Copper Rectangular Wire Rolling Line

In high-end electrical manufacturing, achieving absolute dimensional consistency and structural integrity in conductors is critical. The Copper Rectangular Wire Rolling Line by Jiangsu Goodroller Machinery Co., Ltd. (GRM) offers an advanced, fully integrated solution that combines wire drawing, precision cold rolling, online measurement, and automatic take-up into a single continuous production process.

By eliminating intermediate material handling, this high-speed line guarantees superior surface quality and ultra-tight tolerances for demanding applications in the EV, transformer, and power electronics industries.

Technical Specifications & Line Configuration

Engineered for high-volume, continuous industrial output, our 5-stand configuration optimizes reduction ratios across multiple stages to maintain material stability at high speeds.

Standard 5-Stand Mill Configuration

• First Two-High Mill: Ø 300 mm
• First Edger Mill (Side Mill): Ø 155 mm
• Second Two-High Mill: Ø 200 mm
• Second Edger Mill (Side Mill): Ø 155 mm
• Third Two-High Mill: Ø 160 mm

Key Performance Parameters

• Maximum Inlet Wire Diameter: Ø 8 mm
• Design Line Speed: Up to 400 m/min
• Finished Thickness Range: 2.0 mm – 12.0 mm
• Finished Width Range: 0.5 mm – 4.0 mm
• Achievable Tolerances: Thickness: ±0.005 mm | Width: ±0.01 mm

* Tailored Engineering: The exact production process layouts, roll diameters, and stand sequences can be fully customized according to your specific raw material dimensions and target finished product profiles.

Core Components of the Production System

Every GRM Copper Rectangular Wire Rolling Line is built with synchronized, high-precision equipment to ensure automated, end-to-end processing without manual intervention:

• Vertical Coil Payoff Stand (1 Set): Ensures smooth, tension-controlled decoiling of the inlet copper rod.
• DLF6D/500 Six-Die Drawing Machine (1 Set): Initial continuous reduction to prepare the precise entry wire diameter.
• Two-Roll Precision Rolling Mills (3 Sets): Heavy-duty, high-precision rolls that dictate final thickness and material density.
• Side Rolling Mills (2 Sets): Dedicated vertical formatting stands that maintain perfect rectangular edge geometry.
• Online Polishing & Dust Collection Device (1 Set): Continuous surface conditioning to eliminate particulates and copper dust before final measurement.
• Online Thickness & Width Measuring Device (1 Set): Real-time, closed-loop monitoring system to ensure zero-defect output.
• Transverse Take-Up Machine (1 Set): Precision tension-controlled spooling for flawless, layer-by-layer winding.

Key Advantages & Industrial Benefits

Upgrading to an integrated Copper Rectangular Wire Rolling Line eliminates the inefficiencies and quality risks inherent to split, standalone manufacturing methods.

Uncompromised Dimensional Accuracy

Equipped with rigid roll housings and an integrated PLC control system, the line achieves a thickness tolerance of up to ±0.005 mm. Real-time online measurement feedback allows for dynamic adjustments, preventing out-of-tolerance batches during long-duration runs.

Enhanced Efficiency and Reduced Handling

Integrating drawing and rolling into one automated line boosts efficiency while minimizing manual transfer hazards. This continuous workflow limits surface scratching, reduces work-hardening variables, and lowers overall operational costs.

Engineered Surface Quality for Downstream Insulation

An inline polishing and dust extraction system removes surface impurities continuously. This creates a clean, burr-free surface profile with optimized edge radiuses—critical for flawless downstream enameling, paper wrapping, or CTC strand bundling.

Typical Applications

The output from the GRM Copper Rectangular Wire Rolling Line strictly complies with international standards for high-conductivity, precision electrical copper conductors utilized in:

• EV Motor Hairpin Conductors: Providing the tight tolerances and precise corner radii required for high-slot-fill electric vehicle stators.
• Continuously Transposed Conductors (CTC): Delivering consistent flat wire profiles for high-voltage power transformer windings.
• Enameled Rectangular Magnet Wire: Smooth surface profiles ensure uniform insulation thickness and high dielectric breakdown resistance.
• High-Power Distribution Transformers: Heavy-duty flat copper busbars and strip conductors.

Why Partner with GRM?

Jiangsu Goodroller Machinery Co., Ltd. delivers field-proven expertise, verifiable certifications, and robust industrial backing:

• 16 Years of Industrial Expertise: Rooted in metal forming technology since 2008, growing into a specialized manufacturer of intelligent precision rolling mills.
• Advanced Manufacturing System: Our 13,300㎡ facility is equipped with Japanese CNC machining centers, laser precision tools, and dedicated QC testing laboratories.
• Strong Technical Talent: Over 30% of our 60-strong workforce comprises dedicated R&D engineers specializing in precision wire processing and automation control.
• Certified Standards & Intellectual Property: GRM is a National High-Tech Enterprise holding over 50 product patents, an AAA Credit Rating, and official EU CE Certification (M.2022.206.C74631).
• Global Project Footprint: Trusted by tier-one domestic institutes and corporations (including Beijing General Research Institute for Nonferrous Metals, Baosheng Cable, and China Steel Group) alongside active exports to the U.S., Russia, and Southeast Asia.

FAQ

Can this line manufacture copper flat wire specifically for power transformers?

Yes. The line is engineered to produce high-conductivity copper rectangular wires that meet the strict dimensional and surface criteria needed for transformer conductors, CTC strands, and distribution magnet wires.

What level of tolerance can the rolling mills consistently maintain?

The system consistently maintains a thickness tolerance of up to ±0.005 mm and a width tolerance of up to ±0.01 mm, verified by our real-time online gauging systems.

Why is an integrated line superior to standalone drawing and rolling machines?

An integrated line ensures a continuous tension profile and prevents oxidation or physical contamination between processing stages. It eliminates intermediate storage, drastically reduces labor costs, and provides uniform material consistency across the entire production lot.

What scope of technical support does GRM offer for international installations?

We provide full life-cycle services: customized 3D modeling and process simulation in the pre-sales stage, ISO-compliant production tracking, and global 48-hour field response paired with lifetime technical support after installation on your Copper Rectangular Wire Rolling Line.