REELEX designs and manufactures specialized coiling machinery to produce REELEX coils and packaging.
REELEX Coiling Machine Components
How is a REELEX coil made?
Specialty equipment, unique electronics and advanced know-how.
Where it all happens.
The product enters the guide tube and exits the wire guide which are connected to the traverse. The traverse is controlled via unique electronics and REELEX-approved drives for precise layering. The traverse moves back and forth and moves in sync with the rotation of the mandrel as the coil is wound.
The coil builds along the walls of the endforms, which require mathematically-derived curves designed to maintain coil shape and density. When the coil is finished winding, the outer endform attached to the endform arm is pneumatically removed, and the mandrel segments collapse. The coil is now removed from the machine and placed into its final package.
REELEX Machine Features
Safety is Priority #1
M340 Automated Doors Example:
Adjustable Precision
Ensuring the perfect fit.
Winding a REELEX coil precisely is a complex operation. In order to produce precision coils at high speed, electrical and mechanical components of the machine must run in complete harmony while still allowing for flexibility.
Parameters such as holesize, layer spacing, density, hole shift and hole taper are all adjustable, allowing the coil to be fine-tuned to accommodate different products, packaging sizes and characteristics.
Advanced HMI
Specially designed for REELEX.
All new REELEX machines feature G3 or G4 REELEX control systems, integrating equipment control with troubleshooting, on-screen manual, packaging calculator, multi-language support, product storage, networking capability and more.
Validated Components
Selected for superior performance.
The unique aspects of the REELEX coiling process require not only bespoke mechanical components, but high-performance electronics as well.
For example, the large amount of energy produced by the rapid changes in traverse motor speeds requires a validated AC drive. REELEX carefully selects high-performance products to ensure the REELEX coil is not jeopardized.
Adaptability
Easy integration.
REELEX equipment is designed to be incorporated with third party components in a line, and can be adapted to include additional features.
Stretch wrapping, spark testing, printing and other capabilities can all be added to existing machinery and control systems for seamless operation.
Tension Control
Designed for premium cables.
One of the keys to precise coiling is tension control. Over 40 years, REELEX machines have improved tension control methods to overcome issues such as electrical performance issues on LAN cables. Today’s buffers are precise, lightweight components specifically designed to put minimal stress on the product while maintaining tension requirements.
Purpose Built
Over 40 years of know-how.
From the ground-up, all REELEX machines are designed and built at our Patterson, NY facility.
Because REELEX Packaging Solutions is the only manufacturer of REELEX coiling machines, every part is designed and manufactured in-house for dependability and performance.
Coiling Machine Models
Every REELEX machine is capable of making the same figure-eight, self-supporting REELEX coil, but do so at varying speeds and levels of automation. From the online-capable M340, to the single-spindle S320, we manufacture a wide range of coiling machines for various budgets, products and production needs.
Standard REELEX Machine Models
These machines are REELEX’s most popular coiling machine models, and are suitable for packaging all low-voltage and structured cable types, including Category cables, some fiber optic cables and other flexible cable constructions.
S320
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M340
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D-2050
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Boxes per Hour (1,000ft/305m) |
40 |
80 |
45 |
Average Line Speed |
0 Feet/Min |
0 Feet/Min |
0 Feet/Min |
Operators |
1 | 1 required, 2 suggested for maximum output. | 1 part time operator to fill box and tube magazines. |
Online Capable |
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Features |
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Ancillary Equipment
In order to support REELEX coiling machines, we also design and manufacture our own ancillary equipment, including dancers, payoffs and accumulators. These machines are specially-designed to achieve maximum performance from the unique characteristics of the REELEX coiling process, including precision tension control, rapid response to changes in line tension, and frequent starts and stops.
Payoffs |
Dancers |
Accumulators |
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Purpose |
Feeds cable to REELEX machine by controlling supply reel in offline (rewind) packaging setups. | Sets line tension by controlling the incoming speed of cable to the REELEX machine. Also accumulates product during startup and stop. | Accumulates incoming product when REELEX machine is stopped during transfer between mandrels. |
Usually paired with |
S320, M340 or D-2050 when used in offline (rewind) configurations. | All REELEX configurations. Included as part of accumulator system. | M340 or D-2050 when used in online (or “inline”) configurations |
Capability |
Rotates and brakes supply reels measuring up to 52 inches (132cm) diameter and 3,500 lbs (1,587kg) | Controls line tension via digital air regulator and laser potentiometer. Accumulates up to 40 feet (12m) | Accumulates up to 500 feet (152m) of product. |
Online Capable |
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Features |
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Unique Purchasing Propositions
Featuring equipment buy-back programs, and most-favored licensee pricing, REELEX equipment acquisition is a low-risk, high-reward proposition.
Coiling Offline from Supply Reel, Barrel, Cage or Stem
In this configuration, the REELEX machine is rewinding from a supply source that can be stopped and started. This is typically a supply reel, but could also be other form of bulk supply such as stem or barrel package. If using a supply reel, the incoming line speed is controlled via a Motorized Payoff. This Payoff must be capable of stopping and starting the line each time a coil is produced, thus our REELEX-designed high-performance payoff is highly recommended.
Coiling Online from Extruder
If coiling product coming directly from a constant-speed source (such as in line with an extruder), only the M340 or D-2050 are suitable, as they can switch between mandrels without operator intervention. However, because the incoming product must stop while the transfer takes place, an Accumulator is required to take up the incoming product. The accumulator is then emptied when the transfer is complete and the coiling machine begins winding again.
