Introduction｜Automation Redefines Cable Production

Across the modern manufacturing landscape, smart factories are no longer futuristic concepts—they are the new industrial reality. From Europe to Southeast Asia, cable plants are embracing full automation, robotics, and real-time data integration to meet growing demands for high-speed production, traceability, and consistency.

At the center of this transformation lies one critical component: the stranding process. Whether in data cables, power conductors, or EV wiring harnesses, the precision of wire stranding directly determines cable durability, performance, and overall manufacturing cost.

Leading the shift toward automation-ready solutions is Dongguan Dongxin (DOSING) Automation Technology Co., Ltd., a national high-tech enterprise founded in 2009. With nearly three decades of R&D expertise from its founder Mr. Lin Huazhong, DOSING has introduced revolutionary mechanical systems—especially advanced stranding machine types—engineered for the next generation of smart cable factories.

Why Smart Factory Lines Demand New Stranding Machine Types

In conventional plants, wire stranding relied heavily on manual adjustments and mechanical synchronization. Operators had to monitor strand pitch, tension, and concentricity constantly. Minor errors could cause conductor distortion, resistance imbalance, or even full production stoppages.

Smart factories change that equation. Equipped with PLC control systems, digital feedback loops, and IoT connectivity, these lines require stranding machine types that can communicate in real time with upstream and downstream processes—ensuring precision, speed, and self-optimization.

Key Smart-Factory Needs Include:

• Continuous data acquisition and storage

• Predictive maintenance and automatic fault alerts

• Seamless integration with MES/ERP platforms

• High-speed energy-efficient operation

• Flexible adjustment for multiple cable standards

This digital integration transforms the stranding process from a mechanical operation into an intelligent manufacturing module—capable of adapting instantly to new cable types or production parameters.

DOSING China：Innovation Through Control Intelligence

As one of China’s most respected wire and cable automation manufacturers, DOSING has long focused on bridging mechanical reliability with electronic intelligence.

Under the leadership of Mr. Lin Huazhong, DOSING engineers pioneered the application of PLC control panels within cantilever single-strand machines—solving long-standing speed fluctuation issues that limited traditional stranding systems. This innovation improved line speed stability and increased production efficiency by more than 40%, while reducing conductor tension and wire damage.

Today, DOSING’s stranding machine types reflect that same spirit of intelligent control and precision manufacturing. Each system—whether single twist, double twist, or pair twist—is designed to meet the operational requirements of smart factory lines operating 24/7 with minimal human intervention.

Overview of Stranding Machine Types for Smart Factories

Smart factories depend on modular, data-driven equipment that supports full automation. Below are the three primary stranding machine types optimized by DOSING for intelligent cable production environments.

1. Single Twist Machine – Reliable Precision for Core Stranding

The single twist machine remains a foundational element in most wire plants. It is ideal for compact conductors, communication wires, and fine copper strands used in flexible cables.

Smart Features:

• Full PLC-based synchronization with payoff and take-up systems

• Automatic tension compensation and error alarms

• Integrated speed management via digital torque monitoring

Advantages in Smart Lines:

• Stable conductor formation with high repeatability

• Minimal downtime through diagnostic monitoring

• Adaptable to multiple cable specifications via saved digital “recipes”

For plants emphasizing high accuracy and stable mid-speed performance, the single twist system delivers dependable operation with advanced automation compatibility.

2. Double Twist Machine – High-Speed Output for Efficiency

Among all stranding machine types, the double twist model offers unmatched throughput for data and power cable production. Each rotation of the bow produces two twists, effectively doubling output capacity without sacrificing pitch control.

Smart Integration Points:

• Digital synchronization between bow motor, dancer tension, and take-up

• Automatic lubrication and vibration monitoring sensors

• Remote production data logging for process optimization

Operational Benefits:

• 30–50% higher output speed than single twist types

• Improved concentricity, minimizing conductor unbalance

• Lower power consumption due to optimized motor control

DOSING’s double twist system has become a core solution for LAN cable, telephone cable, and multi-pair signal line production lines operating under Industry 4.0 protocols.

3. Pair Twist Machine with Back-Twist Function – The Communication Specialist

For high-frequency data transmission, pair twist machines with back-twist functions ensure precise geometrical integrity and reduced signal interference. These machines are indispensable for CAT5E, CAT6, CAT7, and industrial Ethernet cables.

