> **Executive Summary**
>
> Automated cable coiling and orbital film wrapping integrates precision continuous length-cutting, pneumatic orbital shuttling, and eye-through stretch wrapping into a single, fully automated workcell. The system eliminates manual coil handling, prevents loose or de-spooled windings, and applies continuous moisture-barrier protection without requiring structural strapping ties. The **FPCA-200** cable coil wrapping unit processes industrial cable coils with an outer diameter (OD) of 250–500 mm, inner diameter (ID) of 150–400 mm, and weight capacities up to 50 kg at variable ring rotation speeds of 10–120 RPM. This engineering guide details the automated cell kinematic layout, wrapper mechanical data, orbital film tension calculations, and critical pre-commissioning procurement criteria.
<iframe width="940" height="535" src="https://www.youtube.com/embed/JFtNeOZU4II?list=PLL0Os4Q7zDgmXZpbLwEtgC0kDRPveH03V" frameborder="0" allow="accelerometer; autoplay; clipboard-write; encrypted-media; gyroscope; picture-in-picture; web-share" referrerpolicy="strict-origin-when-cross-origin" allowfullscreen></iframe>
---
The FPCA-200 automated cell integrates an indexed coiling table, a heavy-duty pneumatic cantilever pick-and-place transfer arm, and a vertical orbital wrapping ring mounted on a rigid structural steel chassis. The transfer gripper handles finished coils directly from the winding mandrel and seats them centrally onto powered polyurethane-coated cradle support rollers. A pneumatically modulated top stabilizer roller exerts synchronized downward holding force to prevent axial displacement, while the high-speed orbital shuttle ring feeds linear low-density polyethylene (LLDPE) or PVC film through the coil center eye. Once the programmable wrap cycle completes, an integrated pneumatic pneumatic hot-wire or mechanical shear knife cuts and clamps the film tail, and a pneumatic pusher sweeps the sealed coil onto an exit gravity or motorized roller conveyor.
<h2 id="table-of-contents">Table of Contents</h2>
<ul>
<li><a href="#why">Why Combine Coiling and Wrapping</a></li>
<li><a href="#cell">How the Cell Works: Kinematic Sequence</a></li>
<li><a href="#specs">FPCA-200 Technical Specifications</a></li>
<li><a href="#film">Film Consumption and Cycle Time Mathematics</a></li>
<li><a href="#selection-checklist">Engineering Selection Checklist</a></li>
<li><a href="#safety">Safety Standards and Interlocks</a></li>
<li><a href="#engineering-faq">Engineering FAQ</a></li>
<li><a href="#next-step">Next Step: Technical Quote and Layout Approval</a></li>
<li><a href="#related-reading">Related Reading</a></li>
<li><a href="#sources">Sources</a></li>
</ul>
<h2 id="why">Why Combine Coiling and Wrapping</h2>
Operating cable winding and stretch wrapping as isolated, disconnected stations creates significant operational bottlenecks and product damage risks:
* **Tension Loss and Coil De-spooling**: Flexible flexible cords, rubber cables, and building wires release elastic stress immediately when removed from a coiling arbor without external retention. Transferring loose coils manually often causes core collapse, tangling, or edge loosening.
* **Surface Protection Without Mechanical Strapping**: Orbital stretch wrapping applies continuous circumferential radial compression directly through the coil eye. The film web encapsulates the coil against environmental moisture, particulate dust, and scuffing, eliminating the surface indentations frequently caused by steel or rigid plastic PP/PET strapping.
* **Streamlined In-Line Packaging**: Synchronizing winding with through-eye orbital wrapping keeps cable packages dimensionally stable and structurally unified, delivering a flat outer package face ready for automated labeling, barcode verification, and secondary carton packing.
<h2 id="cell">How the Cell Works: Kinematic Sequence</h2>
[ Winding Station ] ──> [ Pneumatic Transfer Arm ] ──> [ Rotary Cradle Rollers ] │ (Overhead Hold-down) │ [ Exit Gravity Conveyor ] <── [ Pneumatic Pusher ] <── [ Orbital Eye-Ring ]
1. **Precision Coiling and Metered Cut**: The motorized coiler pulls cable through an encoder-controlled dual-wheel measuring system, winds the preset length onto an expandable mandrel, and activates a shear cutter when the target length is met.
2. **Cantilever Coil Transfer**: A pneumatic multi-jaw clamping gripper grasps the finished coil securely around its perimeter, lifts it off the collapsed arbor, traverses along linear guide rails, and places it directly onto the wrapper's support rollers.
3. **Pneumatic Overhead Hold-Down**: A polyurethane-coated top stabilizer roller lowers under controlled air pressure (0.4–0.6 MPa) to retain coil concentricity without scuffing the outer cable jacket.
