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Wire Insulation Extrusion Machine

PE/PP Series High Speed Wire Insulation Extrusion Line

PE/PP Series Cable High-Speed Wire Insulation Extrusion Line is non-standardized equipment with customization. It adopts a series production line of copper wire drawing, copper wire annealing, insulation extrusion, and automatic reel rewinding. It is suitable for high-speed insulation extrusion of signal wire. Series production line can maintain immediate insulation coating of the conductor after copper drawing. It can avoid copper wire's surface oxidation, enlarge the skin effect of electron transmission, maintain the conductivity of the conductor, reduce signal attenuation, and increase the signal transmission distance. Rolls of copper material can be produced in large lots without interruption, which can also ensure the consistency of the transmission performance of the wire in the entire batch. The series production can be used to prepare for the pair twisting in the next step, improving product quality, saving costs, and thus increasing product market competitiveness. A desirable PE/PP series production line has the following characteristics: smooth screw barrel and non-stick to materials, small deviation in the outer diameter of the copper wire conductor, high ovality of the copper wire conductor, stable elongation of the copper wire conductor, accurate temperature control, high concentricity of the main extruder head, stable wire diameter and small tolerance, low resistance to cool down wire, and 100 % successful wire reel changing rate. Our company can support personalized customization according to user needs. In terms of hardware, we can provide a variety of models and core accessories brands for users to choose from. In terms of electrical control software, we can also provide economical and practical or advanced electrical control methods. Due to different overall configurations, the price of this machine also varies greatly. Therefore, the main factor that determines the price of this machine is the user's product configuration level positioning. In addition, because this product is non-standardized customized equipment with only a small lot of production, it takes a longer period to design, manufacturing, installation, and debugging cycle is long. Users must reserve sufficient procurement cycles to achieve desirable product delivery.

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Product Details

COMPONENTS

Pay-off stand
Continuous medium-drawing annealing and preheating machine
Copper powder filter cooler
Main extruder
Injection machine
Feeding hopper dryer
Color spiral doser
Extruder head
BY-PASS material discharge valve
Movable flume
Cooling water tank
Air blowing nozzle
Capstan
Blow dryer
Meter counter
Laser diameter gauge
High-frequency spark tester
Take-up
Electricity Control Box
The following are custom options
Printer
Vacuum device
Lump detector
Water electrostatic capacitor
Eccentricity gauge
Electronic billboard
Other peripheral auxiliary equipment can be customized and added.