Smart Capabilities:

• Closed-loop pitch control with automated back-twist synchronization

• High-speed digital counter ensuring consistent lay length

• Integrated feedback for crosstalk and impedance testing

Benefits:

• Superior signal performance and cable uniformity

• Reduced material waste through digital alignment verification

• Easy integration with downstream taping or extrusion modules

In smart factories, the back-twist system seamlessly communicates with the central control platform, automatically adjusting parameters when cable diameter or material changes occur.

Supporting Automation Ecosystem

DOSING’s commitment to smart production extends beyond stranding. The company provides complete cable production solutions that interconnect seamlessly through unified control architecture:

Complementary Equipment Portfolio

• Extruder Production Lines: core wire insulation, PVC sheathing, physical/chemical foaming systems

• Automatic Coiling & Taping Machines: single/double/multi-layer configurations

• Pay-Off and Take-Up Systems: shaftless, multi-head, or winch-assisted designs

• High-Speed Cutting Machines: precision control for post-processing

By offering a full-cycle system—from wire feeding to final packaging—DOSING enables factories to achieve genuine one-stop smart manufacturing, eliminating cross-vendor compatibility issues.

Technical Design Features Powering DOSING’s Stranding Machine Types

To meet the demands of continuous, unmanned production, DOSING integrates several proprietary technologies into its machines:

1. PLC + HMI Unified Interface

All machine parameters—speed, torque, pitch, and tension—are controlled from a single touch-screen interface. Operators can store and recall multiple cable recipes, reducing setup time by up to 70%.

2. Real-Time Monitoring and Predictive Maintenance

Sensors throughout the mechanical system monitor vibration, bearing temperature, and tension load. Data is transmitted to the central factory server, where predictive analytics identify maintenance needs before downtime occurs.

3. Digital Torque Balance System

Dynamic torque correction ensures uniform stranding even under variable material loads, preventing micro-fractures and enhancing overall cable flexibility.

4. Noise and Vibration Reduction

Optimized bow design and lightweight alloys minimize mechanical noise, ideal for high-speed operation exceeding 3000 rpm in double-twist configurations.

5. Energy-Saving Motor Control

Advanced inverters synchronize acceleration and deceleration phases, cutting energy usage by up to 15% during idle transitions.

Industry Applications：Smart Factories in Action

DOSING’s advanced stranding machine types are deployed across multiple sectors adapting to smart production:

Each sector benefits from real-time traceability, remote troubleshooting, and customizable quality reports—hallmarks of smart factory integration.

Choosing the Right Stranding Machine Types

Selecting the best stranding system depends on several production parameters:

By analyzing conductor diameter, lay length requirements, and daily output targets, DOSING engineers customize control logic and mechanical setups to maximize both efficiency and reliability.

Future Trends：AI and Data-Driven Stranding

The next generation of stranding machine types will rely even more heavily on artificial intelligence and cloud connectivity. DOSING’s R&D roadmap includes:

• AI-Assisted Pitch Optimization using machine learning from production data

• Cloud-based Diagnostic Dashboards for global equipment monitoring

• Integrated Robotic Material Handling between payoff and take-up modules

• Green Manufacturing Programs focusing on lower energy consumption and recyclable materials

These advancements are part of DOSING’s vision to deliver a fully intelligent cable manufacturing ecosystem aligned with Industry 4.0 and future Industry 5.0 standards.

Why DOSING Leads the Smart Factory Transition

Several key differentiators make DOSING a preferred supplier for international cable producers upgrading to smart factory systems:

✅ Proven Experience: Nearly 30 years of specialized R&D and engineering in wire and cable machinery.
✅ One-Stop Capability: From extrusion to coiling—complete line solutions under one brand.
✅ PLC Integration Expertise: Early adopter of automation in cable twisting systems.
✅ Customization: Tailored control logic and mechanical design for unique production environments.
✅ After-Sales Engineering Support: Remote service, spare parts supply, and operator training.

Conclusion｜Building the Future of Intelligent Cable Manufacturing

As global manufacturers accelerate toward fully automated production, the choice of stranding machine types becomes more critical than ever. Precision, efficiency, and data transparency are no longer optional—they are essential for competitiveness.

DOSING China has demonstrated how deep technical expertise and continuous innovation can merge mechanical reliability with digital intelligence. Its suite of single twist, double twist, and pair twist machines represents the best combination of smart control, energy efficiency, and production scalability available today.

By adopting DOSING’s smart-enabled stranding machine types, cable factories not only gain measurable increases in output and quality but also secure their place within the evolving digital manufacturing ecosystem—where every meter of wire tells a story of precision, innovation, and progress.