From copper wire to automotive wiring harness: Multiple applications of the Wire Take-Up Machine

Importance of Wire Take-Up Machine

In the vast field of modern industrial production, metal wires are widely used as basic materials in many industries such as electricity, telecommunications, automobile manufacturing, construction and electronics. Whether it is the wires that can be seen everywhere in the home or the complex wiring harnesses in the car engine, the quality and performance of metal wires are directly related to the safety and reliability of the final product. Behind all this, there is a key equipment-wire take-up machine.
Wire take-up machine, as the core mechanical equipment for metal wire manufacturing, is a special equipment that gradually stretches and reduces the diameter of thick metal rods or wires through a series of precision molds. Through this process, the metal wire is not only made thinner, but also significantly improves its mechanical properties, such as strength and toughness. In other words, the wire take-up machine gives the metal wire an ideal shape and performance, enabling it to meet the diversified and high-standard requirements for wires in industrial production.
With the continuous development of science and technology and industry, the importance of wire take-up machine has become increasingly prominent. It is not only the basis of traditional metal wire production, but also an important link in efficient production lines driven by the wave of automation and intelligence. Modern wire take-up machines integrate precision control systems that monitor tension, speed and temperature in real time to ensure that every meter of wire meets strict quality standards. Automated wire drawing equipment greatly reduces the complexity and errors of manual operations, and improves production efficiency and safety. It is these advanced technologies that have made wire take-up machines widely used in various metal wire manufacturing fields.

What is a wire take-up machine?

To understand how copper wires, cables, and even automotive wiring harnesses are made, we must start with a key process: wire drawing. Behind this process, the "wire take-up machine" plays a decisive role.

Basic definition of wire take-up machine
A wire take-up machine, as the name suggests, is a mechanical device used to "thin" metal materials. Its main function is to gradually stretch thick metal wires through a series of high-strength dies, thereby reducing their diameter, extending their length, and improving their physical and mechanical properties. This process sounds simple, but it actually involves precise control of multiple links, such as speed, tension, lubrication, and die material, none of which can be missing.
In layman's terms, after the original metal rod or thick wire enters the wire take-up machine, it will be "pulled" through one die after another with different inner diameters. Each die will reduce the diameter of the wire a little, and the final output may be a finished wire with a diameter of only 1 mm or even thinner. These finished wires will be coated, twisted, insulated, etc. in the future, becoming the "ultimate products" we see in cables, wires, and automotive wiring harnesses.

Working principle: diameter reduction, stretching and precision control
The working principle of the wire take-up machine revolves around "stretching" and "diameter reduction", but its implementation is not as simple as "pulling hard", but a complex continuous production process.
The entire wire drawing process generally includes the following steps:
1. Wire preparation: Before the rough metal wire is fed into the machine, it is first surface treated to reduce friction and wear during wire drawing.
2. Die stretching: The wire passes through several wire drawing dies in turn, and the aperture of each die gradually becomes smaller. The wire is "forced" to pass through these apertures and undergoes plastic deformation. Because it is a stretching process, the length of the wire will become longer, and the diameter will become thinner accordingly.
3. Tension control system: This is the "heart" of the whole process. If the tension control is not accurate, the wire may break, deform or rebound, resulting in unqualified products or even equipment damage. Modern wire take-up machines are equipped with automatic tension adjustment devices to ensure that each section of wire is processed within the correct stress range.
4. Cooling and lubrication system: A large amount of friction heat is generated during the wire drawing process, and it must be cooled by lubricating fluid or water cooling system to prevent the mold and wire from deteriorating due to overheating.
5. Wire collection and alignment: The wire after wire drawing will eventually be wound on the wire take-up reel in an orderly manner, ready for the next manufacturing process, such as twisting or insulation.
This process can be continuous or multi-stage partitioned, and each stage has different mold specifications and speed matching requirements. High-end wire take-up machines are even equipped with digital monitoring systems that can detect wire diameter, tension, temperature and other data in real time to ensure that the final product meets the standards.