4. **Orbital Eye-Through Wrapping**: The main alloy ring rotates through the coil eye while the cradle rollers rotate the coil along its horizontal axis. The overlapping stretch film web binds both internal and external diameters simultaneously.
5. **Film Clamping and Cutting**: Upon cycle completion, an automated pneumatic clamp captures the film edge while a heated cutter or mechanical blade severs the web, tucking the trailing tail beneath the final film layer.
6. **Conveyor Discharge**: The overhead stabilizer cylinder retracts, and a rodless pneumatic sweep cylinder ejects the packaged coil onto an accumulator roller conveyor for inspection, printing, or boxing.
<h2 id="specs">FPCA-200 Technical Specifications</h2>
The FPCA-200 provides orbital through-eye packaging for low-to-medium diameter building wires, data cables, and rubber cords.
| Engineering Parameter | FPCA-200 Standard Value | Unit / Specification |
| :--- | :--- | :--- |
| **Coil Outer Diameter (OD)** | 250 – 500 | mm |
| **Coil Inner Diameter (ID)** | 150 – 400 | mm |
| **Coil Width / Height Range** | 80 – 200 | mm |
| **Coil Load Capacity** | 2.0 – 50.0 | kg |
| **Orbital Ring Rotation Speed** | 10 – 120 (Inverter Driven) | RPM |
| **Roller Table Rotation Speed** | 2.0 – 12.0 (Variable) | RPM |
| **Pneumatic Supply Pressure** | 0.5 – 0.7 | MPa (Dry, Filtered Air) |
| **Film Pre-stretch Ratio** | 150% – 200% (Gear Driven) | % |
| **Compatible Packaging Materials** | LLDPE Stretch Film, PE, PVC Band | Width: 50–100 mm; Core: 50 mm |
| **Connected Electrical Power** | 2.0 kW (380 V / 50 Hz, 3-Phase) | Optional custom voltages |
*Line Extension Note*: For extra-heavy building cables or coils exceeding 500 mm OD, refer to the [FPCA-300](https://www.fhopepack.com/Cable-packing-machine/Cable-coil-wrapping-machine-FPCA-300.html). In fully integrated lines, the upstream automatic cable winding unit supports cable diameters from 2.0 to 20.0 mm at line speeds up to 200 m/min, equipped with a dual-axis traversing unit for level winding.
<h2 id="film">Film Consumption and Cycle Time Mathematics</h2>
Orbital wrapping cycle time and film consumption depend on coil geometry, target overlap percentage, ring rotational velocity, and roller surface friction.
### 1. Ring Revolutions per Complete Wrap Layer
To ensure complete coverage across the entire outer circumference, the minimum number of ring revolutions (N_ring) required is determined by the outer perimeter, film ribbon width, and target overlap ratio:
N_ring = (π × OD) / (W_film × (1 – Overlap))
*Where:*
* `OD` = Cable coil outer diameter (mm)
* `W_film` = Effective film web width after neck-in (mm)
* `Overlap` = Web overlap fraction (typically 0.50 for a standard 50% overlap)
### 2. Net Orbital Wrapping Time
The pure orbital wrapping cycle duration (T_wrap, in seconds) is calculated from the programmed ring speed:
T_wrap = (N_ring / RPM_ring) × 60
### 3. Engineering Application Example
For a standard building wire coil with `OD = 400 mm`, using `100 mm` wide stretch film with an effective post-stretch width of `80 mm` and `50% overlap` (`0.50`):
N_ring = (3.1416 × 400) / (80 × (1 – 0.50)) = 1256.6 / 40 ≈ 31.4 (rounded up to 32 revolutions)
Operating the orbital ring at a conservative speed of `96 RPM`:
T_wrap = (32 / 96) × 60 = 20.0 seconds
Adding mechanical staging times (mandrel release, gripper transfer, stabilizer clamp, film cut, and discharge: ~10 seconds total) yields an overall cell cycle of **30 seconds per coil**, yielding a gross output rate of **120 coils per hour**.
*Crucial Geometric Note on Inner Diameter (ID) Build-up*: Because the coil inner perimeter (`π × ID`) is significantly shorter than the outer perimeter (`π × OD`), the same number of ring passes covers a reduced surface area at the inner eye. This creates an intrinsic geometric film accumulation factor:
Buildup_factor = OD / ID
For a 400 mm OD / 200 mm ID coil, the inner eye receives twice the film thickness of the outer perimeter. Tension clutches must be calibrated correctly to prevent inner diameter compression or film strand snapping during high-speed rotation.
<h2 id="selection-checklist">Engineering Selection Checklist</h2>
Provide the following electrical and mechanical data points during technical review to finalize motor torque, cradle center distances, and clamping stroke configurations:
1. **Cable Physical Characteristics**: Cross-sectional outer diameter range (mm), minimum bending radius, jacket compound (PVC, XLPE, PUR, or rubber).
