Wire Cable Extrusion Production Line
NO.1 Power Cable , Building wire production process(300-800 high speed bunching machine-70-120mm insulation extruder-Cantilever single twisting machine-120-150mm jacket sheath extruder) as below:A. 300-800 high speed bunching machine(1.5 square milimeter-16 square milimeter)
| Equipment models | XJ-300A | XJ-500A | XJ-630A | XJ-800A |
| Twisting usage | it is applied to the twisting of above seven pcs of bare copper wires, tinned wires, silver jacketed wires and enameled wires,double twisting for core wires. | |||
| Single wire dia(mm) | φ0.08~φ0.28 | φ0.10~φ0.64 | φ0.15~φ1.04 | φ0.2~φ1.7 |
| Stranding section area (square milimeter) | 0.035~0.45 square milimeter | 0.05~2.5mm2 | 0.5~6mm2 | 1.0~16mm2 |
| Core wire single wire dia | φ0.25~φ0.8mm | φ0.75~φ1.5mm | φ1.0~φ3.0mm | φ1.0~φ4.0mm |
| Core wire stranding outer dia | φ0.5~φ1.6mm | φ1.5~φ3.0mm | φ2.0~φ6.0mm | φ2.0~φ8.0mm |
| Pitch(mm) | 4.5-17.5(10 kinds) | 5.82-53.73(34 kinds) | 11.48-100(36 kinds) | 19.8-200(30 kinds) |
| Direction of lay | Optional for right or left | |||
| Outer dia*bore*outer width | φ300*φ30*160 | Φ400*φ56*300 φ500*φ70*320 | φ630*φ80*360 | φ800*φ80*600 |
| Max rotating speed | 3000(6000/twist) | 2200(4400/twist) | 1600(3200/twist) | 1200(2400/twist) |
| Main motor power | 3.7KW | 5.5KW | 7.5KW | 11KW |
| Inverter power | 3.7KW | 5.5KW | 7.5KW | 11KW |
| tension control method | (Mechanism friction) | |||
| protection | Machine will automatically brake when wire inside and outside is broken, the machine will automatically stop when the preset length is arrived. | |||
| Brake mode | Electromagnetic brake | |||
| Traversing method | ,Rolling ring drive units, winding pitch and breadth are adjustable | |||
| operation mode | Push-button control | |||
| Dimension (L*W*H) | 2300*1000*1150 | 2800*1280*1300 | 3280*1600*1600 | 3600*1850*180 |
B. 70-120mm insulation extruder
| Equipment model | XJ-70 | XJ-80 | XJ-90 | XJ-120 |
| Usage: | Power Wire/ computer wire/ building wire/data wire/ high frequency wire insulation/jacket sheath extrusion | |||
| Wire specification | 1.5-12mm | 2-20mm | 3-25mm | 10-50mm |
| Extrusion material | PVC/SRPVC/LHNF/PE/PP/PU etc | |||
| Screw parameter | L/D ratio:26:1, compression ratio: 2.7-3.2, Screw material:38CrMoAIA, Vacuum heating treatment, Surface Grinding Polishing chromium plating | |||
| Temperature control segments (body+head) | 5+3 | 5+3 | 6+3 | 6+3 |
| Power | 40HP | 50HP | 60HP | 100HP |
| The highest output | 140KG/H | 180KG/H | 240KG/H | 360KG/H |
| The highest wire speed | 400M/min | 300M/min | 250M/min | 180m/min |
| Movable water tank | Extension type movable tank, movable lenth is 300mm, over length 1.5m with single segment water dryer. Or as requirement | |||
| Length of U type cooling tank | 7.5M | 7.5M | 10M | 15M |
| Accumulate wheel parameter(11+10 grooves) | 250 | 300 | 400 | 500 |
| Capstan power | 5HP | 7.5HP | 7.5HP | 15HP |
| pay off type | How may shafts, active with moter and passive without moter just as request | |||
| Take up Type | As request | |||
C. Cantilever single twisting machine
| Equipment model | XJ-630 | XJ-800 | XJ-1000 | XJ1250 |
| Usage | Power cable, computer cable, building cable, data/high frequency cable muiti group twisting | |||
| Wire specification | 0.6-3.0mm | 0.6-5.0mm | 1.0-8mm | 3-10mm |
| Twisted OD | 15mm | 20mm | 25mm | 30mm |
| pitch range | Set pitch on touch screen:20-250mm. PLC control, pitch is stable when it is accelerate and decelerate | |||
| Rotate speed | MAX900RPM | MAX800RPM | MAX600RPM | MAX400RPM |
| Power(Motor+differential mechanism) | 15HP | 20HP | 25HP | 40HP |
| Taping type | Single-head gorizontal type high speed centering taping device+ double head longitudinal taping device | |||
| Taping tension | Adopt Magnetic Clutch+PLC automatic caculation. Taping tension keep constant from start to the end, need not adjustment. | |||
| Take up | Movable shaft type take up, No damage during the traversing process, traversing space and distance can be set freely according to the wire specification | |||
D. 120-150mm jacket sheath extruder (bigger machine can be made also)
| Equipemnt model | XJ120 | XJ150 |
| Pay off type | big shaft | big shaft |