Wire drawing is not just "thinning"
It is worth noting that wire drawing does not just make the metal wire "thinner". In material science, this process will cause the refinement of metal grains and changes in organizational structure, thereby significantly improving the strength and toughness of the material. This property is of great significance for subsequent processing and the service life of the product.
For example, automotive wiring harnesses need to withstand the high temperatures and vibrations in the engine compartment, and ordinary metal wires simply cannot meet these harsh use environments. Through precise wire drawing processes, metal wires can have higher tensile strength and corrosion resistance, which is exactly where the value of wire drawing technology lies.

Adaptability of different metal materials
Although copper wire is one of the most common wire drawing products, wire take-up machines are also widely used in other metal materials, including aluminum, stainless steel, nickel alloys and even tungsten wire. The physical properties of different metals determine their parameter settings and die requirements during the wire drawing process. Therefore, modern wire take-up machines have strong adaptability and can meet the wire drawing needs of various metal wires by replacing die sets and adjusting control programs.

The core goal of wire drawing process
In the metal processing industry, wire drawing is an ancient and efficient plastic processing method. Although on the surface, it is just a process of making a metal wire thinner and longer, in fact, this process carries multiple functions and technical values. It not only concerns the geometric shape change of the wire, but also affects the physical structure and mechanical properties of the metal at a deeper level, becoming a key link in determining the quality and applicability of the wire.

Changing the diameter and extending the length: the physical nature of deformation
The most intuitive goal of wire drawing is to turn thick wire into thin wire. This "diameter reduction" process is achieved by pulling the metal wire through a series of dies (wire drawing dies) with gradually decreasing inner diameters by external force. In each die, the wire is subjected to strong axial tension, causing its cross-sectional area to continue to decrease while its length continues to increase.
This ability to customize diameter reduction makes wire drawing one of the irreplaceable processes in the manufacturing industry: whether it is thick wire used as a conductor for power transmission or ultra-fine wire used for internal connection of precision electronic components, the wire take-up machine can meet the strict requirements of dimensional accuracy.

Improve mechanical properties: not only "thinning", but also "strengthening muscles and bones"
Many people think that metal will become fragile after being "thinned". In fact, on the contrary, a proper wire drawing process can greatly improve the strength of metal wires.
This is because plastic deformation occurs inside the metal material during the wire drawing process, and the metal grain structure is affected by both "compression" and "stretching". The grains are gradually refined and arranged more closely, thereby improving the tensile strength, hardness and fatigue resistance of the material.
During the metal deformation process, a phenomenon called "work hardening" may also occur. Although this hardening phenomenon can increase strength, it will also reduce the ductility and toughness of the material. Therefore, in some scenarios where strength and flexibility need to be taken into account, the degree of deformation needs to be properly controlled during the wire drawing process, and annealing and other heat treatment processes need to be used to keep the metal wire in good overall performance.

Improvement of flexibility and fatigue resistance: Serving complex industrial environments
Many people may not realize that flexibility is also an extremely important performance indicator of wires in industrial applications, especially in automotive wiring harnesses, precision instruments, and electrical equipment, where wires often need to be bent, wound, vibrated, or even folded. If the wire is too brittle and hard, it is not only inconvenient to process, but also easy to break and fail during use.
Key technologies such as controlling deformation rate, tension distribution, and multi-stage stretching ratio in the wire drawing process can help produce thin and flexible metal wires. These flexible wires can maintain their shape and function unchanged in extreme environments, thereby ensuring the service life and safety of the product.
Taking automotive wiring harnesses as an example, wiring harnesses usually pass through multiple locations such as the engine compartment, dashboard, and battery system, and experience drastic temperature changes, continuous vibration, and moisture corrosion. Only metal wires processed by high-quality wire drawing can maintain unchanged conductivity and insulation layer without rupture under these conditions.

Consistency and controllability: the basis of industrialized production
In modern manufacturing, large-scale and standardized production is a basic requirement. The wire take-up machine ensures the dimensional consistency and performance controllability of each metal wire with its precise die system and automatic control device.
High-end wire drawing equipment can monitor the diameter change, tensile load, surface quality of the wire in real time, and can even automatically detect tiny defects and make feedback adjustments. Through this highly integrated process control system, the wire take-up machine not only improves the yield rate, but also greatly reduces manual errors and defective rates.