2. **Finished Coil Dimensions**: Minimum and maximum Coil ID, OD, and axial Width (mm).
3. **Coil Mass Range**: Minimum and maximum weight per coil (kg).
4. **Primary Packaging Film**: LLDPE orbital stretch film, woven PE ribbon, or rigid PVC banding tape (including core size and film thickness in µm).
5. **Throughput Requirements**: Target production rate (coils per hour or line speed in meters/minute from the extrusion/rewind line).
6. **Downstream Integration**: Requirement for automated optical barcode inspection, top labeling, thermal transfer printing, or direct pick-and-place into carton boxes.
<h2 id="safety">Safety Standards and Interlocks</h2>
Every FHOPE automatic coiling and wrapping cell is built to satisfy international safety regulations for high-speed automated packaging machinery:
* **EN ISO 12100:2010**: Comprehensive risk assessment and hazard mitigation for rotating industrial machinery.
* **EN 415-10**: Specific safety standards for packaging machines, wrapping cells, and peripheral conveyors.
* **EN 60204-1**: Industrial electrical safety, grounding integrity, and control panel wiring topology.
* **ISO 13849-1 (Category 3, PL d)**: Dual-channel safety interlock switches on perimeter guard fencing, light curtains at the conveyor discharge aperture, and self-latching emergency-stop (E-stop) pushbuttons adjacent to all moving stations.
<h2 id="engineering-faq">Engineering FAQ</h2>
**Q: Is secondary PP or polyester strapping necessary before wrapping?**
A: For standard building cables and flexible conduits under 50 kg, orbital stretch film provides sufficient radial hoop tension to maintain coil geometry throughout handling and distribution, completely replacing manual ties or automated plastic strapping. For heavy rigid industrial power cables, an integrated intermediate tie unit can be positioned ahead of the wrapper.
**Q: Can the FPCA-200 handle non-stretch packaging materials like PVC or paper tape?**
A: Yes. The orbital shuttle carrier accommodates non-elastic wrapping materials such as PVC tape, woven PE cloth, or reinforced anti-corrosion crepe paper by disengaging the powered pre-stretch drive and utilizing an adjustable friction mechanical brake.
**Q: Can the wrapper run as an independent, standalone machine?**
A: Yes. The FPCA-200 functions as a standalone unit utilizing manual batch loading via an overhead hoist or conveyor, or as an in-line station fully interlocked with upstream pay-offs, tension dancers, and automated coiling machines via dry-contact PLC handshakes.
**Q: What mechanisms prevent cable jacket damage during wrapping?**
A: The support cradle rollers and overhead stabilizer cylinders are vulcanized with high-durability, non-marking polyurethane. The orbital film tension is modulated via a sensitive mechanical slip-clutch or closed-loop electronic dancer, preventing jacket indentation on soft jacket formulations.
<h2 id="next-step">Next Step: Technical Quote and Layout Approval</h2>
1. **Submit Application Parameters**: Send your cable diameter, coil dimensional envelope (ID/OD/Width), coil weights, and required hourly throughput to **info@fhopepack.com**.
2. **Engineering Layout Drawing**: Our design team generates a 2D plant footprint and 3D step model matching your extrusion line centerline elevation within 48 hours.
3. **Formal Proposal Delivery**: Receive a detailed commercial offer, including electrical schematics, utility consumption data, and comprehensive cycle time validation.
<h2 id="related-reading">Related Reading</h2>
* [FPCA-200 Cable Coil Wrapping Machine (Product Page)](https://www.fhopepack.com/Cable-packing-machine/Cable-Coil-Wrapping-Machine-FPCA-200.html)
* [FPCA-300 Cable Coil Wrapping Machine (Product Page)](https://www.fhopepack.com/Cable-packing-machine/Cable-coil-wrapping-machine-FPCA-300.html)
* [Automatic Cable Winding and Packing Machine (Product Page)](https://www.fhopepack.com/Cable-packing-machine/automatic-cable-winding-and-packing-machine.html)
* [Cable Coil Packing Machine and Wire Packing Machine (Video Demonstration)](https://www.fhopepack.com/videos/cable-coil-packing-machine-and-wire-packing-machine/)
* [Full Wrapping-Through Packaging Machine (Application Case)](https://www.fhopepack.com/videos/full-wrapping-through-packaging-machine/)
<h2 id="sources">Sources</h2>
* FHOPE Technical Documentation: FPCA-200 and FPCA-300 Engineering Product Line Manuals
* International Organization for Standardization: EN ISO 12100:2010 (Safety of Machinery - General Principles for Design)
* European Committee for Standardization: EN 415-10 (Safety of Packaging Machines - Part 10: General Requirements)
* International Electrotechnical Commission: EN 60204-1 (Safety of Machinery - Electrical Equipment of Machines)
<p><strong>Last reviewed:</strong> 2026-10-20</p>
