Rosendahl’s R&D is continually providing solutions to the international wire and cable industry. In order to complement the product range, Rosendahl has established beside our Extrusion and SZ Stranding technology, a third core competence for Metal Tape Forming & Welding equipment. This involves both TIG and LASER welding technology in combination with static and dynamic metal tape forming solutions, according to the application requirements.

With the progress made in forming and longitudinal welding, many new applications have been developed for this technology. This process was originally designed for RF-cable inner and outer conductor manufacturing. At this process it is important to have perfect forming without periodical influences to keep electrical parameters as VSWR at desired levels. The corrugation process for this application requires high productivity (equipment designed for up to 8000 rpm) and perfect quality.

Rosendahl has therefore developed a patented line configuration to surpass existing quality and productivity levels. As an addition to the forming, welding and corrugation equipment, a measuring gauge has been developed, which offers the opportunity to control the contours of the corrugated products online. Parameters like major OD, minor OD, corrugation pitch are measured with a resolution of 0,01 mm in X and Y axis. With this device inline quality control and process setup is made very easy.

Furthermore, the experience gathered from RF-cable manufacturing has been transformed to other technologies. Forming of aluminum tapes and steel tapes with multi stage roll formers has been developed for High and Medium Voltage Cable armoring and shielding. Aluminum, copper and steel tapes are longitudinally welded and corrugated to provide a sealing and the required flexibility of this type of cables. Other fields for this application are copper cladding of aluminum rods and steel rods for CCA and CCS wire manufacturing as well as submarine optical fiber cable manufacturing with longitudinally welded copper tapes.