Application of wire take-up machine in copper wire manufacturing
In the family of metal conductors, copper wire has become the core material of power transmission and telecommunication communication industry with its excellent conductivity, good ductility and reliable corrosion resistance. Whether it is high-voltage transmission lines, household wires and cables, or supporting lines in optical fiber communication, or conductors inside mobile phone chargers, copper wires are everywhere. One of the core equipment supporting this huge copper wire market is the wire take-up machine.

Wide application of copper wire: the "invisible skeleton" supporting modern society
The excellent conductivity of copper makes it the preferred material for power transmission. In the power industry, the power sent from the power plant needs to rely on copper conductors to efficiently transmit to thousands of households and industrial power facilities with extremely low energy loss. Therefore, copper wires are widely used in various power cables, busbars, power cords and other products.
In the field of telecommunications, although optical fiber has become the mainstream transmission medium, a large number of devices still need copper wires as internal signal and power connection carriers. For example, base station power cables, server cables, and network cables in home wiring systems all rely on the support of high-quality copper wires. Especially with the rapid development of 5G, data centers and smart cities, the demand for copper wire continues to grow.
In addition to transmission performance, the mechanical properties of copper wire are equally important. In the process of laying cables and wiring installation, copper wire must have good flexibility and fatigue resistance to cope with complex situations such as multiple bending, pulling, vibration, etc. All of this depends on the physical properties given by the high-precision wire drawing process.

The core role of wire take-up machine in copper wire manufacturing
Copper wire production usually starts with thick copper rods, such as oxygen-free copper rods with a diameter of 8 mm. To make it into copper wire with a diameter of 1 mm or even thinner, it needs to go through multiple wire drawing processes. The wire take-up machine is the key equipment to complete this diameter reduction deformation task.
The modern copper wire take-up machine is not only a mechanical stretching device, but also an automated system that integrates tension control, speed regulation, lubrication cooling and online detection. It ensures high consistency in size, performance and structure of copper wire through the following core mechanisms:
1. Multi-stage die system ensures stable diameter reduction
The wire drawing of copper wire usually adopts the process mode of "multi-stage continuous wire drawing", that is, the wire passes through multiple wire drawing dies with decreasing apertures continuously, and a certain proportion of diameter reduction is completed in each stage of the die. This continuous wire drawing structure can smoothly disperse stress, so that the copper wire maintains integrity while being thinned, and is not easy to break or produce surface defects.
2. Precision tension control system
Copper materials are very sensitive during the wire drawing process. If the tension is not properly controlled, it is easy to break or "spring back" problems. The advanced wire take-up machine adopts a closed-loop tension control system, which monitors the stress state of the copper wire in real time through sensors, and automatically adjusts the wire taking-up speed or wire release tension to ensure that the entire production process is always in the optimal state.
3. Efficient lubrication and cooling system
A large amount of friction heat is generated during the wire drawing process. If it cannot be cooled in time, it will not only damage the die, but also affect the surface finish and metal structure of the copper wire. The wire take-up machine is equipped with a special lubricant and coolant system, which can effectively reduce the temperature rise, protect the wire from heat damage, improve the wire drawing effect, and improve the surface quality of the copper wire.
4. Online detection and feedback adjustment
In order to meet the high-standard needs of the power and telecommunications industries, the wire take-up machine often integrates advanced detection equipment such as online diameter gauges, broken wire detectors, and surface defect recognition systems. These systems can detect the dimensional deviation or surface abnormality of the copper wire in production in real time, and achieve efficient closed-loop control of "correction while producing" by automatically adjusting parameters.

Key guarantees for improving the quality of copper wires
Through the collaborative work of the above systems, the wire take-up machine not only realizes the geometric deformation of the copper wire, but also improves the comprehensive performance of the copper wire through micro-level grain refinement, internal stress control and other mechanisms. High-quality copper wire needs to have the following core indicators:
High conductivity: The wire drawing process needs to retain the conductivity of copper to the maximum extent, especially oxygen-free copper;
Good ductility and flexibility: convenient for subsequent winding, insulation coating, plug-in and other processes;
Uniform surface and consistent diameter: ensure the stability of signal transmission and the reliability of mechanical connection;
High fatigue resistance and corrosion resistance: improve product life and reduce maintenance frequency;
Low defect rate and high yield rate: reduce overall manufacturing costs and improve industrial efficiency.
The wire take-up machine plays a decisive role in the realization of these performance indicators. It is an important link between metallurgical processing and terminal manufacturing, converting raw copper materials into key materials suitable for multiple scenarios and high-demand applications.

