PTFE Insulation Wrapping Machine for Copper Busbars

This machine is designed for wrapping copper busbars with PTFE insulating tape. The insulation material is supplied from a reel with a width of 10 mm, an outside diameter of 150 mm, and a thickness of 0.5 mm. The copper busbar passes continuously through the wrapping head, where the PTFE tape is helically wrapped around the bar with controlled overlap to provide continuous insulation coverage. The machine consists of three main sections: 1. Infeed Feeder The infeed feeder consists of 15 steel rollers coated with polyurethane. The rollers are connected through a gear system and chain drive and are powered by a 0.5 kW motor integrated with a gearbox. The motor speed is controlled by a VFD to adjust the feeding speed according to the required wrapping speed. 2. Wrapping Head The wrapping head contains five steel rollers carrying polyurethane-coated rollers. Two driven rollers are powered by a 1.5 kW geared motor through belt drives, while three rollers provide free rotational support and adjustment. The rollers are adjustable through slots to control the position and contact with the rotating aluminum ring. The aluminum ring has an outside diameter of 500 mm and incorporates a V-shaped groove for guiding and carrying the insulation material. The rotating ring produces the wrapping motion while remaining synchronized with the linear movement of the copper busbar. This synchronization controls the wrapping pitch and overlap of the PTFE insulation. 3. Outfeed Feeder The outfeed feeder has the same basic construction as the infeed feeder, including 15 polyurethane-coated steel rollers, gears, chain transmission, and a geared motor. The two feeders operate in the same direction and at synchronized speed to maintain continuous and stable movement of the copper busbar through the wrapping head. Manufacturing and Fabrication The machine structure and sheet metal components were designed for fabrication using laser-cut sheet metal, press brake bending, and rolling processes. Mechanical components were manufactured using turning and machining operations. The steel rollers were coated with polyurethane to provide controlled traction and prevent damage to the copper surface. The complete machine was designed as a functional mechanical assembly, including the feeding system, wrapping mechanism, transmission components, adjustable roller system, and supporting structure.