4.4.1  Structural Features

  1.  Multi-nozzle grouped installation;
  2.  The position of each dispensing valve can be fine-tuned via a slide table;
  3.  High-precision dispensing valves for precise control;
  4.  Dispensing jet valves arranged in a 5+5+1 or 5+5+5 configuration; (for 12F and 16F IBR systems respectively)
  5.  Intermittent dispensing nozzles and their respective control units allow for editing of the spacing between adhesive dots and the number of adhesive dots via the operator interface.
  6.  Each dispensing system can operate and be controlled independently or in a linked configuration.
  7.  The dispensing medium requires the use of a dedicated coating and curing adhesive.

 4.5  Pressure-Fed Adhesive Supply System

 4.5.1  Structural Features

  1.  It employs an integrated pressure-fed adhesive supply structure;
  2. Each valve has an independent on/off switch and can be opened or closed as needed.
  3.  All adhesive supply lines are black to prevent reactions caused by UV exposure.
  4.  Precision pressure-regulating valves control the adhesive supply pressure.

 e) Air pressure range: ≥0.5 MPa (adjustable);

 4.6  UV Curing Oven

 4.6.1  Structural Features (3 precure small uv-LED and 1 main uv-LED)

  1.  The system primarily consists of dedicated LED-UV curing units, divided into pre-curing and post-curing sections;
  2.  The pre-curing section consists of three sets of specialized small LED-UV curing ovens 800w each performing pre-curing on the optical fibers coming from a respective mold group. The pre-curing ovens are designed for compact installation.
  3. The post-curing section consists of a high-power uv-LED curing oven of 6kw; adjustable shutters are installed at both ends of the chamber to effectively prevent UV light leakage and nitrogen loss during production;
  4.  The post-curing system features an automatic fiber-threading function, with an air-blow fiber-guiding device installed at the oven opening;
  5.  Nitrogen flow rate and pressure can be manually adjusted as needed, and the system automatically activates and deactivates during startup and shutdown;
  6.  Each LED lamp assembly is equipped with an independent oven temperature sensor and features a dedicated cooling system;
  7.  Lamp Array Power Control: During continuous, stable production at production speed, the power consumed by the lamp array should not exceed 80% of the total power;

 4.6.2  Technical Specifications

  1.  Maximum efficiency of the LED chip matrix: 95%;
  2.  Interlock analog signal voltage: 0–10 V;
  3.  LED dominant wavelength: 395 nm ± 3 nm;
  4.  Curing Requirements: Curing degree ≥ 85% (under stable, high-speed curing conditions);
  5.  Post-curing power: ≥2.5 kW.

 4.7  Visual inspection device

 Utilizes a microscope combined with a camera to display images in real time on a monitor, clearly magnifying the fiber arrangement to facilitate verification of fiber color sequencing and resin jet dispensing points, while also enabling real-time online monitoring of operational status.

 4.8 Capstan

 4.8.1  Structural Features

  1.  Directly driven by an imported AC servo motor; aluminum traction wheel with ceramic-sprayed hardening treatment;
  2.  Meterage is measured using the servo motor’s built-in encoder, with a five-digit display;
  1.  Angular-wrap tensioning pulley equipped with a safety guard;
  2.  Take-up tension system: swing-arm tension roller, with counterweight for tension adjustment; the swing arm features a scale, a non-contact analog sensor, and PID midpoint control mode;
  3.  Provides a reserved mounting location for a coding head; the flat-groove guide rollers feature a cable stabilization function;
  1.  Inkjet printer to be provided by the customer

 4.8.2  Technical Specifications

  1.  Traction wheel outer diameter: Φ190 mm
  2.  Metering accuracy: Better than 1‰
  3.  Drive motor: 1 kW AC servo motor.
  4.  Tension range: 50–500 g (adjustable);
  5.  Tension control accuracy: ±5 g.

 4.9   Take up unit

 4.9.1  Structural Features

  1.  Components: Winding, cable laying, automatic direction reversal, and cable laying guide mechanisms;
  2.  Independent cabinet structure, aluminum profile enclosure, equipped with a transparent safety sliding door;
  3. Servo motor-driven winding, pneumatic center-point-style reel loading;
  4.  Servo motor-driven ball screw for precision IBR laying, with reel-feed wire winding and laying; integrated precision slide table;
  5.  The cable routing direction-change device uses a non-contact photoelectric sensor for mid-position detection, counting, and direction reversal; the cable pitch is adjustable, with limit position protection;
  6.  Equipped with an anti-static device;
  7.  Cable guiding mechanism: Servo motor-driven. Lifting increases progressively with the number of cable layers. The guiding thumb is replaced according to the tape width.

 4.9.2  Technical Specifications

  1.  Structural Speed

 600 m/min
  1.  Tape Reel Specifications

 Φ410 × Φ50.8 × 390 × Φ310 mm (standard IBR reel)

 
  1.  Maximum Weight spool

 30 kg
  1.  Cable pitch

 1–6 mm, continuously adjustable
  1.  Thumb Guide Specifications

 12F, 16F
  1.  Take-up

 2 kW servo motor
  1.  Traversing

 0.75 kW servo motor
  1.  Positioning

 0.4 kW servo motor

 

 4.10   Electrical Control System

 4.10.1 The PLC is a product from Siemens S7-1200 and 1500 series.

 4.10.2  The touchscreen is a 10.4-inch Siemens product.

 4.10.3  The low-voltage switchgear is manufactured by Schneider Electric, a Sino-foreign joint venture.

 4.10.4  It features both full-line interlocking and individual unit operation functions.

 4.10.5  The touchscreen includes settings for various process parameters, curing oven activation, wire feeding settings, alarms, and more.

 4.10.6  The monitoring screen on the touchscreen displays the cumulative operating time of the lamps, real-time operating current of the lamps, and real-time oven temperature; it also displays the cumulative operating time of the equipment, facilitating the recording of equipment utilization rates; the meter counter has a correction function; preset lengths enable precise shutdown or deceleration.

 4.10.7  All independent components in the production line are equipped with corresponding independent power switches and terminal blocks to ensure that powering off an individual component does not affect the operation of other components.

 4.10.8  The main cabinet is equipped with an independent exhaust fan.

 4.11   Accessories

 4.11.1  This equipment does not include connection cables or cable trays.

 4.11.2  The main power supply feed-in cable shall be provided by the Buyer.

 5   Technical Documentation Provided by the Supplier to the Buyer

 5.1  Equipment instruction manuals and operating manuals shall be provided to the Buyer prior to commissioning.

5.2  General layout drawing of the equipment.

 5.3  Electrical Schematics and Wiring Diagrams for the Equipment (actual wiring must match the wire numbers, including the control system).

 5.4  Certificates of Conformity and date of manufacture for outsourced components.

 5.5  Components and detailed drawings for installation and maintenance.

 5.6  Equipment operation and maintenance manuals, as well as instruction manuals for purchased parts.

 5.7  Provide a list of equipment wear parts.


Keywords
Shanghai Weiye OFC, Fiber drawing machine, optical fiber proof-testing machine, optical fiber coloring machine, optical fiber ribbon machine, secondary coating line, SZ stranding line, Sheathing line, FTTH cable production line, simplex, duplex, fiber pay-off, kevlar server, extruder, Stainless teel tube production line, take-up, cable rewinding line.
Contact
Shanghai Weiye Optic Fiber Communication Equipment Co., Ltd.// Head Quarter: 201 Minyi road, Songjiang disctrict, Shanghai//
E-mail: info@weiye-ofc.com // Phone 021-60701630