Wire drawing of aluminum wire and steel wire
In the production system of metal wire, copper wire is certainly the most widely used main material, but it is not the only one. In many specific industries, aluminum wire and steel wire also play a key role: the former is known for its light weight and economy, while the latter is an important basis for structural parts and load-bearing parts due to its high strength and wear resistance. These two types of metal wires have their own characteristics in performance and use, and also put forward different process requirements for the wire drawing process than copper wire. Wire take-up machine, as the core equipment for metal wire forming, must have excellent adaptability and flexible configuration to be competent for efficient processing of various materials.

Wire drawing of aluminum wire: flexible challenges of lightweight materials
Aluminum wire is widely used in aerospace, power transmission (especially high-voltage overhead lines) and automotive lightweight engineering due to its excellent electrical conductivity, good corrosion resistance and relatively low density. Compared with copper, the density of aluminum is only about 1/3 of that of copper, which makes aluminum wire lighter under the same volume and convenient for large-scale laying.
However, the softness and easy oxidation of aluminum also bring several challenges to the wire drawing process:
1. Easy to deform but difficult to maintain stable shape: The yield strength and hardness of aluminum are lower than those of copper and steel, which can easily cause "tailing", uneven wire shape and even partial tearing during wire drawing. Therefore, the wire take-up machine needs to optimize the mold design and tension control when processing aluminum wire so that it can maintain a uniform and stable wire diameter during flexible deformation.
2. Surface oxide film affects mold life and wire drawing stability: Aluminum wire is very easy to form an oxide film in the air. Although this film protects the material itself, it is easy to wear the mold during the wire drawing process, resulting in scratches and irregular particles. Therefore, the wire take-up machine needs to be equipped with a special aluminum wire lubrication system to prevent increased wear and appropriately increase the frequency of mold cleaning and replacement.
3. Different annealing requirements: Aluminum wire often needs to be annealed after wire drawing to restore ductility, but annealing temperature control is more sensitive than copper wire. Some advanced wire take-up machines have integrated annealing units, making "wire drawing + annealing" integrated production possible, improving processing efficiency and the stability of wire performance.

Wire drawing of steel wire: Rigidity challenge of high-strength metal
Compared with aluminum wire, the application of steel wire is more concentrated in structural, support and load-bearing scenarios, such as steel wire rope for construction, automobile tire skeleton, bridge tensioning cable, elevator cable, etc. Steel wire drawing has the typical characteristics of "high strength, high rigidity, and high wear", which puts higher requirements on the durability and process control of wire drawing equipment.
1. High strength means higher tensile force demand: Steel has high hardness and high tensile strength, and requires greater traction when drawing. This requires the wire take-up machine to have a high-torque motor and a powerful drive system, and the mold material must have extremely high wear resistance to resist the rapid erosion of steel wire under high pressure.
2. Strong friction leads to more serious heat accumulation problems: The friction between steel wire and mold is more intense than copper and aluminum, and it is easy to generate high temperature. High temperature not only accelerates die wear, but may also affect the steel wire structure, causing problems such as "grain coarsening" or "thermal cracking". Therefore, efficient cooling and lubrication systems and multi-stage forced air cooling/oil cooling devices have become an indispensable part of the steel wire drawing process.
3. High hardness but low toughness, easy wire breakage: Especially in the wire drawing process of high carbon steel or spring steel wire, if the tension is improperly controlled or the die wear is uneven, it is easy to cause local stress concentration and wire breakage. Modern wire take-up machines use online wire break detection and automatic speed compensation systems to automatically stop pulling and alarm at the moment of wire breakage, improving safety and yield rate.
4. Pickling and phosphating pretreatment: In order to reduce friction and remove the oxide scale on the surface of the steel wire, the steel wire often needs to be pickled and phosphated before drawing. This process is usually carried out automatically in conjunction with the wire drawing production line. Some high-end wire take-up machines have pre-integrated pretreatment devices to make the entire production line more compact and coherent.