TECHNICAL SPECIFICATIONS

Main Technical Parameters 65+30 80+45
Suitable wire type Suitable for data cable (CAT5E/CAT6/CAT6A), high-frequency cable, automotive cables, computer cables, electronic cables, power cables, and other wires of copper wire conductor with solid insulation extrusion.
Conductor range for US standard Copper rod (Ø2.6-3.0mm) → copper wire (AWG26-20) Copper rod(Ø2.6-3.0mm)→copper wire(AWG26-18)
Conductor diameter range Ø0.40-0.81mm Ø0.40-1.02mm
Conductor area range 0.16-0.52m㎡ 0.16-0.81m㎡
Extrusion outer diameter Ø0.9-2.0mm Ø0.9-2.5mm
Wire speed range 600-1500m/min 600-1500m/min
Main indicators Copper wire outer diameter tolerance ±0.001mm, copper wire ovality ±0.001mm, copper wire elongation 18-30%, insulation core outer diameter tolerance ±0.005mm, eccentricity <0.007mm
Machine structure Taking the centre line of the head of the extruder as the axis, it is arranged in a straight line from the pay-off to the take-up, the centre of the standard model is 1m high and the total length is 40-25m.
Pay-off type Standard use of the whole roll of oxygen-free copper rod continuous pay-off, single-station vertical copper wire pay-off stand, other types such as flyer pay-off, shaftless power pay-off etc. can also be customized.
Middle wire drawing machine 17 moulds, Z4 series 55KW DC motor, wire drawing and reduce polygons coefficient is 1.25, fixed speed wheel diameter is Ø200
Continuous annealing machine Direct contact triangular short-circuit annealing method, without gas protection, annealing voltage is MAX50V, annealing current is MAX800A, total annealing power is MAX40KVA
Continuous preheating machine Z4 series 7.5KW DC motor traction, preheating voltage is MAX50V, preheating currentis MAX400A, preheating total poweris MAX20KV, conductor preheating temperature is 80-120℃
Copper powder filter cooling machine
It is composed of copper powder filtering device, 1200L water tank, 4.5KW plate heat exchanger and 2.2KW water pump, etc., which filters the copper powder in the drawing solution and cools down the drawing solution.
Extruder output 130kg/h 180kg/h
Extruder power 30KW DC motor made in China, AC motor can be customized 30KW DC motor made in China, AC motor can be customized
Screw parameters L/D ratio: 26, compression ratio: PE3.0. It consists of 38CrMoAlA screw material with vacuum nitride heat treatment and surface-grained chrome-plated polishing.
Heating type The machine body is cast aluminium heating ring, the neck is copper heating ring, the head clamp/head/die is quartz heating tube.
Temperature control  Body 4+clamp 1+neck 1+head 1+die 1
Heating power 18KW 22KW
Barrel cooling 4-section centrifugal fan 4-section centrifugal fan
Injection machine power Horizontal strip-injection machine with 3-stage temperature control for the body and 1-stage temperature control for the neck, vertical strip-injection machine can also be customized.
Injection machine specification Ø30 vertical type Ø45 vertical type
Injection machine ouput 15kg/h 25kg/h
Injection machine power 7.5KW 11KW
Feeding hopper dryer Made-in-China Feeding hopper dryer, other brands can be customized.
Color spiral doser Made-in-China Color spiral doser, other brands and quantities are available.
Honeycomb plate The machine is made of 316 stainless steel without electroplating. It has an internally guided flow structure, with flow holes interconnected by chamfers with no dead corners. The honeycomb plate and flange are sealed with a tapered sealant to prevent leakage.
Head type U7-type auto centering head, outer runner uniform pressure movement, can be customized with different structures such as single layer/double layer/single injection strip/double injection strips etc., and  (auto centering + micro adjustable) extruder head can also be customized.
Head brand The machine head is made in China, and can be customized to other brands such as EUROTEK, UNITEK, EUROCAB, and MICRODIA
Head clamp There are two halves of a machine head clamp, with two up-and-down sets of screws rod clamp synchronizely. A one-way wrench can be included, and other types of machine head clamps can be customized.
Pressure test Pressure sensor or explosion-proof safety valve on the head flange.
BY-PASS material discharge valve One set of three-way electric automatic rotary BY-PASS, can be customized pneumatic or other types.
Head levelling Adopting double locating pin structure of head flange, the level of head will not be shifted for a long time.
Moveable flume Constant temperature type movable flume, self-circulating warm water tank, 9KW heating pipe 2 pcs, whole SUS304 material, standard length of small water tank 2500mm, can be customized.
Cooling tank 20 metres single-layer U-shaped tank, V-shaped water tray internal, SUS304 material, anti-condensation interlayer design on the outside of the tank
High-pressure air blowing nozzle Flipped-type blowing nozzle, POM material, double stage blowing structure, set in the movable water tank, cooling water tank, capstan. Other types of blowing nozzle type can be customized.
Blow dryer Adopting high-pressure flat blowing nozzle, the water on the surface of the wire is blown away when the wire passes through the hot air blowing port. At the same time, it adopts negative pressure suction, the water on the surface of the wire is taken away when the wire passes through the vacuum suction slot hole.
Capstan type Wire deposited type high-speed spray cooling double wheel capstan, with 50 meters wire cooling length.
Capstan wheel diameter Ø350 flat fixed wheel + multi-groove segment wheel
Capstan power 7.5KW made-in-China DC motor, AC motor can be customized
Metre counter Guide wheel type meter counter, with 400mm of meter wheel circumference, encoder detection, meter correction coefficient adjustable, other types of meter counters are customizable.
Take-up type Ø500 double-reel automatic shaft changing take-up machine, with 11KW take-up power, pneumatic clamping, and automatic reel change when meter is reached, automatic loading and unloading of wire reel.
Laser diameter gauge Made-in-China wire diameter gauge, measurement accuracy is 0.001, other brands, such as SIKORA/ZUMBACH/PROTON/TAKIKAWA/BETA, etc are customizable.
High frequency spark tester Made-in-China bead-type high-frequency spark tester, voltage is 0-15KV, other brands, such as CLINTON/SIKORA/PROTON can be customized.
Electricity control box Environmentally friendly flame-retardant paint-coated VICTOR electric cabinet, WEINVIEW 10” HMI, SIEMENS PLC, SCHEIDER switches, RKC temperature controller. Motor and frequency converter brands are customizable.
Intelligent formula management system Adopting Profinet bus communication mode, the data of pay-off tension, take-up tension, preheating temperature, host temperature control, extrusion outer diameter, take-up pitch, air pressure value, etc. are stored in the PLC, supporting MES data collection and import, one-click retrieval of production process, one-click start, realizing digital intelligent production.
Total power 160KW 180KW


