Product Overview

Featuring a φ90 mm single-screw extruder (L/D ratio 28:1) with barrier screw design, it delivers 400-800 kg/h output with superior melt homogeneity (viscosity variation ≤3%). Its advanced process control ensures precise insulation thickness (±0.02 mm) and surface finish (Ra ≤0.8 μm), while the high-speed haul-off (up to 250 m/min) supports fast production cycles. Compliant with IEC 60332-1-2 and UL 1581, the line accommodates 0.5-10 mm cable diameters with tool-less die adjustments, making it suitable for both standard and custom cable production.

Product Specifications

Process Technology

Extruder Design: φ90 mm single-screw with 4 heating zones (feed to metering), featuring variable compression ratio (2.5:1 to 4:1) for diverse materials.

Material Compatibility: Handles PVC 70/90, HDPE (density 0.94-0.96 g/cm3), LSZH compounds (LOI ≥30), and EVA (VA content 5-30%).

Temperature Control: PID-regulated heaters with infrared sensors (±1°C accuracy), maintaining melt temperature at 180-250°C with over-temperature protection (≥280°C shutdown).

Mechanical Design

Die System: Coaxial multi-layer die (2 layers) with adjustable flow splitters, enabling insulation+jacket co-extrusion with layer ratio control (10:90 to 50:50).

Cooling Setup: Dual-stage water spray cooling (length 4-8 m) with temperature-controlled water circulation (15-25°C) and air knife drying (0.4 MPa pressure).

Traction Mechanism: Servo-driven capstan with rubber-covered rollers (Shore A 90), providing tension control from 10-100 N (±1% accuracy) and speed up to 250 m/min.

Control System

HMI & PLC: 10-inch color touchscreen with recipe management (50+ profiles), displaying real-time data on line speed, melt pressure (0-25 MPa), and thickness.

Efficiency Features: IE4 motors with variable frequency drives, reducing energy consumption by 20% vs. conventional lines, and automatic shutdown during idle periods.

Applications

Low-Voltage Power Cables

Manufactures 0.6/1kV PVC-insulated cables (16-120 mm2) for building distribution, meeting IEC 60228 and BS 6004 for conductor resistance.

Telecom Drop Cables

Produces PE-jacketed fiber drop cables with steel reinforcement, complying with ITU-T G.652.D for attenuation (≤0.3 dB/km at 1550 nm).

Appliance Wires

Creates H05VV-F wires for household appliances, meeting HD 21.10 and UL 758 for temperature rating (90°C) and flame resistance.

Automotive Battery Cables

Processes PVC-insulated battery cables (4-50 mm2) for starter systems, complying with SAE J1127 for conductor stranding and voltage drop.

FAQ

Q: What is the minimum batch size it can efficiently produce?

A: It maintains consistent quality for batches as small as 500 meters, with material waste <3% due to precise purge control.

Q: How does it ensure uniform wall thickness for irregular cable shapes?

A: The adaptive thickness control uses ultrasonic sensors at 360° around the cable, adjusting die flow rates within 10 ms to correct deviations.

Q: Can it process halogen-free materials without modifications?

A: Yes, it includes a specialized screw design for LSZH compounds, with increased compression to prevent material degradation and ensure smooth extrusion.