How does the wire take-up machine adapt to the processing needs of different metal materials?
To process multiple metals on the same equipment, or to provide customized solutions for different materials, multi-function, modularization and intelligence have become the trend of modern wire take-up machine design:
1. Interchangeable mold and wire system: Different metals require wire drawing molds with different materials and opening angles. High-end equipment is designed with a modular mold frame system, which can quickly replace the mold to adapt to the size and processing characteristics of different materials.
2. Intelligent tension and speed adaptive control: Through the closed-loop control of the tension sensor and the traction motor, the wire take-up machine can adjust the speed and tension according to real-time feedback to avoid the problem of "breaking" the aluminum wire or "cracking" the steel wire.
3. Multi-stage lubrication and cooling channels: Select oil-based, water-based or dry lubricants according to different materials, and combine directional air cooling, water bath cooling and other methods to improve heat dissipation efficiency and protect the surface quality of the wire.
4. Material identification and automatic process switching system: Some intelligent wire take-up machines are equipped with material identification and process parameter databases. When the operator enters the material type, the system will automatically call the corresponding drawing path, speed curve and annealing temperature to simplify operation and reduce human errors.

Wiring Harness Manufacturing Demand in the Automotive Industry

In the field of modern automobile manufacturing, Wiring Harness can be called the "nervous system of the car". Whether it is engine control, electric windows, intelligent navigation, or advanced driver assistance systems and in-vehicle entertainment equipment, all electronic signals and power transmission must rely on wiring harnesses. Although the wiring harness is small, it affects the safety, performance and life of the entire vehicle. The quality standard of the wire used is much higher than that of ordinary cables. As a key link in wire manufacturing, the precision control and material adaptability of the wire take-up machine are the core pillars to ensure the reliability of automotive wiring harnesses.

The key role of wiring harnesses in automotive systems
An average mid- to high-end car contains more than 1,500 wires, and the total length of the wiring harness can exceed 4 kilometers. Its main functions include:
1. Power distribution: delivering current from the battery or generator to various power-consuming components (such as air conditioners, lights, electric seats, etc.);
2. Signal transmission: transmitting data collected by sensors to the control unit (ECU) in real time, such as brake systems, reversing radars, automatic parking, etc., all rely on accurate signals;
3. Connecting multiple electronic control units (ECUs): As the functions of smart cars become increasingly complex and the number of ECUs continues to increase, wiring harnesses have become the central channel for vehicle network communication;
4. Space and heat management: In the process of wiring harness layout, it is also necessary to consider requirements such as anti-vibration, anti-electromagnetic interference, waterproof and dustproof, which further increases the stringent requirements for the performance of the wire itself.

