Product Overview

Designed to handle both thermoplastic (PE, PVC) and thermoset (XLPE, Silicone) materials, this integrated production line combines advanced extrusion technology with intelligent control systems to ensure uniform insulation layers even at high speeds. Its 150mm high-torque screw—crafted from 38CrMoAlA alloy steel with nitride treatment (surface hardness ≥HV900)—and variable-frequency drive system enable stable output rates of up to 800 kg/h, making it ideal for large-scale industrial cable production. A key advantage lies in its closed-loop temperature control system with infrared thermal sensors, maintaining ±1°C accuracy across 6 heating zones to minimize material degradation and reduce waste by up to 15%.

Product Specifications

Screw Diameter: 150mm (38CrMoAlA alloy steel with nitride treatment)

Length-to-Diameter Ratio: 25:1 (optimized for high-viscosity materials)

Maximum Output: 800 kg/h (PE), 650 kg/h (PVC), 500 kg/h (XLPE)

Material Compatibility: PE (LDPE, HDPE), PVC, XLPE, Silicone rubber

Power Consumption: 250 kW (with energy recovery system)

Control System: Siemens S7-1200 PLC with 10-inch HMI touchscreen

Die Head Type: Swappable crosshead (for multi-core cables) or inline design (for single-core)

Cooling System: 3-stage water bath with automatic temperature regulation (15–40°C)

Tension Control: Servo-driven capstan with ±0.5% speed accuracy

Applications

Power Cables:

Specialized for high-voltage (HV: 35–110kV) and extra-high-voltage (EHV: 220–500kV) cables, providing insulation with dielectric strength ≥25 kV/mm. Complies with IEC 60502-2 (power cables for rated voltages from 6kV to 30kV) and GB/T 12706.2 (XLPE-insulated power cables).

Control Cables:

Enables production of multi-core control cables (2–48 cores) with thin insulation layers (0.2–1.0mm) and tight diameter tolerance (±0.05mm), critical for industrial automation and machinery control systems.

Automotive Wires:

Meets stringent requirements of automotive wiring harnesses, with insulation resistant to engine oil, coolant, and temperatures up to 150°C (compliant with ISO 6722-1 Class B).

Specialty Cables:

Ideal for fire-resistant cables (compliant with IEC 60332-3-24) and marine cables (resistant to salt spray per ASTM B117), ensuring durability in harsh environments.

FAQ

Q: What is the minimum insulation thickness this line can produce?

A: With precision die adjustment and micro-tension control, the line achieves reliable insulation thicknesses as low as 0.2mm for fine wires, maintaining uniform coverage across the cable circumference.

Q: Does the system support remote monitoring?

A: Yes, the integrated PLC system includes Ethernet/IP connectivity, enabling remote diagnostics, parameter adjustment, and production data logging via PC or mobile devices, which simplifies factory-wide automation integration.

Q: How long does it take to switch between materials?

A: Material changeovers are streamlined by the self-cleaning screw design and quick-release die heads, typically taking 30–45 minutes (PVC to PE) or 45–60 minutes (thermoplastic to thermoset materials).

Q: What safety features are included?

A: The line is equipped with emergency stop buttons at 3-meter intervals, overspeed protection (shuts down if speed exceeds 110% of set value), temperature alarms (triggers at ±5°C of setpoint), and protective guarding with interlock switches.