| Bobbin size | 1600-2000 | 2500-3150 |
| Screw diameter | 120 | 150 |
| L/D of screw | 26:1 | 26:1 |
| Extrusion capacity | 360kg/h | 600kg/h |
| Power | 100HP | 150HP |
| Wire specification | 10-50mm | 60-120mm |
| cooling tank | single layer u type | Single layer U-type |
| Capstan power | 15HP | 20HP |
| Highest wire speed | 180m/min | 100m/min |
| Take up type | Big shaft | Big shaft |
NO.2 Lan Cable CAT5, CAT5E, CAT6, CAT6A, CAT7 Production Process(50+35 core wire extruder -Core wire pair twisting-Total twisting machine-Jacket sheath extruder machine-Coiling machine) as below:
A. 50+35 core wire extruder
| 50+35 core wire extruder | Extruder material: PVC/PE/SRPVC |
| Wire specification:AWG30-AWG24,0.8-2.8 | |
| The highest wire speed:1000m/min Semi-auto take up(depends on wire dia); | |
| Use for high-speed insulation extrusion for PVC/PE/secondary colour wire and Lan cable(CAT5, CAT5E, CAT6, CAT6A, CAT7) insulation extruder | |
| Operating Direction:left or right is allowed (For example:if the take up direction is right, it will call"right hand machine" when face electric box.); | |
| Dosage of air-pressure:18m³/Hr | |
| Screw parameter: L/D ratio:26:1, compression ratio: 2.7-3.2, Screw material:38CrMoAIA, Vacuum heating treatment, Surface Grinding Polishing chromium plating | |
| Pay off type: as request | |
| Take up type: as request | |
| Centre-height:1000mm; | |
| ø50mm extruder host+35mm stripping extruder | |
| Voltage:Three-phase 410V-450 50HZ or as request |
B.Core wire pair twisting
Type A pair twisting machine: XJ-500B double twisting machine with active pay off for CAT5/CAT5E cable
| Equipment models | XJ-500B double twisting machine |
| Twisting usage | it apply for CAT5/CAT5E core wire pair twisting |
| The max.size of wire-receiving bobbin (outer diameter×total length) | φ500×314 |
| Max core wire diameter | Φ0.5-1.2mm |
| Lay pitch(mm) | 5.8~ 54.53( can adjustable by customer's need); |
| Direction of intertwist: | "S"for left,"Z"for right |
| Rotation speed of intertwist bow(r/min) | 2500RPM(5000 twist) |
| Material of intertwist bow: | spring steel belt |
| Motor | 4KW, frequency-envarying speed control |
| Wire-receiving stretch force structure | Magnetic power clutch |
| The up-and-down structure of wire-receiving wheel: | manual or electricial-hydraulic type |
| Electrical control type | PLC |
| Electrical control operation interface | standard electric accessories |
| achine outside shape size(mm) | 2560×1350×1400 |
| Net weight of machine(kg) | 2000 |
| Main bearing | Nsk |
| Pay off: | Active pay off with motors, double shafts without back-twist |
Type B pair twisting machine: XJ-500C triple twisting machine for CAT5/CAT5E/cat6 cable
| Equipment model | Triple twisting machine XJ-500C |
| Usage | Lan cable cat5, cat5e, cat6 |
| Rotation speed | Max2000 RPM (6000 twist) |
| Wire specification diameter | 0.8-1.7mm |
| Finished OD | 1.5-3.5mm |
| Twisting pitch | 5-50mm, adjustable |
| Pitch tolerance | +-2% |
| Pitch setting | Servo electronic pitch, direct set on the touch screen |
| Backtwisting rate | 0-100% |
| Twisting direction | S/Z |
| Tension range | 0.6-3KG |
| Tnesion display | Digital tension displayer |
| Pay off & take up tension | Stable active rail tension |
| Pay off & take up bobbin diameter | 500mm |
| Twist bow motor | 10HP motor with frequency converter |
| Take up motor | 1/2HP gear motor driving with frenquency converter |
| Triple pitches design, 1.5 times speed than traditional double twisting machine when it is with 33% back twisting rate | |
| Servo electronic pitch, touch screen setting, PLC controller, accuracy within +-2% | |
| Active take up, tension stable from empty to full reel | |
Type C pair twisting machine: XJ-500D active back twist pay off+XJ-500B double twisting machine
| Equipment Model | XJ-500D active back twist pay off | Equipment Model | XJ-500B double twisting machine |
| Max rotate speed | 1000RPM | Wire diameter | 3.1mm |
| Wire diameter | 0.4-1.5mm | Pitch range | 6-54.7mm as request |
| Pay off bobbin diameter | 500mm | Max rotate speed | 2500RPM/MAX |
| Tension range | 1-20N | Max wire speed | 120M/min |