Performance requirements of automotive wiring harnesses for wires
Compared with general industrial or household cables, the wires used in automotive wiring harnesses must face more severe working environments, such as:
Large temperature differences (from -40°C to +150°C); continuous vibration and bending (especially in the engine compartment); corrosive factors such as high humidity, oil, salt spray, and high power current or high-speed data transmission requirements.
Therefore, automotive wires must perform well in multiple key dimensions:
1. Strength requirements: tensile resistance, vibration resistance, and fatigue resistance
During the driving process of the car, the wiring harness is often in a vibration, twisting and impact environment. If the strength of the wire itself is insufficient, it is easy to break, poor contact, and even cause safety accidents. To this end, the wire take-up machine must ensure that the wire grains are uniform and stress-free during the manufacturing process, and precisely control the tension and pulling speed to form a metal wire with good ductility and fatigue resistance.
In some load-bearing harnesses, high-strength steel wire or copper-clad steel wire is also used, which requires the wire take-up machine to be able to cope with the difficulty of stretching high-strength metals and avoid microcracks caused by hard drawing.
2. Heat resistance: Adapt to high-temperature working environment
The engine compartment is the most "harsh" deployment area for the harness, with high temperature, heavy oil pollution and poor ventilation. If the wire softens at high temperature or the insulation layer ages, it will cause a short circuit or an increase in resistance. For this reason, automotive copper wire usually uses oxygen-free copper, and avoids high-temperature annealing or overheating during drawing to maintain its high conductivity and structural stability.
Some high-temperature areas even use tinned copper wire or aluminum-magnesium alloy wire. These materials have higher requirements for thermal control and mold matching of the wire drawing process, and must rely on high-performance wire take-up machines.
3. Corrosion resistance: Extend service life
The automotive use environment is complex, and salt spray, moisture, engine oil, detergents, etc. are all potential sources of corrosion. If the wire surface is rough or there are many microcracks, it is very easy to accelerate the corrosion reaction. The wire take-up machine can effectively reduce surface defects and improve the oxidation resistance of wires through surface finish control and automatic lubrication system.
In addition, some automotive wiring harnesses use tinned copper wire, silver-plated copper wire, aluminum-clad steel wire and other materials to further improve corrosion resistance. Wire drawing equipment must have process compatibility with composite materials, such as low-speed drawing, die gradient design, etc., to prevent material delamination or coating peeling.
4. Dimensional accuracy and consistency
Wire harness manufacturing has extremely high requirements for conductor diameter and roundness, because dimensional deviations will affect the insulation coating thickness, connector matching accuracy, and even cause resistance changes or signal interference. The wire take-up machine needs to be equipped with a high-precision diameter gauge to monitor the wire diameter changes in real time during the production process to ensure that each batch of wires maintains consistent standards.

How does the wire take-up machine respond to the high standards of the automotive industry?
In order to adapt to the multi-dimensional requirements of the automotive industry for wire performance, Hyundai wire take-up machines are constantly evolving in the following aspects:
1. Intelligent control system: The introduction of PLC, inverter and human-machine interface (HMI) can quickly switch parameters according to the wiring harness configuration of different models to improve production flexibility.
2. Automatic tension compensation and speed synchronization: The multi-stage linkage design maintains uniform tension in each drawing section and reduces quality defects caused by wire diameter fluctuations.
3. Integrated online annealing and lubrication system: Especially in oxygen-free copper wire drawing, the online annealing system can improve conductivity and reduce hardness, and improve subsequent crimping and bending performance.
4. High adaptability and multi-material processing capabilities: The same production line can adapt to a variety of metal wires, including copper, aluminum, copper-clad steel, etc., to meet the segmented needs of different models for conductor performance.

Application of Wire Take-Up Machine in other industries
When we mention wire take-up machine, people often think of high-frequency application fields such as copper wire, cable, and automobiles. But in fact, wire drawing technology has been widely penetrated into every corner of modern industry. From electronic manufacturing to communication equipment, from construction steel bars to medical equipment, many industries have precise, stable and large-volume requirements for wires. The wire take-up machine is an important equipment to support these needs. Its flexible adaptability and continuous evolution in different fields have become the "behind-the-scenes engine" to promote the upgrading of industrial foundations.

Electronic Manufacturing Industry: Core Demand for Refined Wires
Modern electronic products are becoming increasingly miniaturized and intelligent, and they place extremely high demands on the fineness and consistency of internal connecting wires. From smartphones, laptops, TVs to industrial control systems, internal wiring almost all relies on fine-diameter wire connections, and the processing accuracy of these wires is directly related to product performance and life.
1. Demand for ultra-fine wires: Copper wires with a diameter of less than 0.1 mm are commonly used in microelectronic connections, and even some high-end equipment requires "micron-level" conductors. Traditional wire take-up machines are difficult to achieve stable drawing at this scale. Modern high-precision wire take-up machines are equipped with super-hard alloy molds and high-speed tension control systems, which can achieve multi-stage continuous drawing to ensure that the thin wire is not broken or deformed.
2. The consistency of insulation coating depends on the stability of the wire diameter: electronic wires often need to be coated with extremely thin insulation films. If the wire diameter fluctuates slightly, the thickness of the insulation layer may cause problems such as breakdown and short circuit. For this reason, high-end electronic wire take-up machines integrate laser diameter gauges and closed-loop control systems to achieve micron-level precision adjustment.
3. High-conductivity copper material processing capacity: oxygen-free copper, which is commonly used in electronic products, is extremely sensitive to wire drawing temperature. If the processing temperature is not properly controlled, it will lose its conductive properties. Advanced wire drawing equipment uses intelligent annealing and cooling systems to keep the material pure and the crystal intact at high drawing speeds.