OPTIONAL CUSTOMIZATION ITEMS

Printer high-speed printer or other printing type can be customized.
Vacuum extractor A vacuum device can be added at the head of the machine upon customization. 
Lump detector Lump detector can be customized, such as SIKORA/ZUMBACH/PROTON/TAKIKAWA.
Water static capacitance gauge Water capacitance gauge, like BETA/SIKORA/ZUMBACH/PROTON/TAKIKAWA, can be added upon customization.
Eccentricity gauge Eccentricity gauge, such as BETA/SIKORA/ZUMBACH/PROTON/TAKIKAWA, can be customized.
Chiller Chiller or tank with insulated layer can be customized.
Hanging electronic board LED double-sided electronic screens or other types are supported.
Peripheral auxiliary Equipment Other peripheral accessories or special customizations for the entire machine can be customized.
Electrical wiring 2.5-meter overhead cable trough stand, air pipes, signal wires, and power cable arranged with isolations, wire inlet from the top of  electrical control box, customizable alternative methods.
Safety regulations standard Manufactured in accordance with China's CCC safety standards, and customizable to meet CE/CSA/UL safety standards.
Power supply standards 3-phase 380V/50Hz power supply, with customizable voltage and frequency for different countries and regions.




PRODUCT FEATURES

High ProductionYield: By adopting a series structure of wire drawing and extrusion, it can achieve high speed insulation extrusion, high production yield and less waste.

Leak-proof design: The unique sealing and positioning structures ensure that the flange does not leak material, and the height level of extrusion head remains stable even for long-term use.

High Quality: Our insulated wires have a concentricity of 93%-97%, an outer diameter variation of ±0.005,

Precise Temperature Control: within ±1℃.

Intelligent: Our intelligent management system can be customized, allowing for easy access to SOP formulas, one-click startup preparations, and intelligent operation.

Easy maintenance: Customers outside of China can customize the use of the Profinet bus control system, which ensures fast and low-interference signal transmission. As long as there is a communication network in any country or region, remote fault detection, troubleshooting, and maintenance services can be quickly implemented.

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A Mature Factory You Can Count On

Gemwell Electrical Machinery Co., Ltd.
Founded in 2005, GEMWELL is a professional wire and cable equipment solution provider in design, manufacture and sales for the United States, Canada, Mexico, Germany, Italy, India, Thailand, Russia and etc. more than 40 countries in the world.

The success of customer is our goal to get success!

● Focus on technological innovation, quality stability, precision manufacturing and considerate service.
● Insist on making all in detail well, repay every customer with high quality.
● Take customer's success as the embodiment of our enterprise value.

The enterprise spirit of dedication, dedication, enterprise and exploration encourages us to innovate and transform the technology of wire and cable into advanced productive forces, in order to build GEMWELL into a new name card of China facing to the world.
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