| Pay off speed | 0-120M/min | Pay off tension | Controlled by tension slider rod feedback |
| Back tiwst rate | 0-50% | Take up tension | Magnetic powder cluth, bobbin diameter auto tracking |
| Back tiwst driving motor | 4KW | Lift bobbin | automatic lift by pay-off motor and take up hydraulic pressure |
| Pay off motor | 0.75KW | Bobbin diameter | 500mm |
| Lift bobbin motor | 0.75KW | Main bearing | Janpan NSK |
| Usage: Apply for Lan cable specially, such as CAT5/CAT5E/CAT6/CAT6A/CAT7 and so on data cable back twist and pair twisting | |||
| Feature: Back twist before pair twisting and reduce wire damaged during twisting process, XJ-500D active back twist pay off and XJ-500B double shafts pair twisting machine are linkage working. | |||
C.Total twisting machine: XJ-630-1250mm Cantilever type single twisting machine
| Equipment model | XJ-630 | XJ-800 | XJ-1000 | XJ1250 |
| Usage | Power cable, computer cable, building cable, data/high frequency cable/Lan cable cat5, cat6, cat7 muiti group twisting | |||
| Wire specification | 0.6-3.0mm | 0.6-5.0mm | 1.0-8mm | 3-10mm |
| Twisted OD | 15mm | 20mm | 25mm | 30mm |
| pitch range | Set pitch on touch screen:20-250mm. PLC control, pitch is stable when it is accelerate and decelerate | |||
| Rotate speed | MAX900RPM | MAX800RPM | MAX600RPM | MAX400RPM |
| Power(Motor+differential mechanism) | 15HP | 20HP | 25HP | 40HP |
| Taping type | Single-head gorizontal type high speed centering taping device+ double head longitudinal taping device | |||
| Taping tension | Adopt Magnetic Clutch+PLC automatic caculation. Taping tension keep constant from start to the end, need not adjustment. | |||
| Take up | Movable shaft type take up, No damage during the traversing process, traversing space and distance can be set freely according to the wire specification | |||
U-UTP do not need taping, but U-FTP/F-UTP/S-STP/F-FTP need taping and the taping machine as below:
| Model | 4 longitudinal taping machine for each pair taping | Model | 1 longitudinal taping machine for total/fully taping |
| Power | Active power taping,1/2 gear motor+converter, stable tension | Taping tension | Magnetic powder clutch control tensiono |
| Longitudinal aluminum foil tape | Full power put aluminum foil, tension can be adjusted | Suitable material | Aluminum foil tape etc |
D. Jacket sheath extruder machine:XJ-70-90mm jacket sheath extruder machine
| quipment model | XJ-70 | XJ-80 | XJ-90 |
| Usage: | Power Wire/ computer wire/ building wire/data wire/ high frequency wire insulation/ Lan cable jacket sheath extrusion | ||
| Wire specification | 1.5-12mm | 2-20mm | 3-25mm |
| Extrusion material | PVC/SRPVC/LHNF/PE/PP/PU etc | ||
| Screw parameter | L/D ratio:26:1, compression ratio: 2.7-3.2, Screw material:38CrMoAIA, Vacuum heating treatment, Surface Grinding Polishing chromium plating | ||
| Temperature control segments (body+head) | 5+3 | 5+3 | 6+3 |
| Power | 40HP | 50HP | 60HP |
| The highest output | 140KG/H | 180KG/H | 240KG/H |
| The highest wire speed | 400M/min | 300M/min | 250M/min |
| Movable water tank | Extension type movable tank, movable lenth is 300mm, over length 1.5m with single segment water dryer. Or as requirement | ||
| Length of U type cooling tank | 7.5M | 7.5M | 10M |
| Accumulate wheel parameter(11+10 grooves) | 250 | 300 | 400 |
| Capstan power | 5HP | 7.5HP | 7.5HP |
| pay off type | In order to do not stop machine and change the bobbin, it can use 2 shafts active pay off with motor, and equip the accumulator to use | ||
| Printer machine | Computer-controued inkjet machine | ||
| Take up Type | As request | ||
E. Coiling machine
| 1. Linkage with jacket sheath extruder machine |
| 2. Lan cable coiling length normally is 1000 feet (305 meter) |
| 3. Coiling with special shape "8" |
F. Reference pictures:
More cable production line such as data/high frequecy cable USB3.0/3.1, HDMI, DVI, SATA etc, please kindly contact the below information:
Dongguan NewTopp Electric Machinery Co. Ltd
Sales engineer: Mr.David hou Mob/: 0086 18822965628
Web Site: http://dgnewtopp.en.made-in-china.com/ http://dgnewtopp.en.made-in-china.com
Add: No.286 Huaide Road, Humen town, Dongguan City, Guangdong provinc
We are looking forward to hearing from you, dear friend!