Communication equipment: the support behind high-speed signal transmission wires
With the rapid development of technologies such as 5G communications, fiber-optic broadband, and data centers, the performance requirements of metal wires in the communication field are becoming more and more stringent. Although optical fiber dominates the backbone network, high-frequency copper wires are still irreplaceable in base stations, servers, short-distance interconnection and other links.
1. Low-loss high-frequency signal lines: such as coaxial cables, USB 3.x cables, HDMI high-speed cables, etc., have high standards for impedance consistency, conductivity, and oxidation resistance of the wires. The core wires of these cables are generally made of high-purity copper, silver-plated copper and other materials. The surface roughness and wire diameter consistency must be strictly controlled during the wire drawing process.
2. Shielding layer metal wire braiding: To prevent electromagnetic interference (EMI), communication cables usually need to be equipped with a metal braided shielding layer, which is usually braided with multiple strands of fine steel wire or copper wire. The diameter of this type of metal wire is usually between 0.05\~0.15 mm, and the flexibility and strength requirements are extremely high. The wire take-up machine needs to achieve high-efficiency filament molding and maintain good toughness and ductility.
3. Optical fiber auxiliary metal core wire: Although the optical fiber itself is not conductive, some optical cable structures still need to add metal core wires to enhance tensile strength or as identification conductors. This type of wire is also pre-processed by a wire take-up machine, requiring high strength and good ductility, and must not break due to excessive stretching.

Construction industry: large-scale rigid demand for load-bearing wire
Construction is one of the traditional industries that uses the most steel wire and metal wire. Although construction wires seem "rough", the wire drawing process behind them should not be underestimated.
1. Prestressed steel wire and steel strand: Prestressed steel wire is widely used in structures such as bridges, high-rise buildings, and railway sleepers. These high-strength steel wires usually need to go through multiple wire drawing procedures to achieve the required hardness and strength. Online annealing and surface treatment are also required during the wire drawing process to prevent fatigue cracks in later use.
2. Brick wall reinforcement wire and binding wire: Although the process is relatively simple, these low-carbon steel wires used in large quantities have extremely high requirements for the wear resistance and production capacity stability of wire drawing equipment. The wire drawing speed of conventional construction steel wire can reach more than 20 meters per second, requiring the equipment to operate continuously and stably for a long time.
3. Wire for metal grids, railings, and welded mesh: This type of wire is generally made of medium-hardness steel wire or galvanized wire, and requires corrosion resistance and good formability. The wire take-up machine needs to maintain the precision of the wire diameter in such applications to ensure that no deformation or breakage occurs during subsequent processing (such as welding and bending).

Refined applications in emerging industries such as medical, aviation, and new energy
With the development of technology, the "stage" of the wire take-up machine continues to expand, gradually moving towards more high-end application scenarios:
1. Fine wires for medical devices: such as heart stents, stainless steel guide wires, nickel-titanium alloy wires, etc., require extremely high precision and biocompatibility, and are often used in interventional surgical instruments. The corresponding wire drawing equipment must not only be highly precise, but also prevent metal contamination and provide a closed drawing system with a clean environment.
2. High-temperature alloy wire for aerospace: used for sensing and connecting components in aircraft engines and spacecraft. The wire needs to work stably under high temperature and strong vibration. The material type is special and expensive, which puts extreme requirements on the precision control of wire drawing equipment.
3. Functional wires in the new energy field: such as lithium battery tab aluminum strips, photovoltaic connection copper wires, fuel cell internal leads, etc., require both conductivity and lightness, and have strict requirements on batch consistency. Advanced wire drawing systems need to integrate data tracking and quality recording functions to achieve intelligent manufacturing.