Drawing and Solid Insulation Tandem Production Line
Product Details
1. Production detail
Nowadays the world has entered the information society. As the basic unit of high-speed information network, the transmission rate of local area network(LAN) is getting higher and higher with the development of society.
Data cable is one of the most important transmission media in LAN , the development of LAN also drives the rapid growth of data cable. Data cables will be used more and more widely for a long period of time in the future.
In order to meet the transmission requirements of high-speed information in today's social networks, data cables have developed from Cat.3, Cat.5e, and Cat.6 with lower transmission rates to Cat.6A, Cat.7, and Cat.7A with higher transmission rates, and even the current highest category Cat.8 at present.
With the development of communication network, Cat.6 and Cat.6A have became the mainstream products of network wiring system. In order to ensure that the insulated wire core reaches the highly precise geometric size and the best quality, the extruding of the insulation layer of Cat.6A (non-foamed insulation) and below types of data cable are all adopted drawing and solid insulation tandem production line.
Insulation extrusion is the most important production process of data cable, and the insulation quality is directly related to the performance indicators of the finished data cables. LINT TOP has many years of experience in R&D and manufacturing of data cable production equipment. Our drawing and solid insulation tandem production line has a number of core technologies, which are suitable for the production of solid insulation of Cat.6A (non-foamed insulation) and the below types of data cable. The performance of the finished data cable can meet the requirements of ISO 11801, IEC 61156, ANSI/TIA 568 and other standards.
2. Features
The drawing and solid insulation tandem production line produced by LINT TOP has the following characteristics.
1) Adopting wire drawing machine with continuous annealing and preheating to make copper conductor adhere well to the insulation.
2) The main extruder adopts the most advanced BM high-speed screw, with stable discharge and uniform outer diameter of insulation.
3) Adopting automatic dual take-up machine, can realize automatic bobbin change without stopping, which greatly improves production efficiency.
4) Full line adopts industrial computer control, which can realize online control of copper wire diameter, insulation outer diameter, concentricity, etc.
The drawing and solid insulation tandem production line provided by LINT TOP has more than 80% market share in China, and is also exported to various countries in the world. By choosing us, you not only choose the first-class data cable insulation production line, but also choose the first-class technical support and services. The commission of this tandem production line is extremely difficult. LINT TOP has a professional technical team that can assist customers to successfully complete the installation and commissioning of the production line, and provide with professional technical training so that you can truly master the production technology of data cable insulation. At the same time, according to the size of the wires produced by our customers, we can design wire drawing and extrusion dies for you free of charge.
3.Main Parameters
|
Inlet dia. of copper wire(mm) |
2.5mm~2.6mm hard(soft) |
|
Outlet dia. of copper wire(mm) |
0.4mm~0.65mm |
|
Outer dia. tolerance of copper wire(mm) |
±0.001mm |
|
Elongation of copper wire(%) |
18~28 |
|
Applicable insulation materials |
HDPE |
|
Applicable insulation type |
solid |
|
Insulation Concentricity(%) |
≥95 |
|
Production speed(m/min) |
theoretical speed: max.1800 |
|
actual velocity: max.1500 |
|
|
Operation direction of production line |
From left to right / right to left |
Main Components
Coil type vertical pay off, wire drawing machine with annealing and preheating, extruding machine (including Swiss MICRODIA high-precision self-centering cross head and Swiss imported diamond die core and tungsten steel die set), automatic vacuum suction dry machine, single bucket masterbatch mixer, cooling water tank, return type spray cooling tractor, blow dry device, DC sparker, zumbach online control system, 500mm fully automatic dual take-up device(including automatic loading and unloading system, automatic entry and exit system), drawing lubricating fluid circulating cooling and copper emulsion filter device, annealing coolant circulating cooling system, electrical control system, etc.
1. Drawing-annealing-preheating Integrated Machine
The production line adopts integrated equipment of drawing, annealing and preheating, which has compact structure and effectively reduces the area of production line.
The wire drawing machine can draw up to 17 drawing dies. By adjusting the number of drawing dies, the copper wire with different wire diameters can be drawn. It is easy to change the dies and has a wide range of outlet wire diameter.
The annealing electric current range of the annealing machine is adjustable, and the wire drawing speed is automatically synchronized, which effectively guarantees the consistency and uniformity of the performance of copper wire after drawing and annealing. The elongation of annealed copper wire can reach 18% ~ 28%.
The annealing machine does not need additional steam injection, it can generate steam autonomously, to protect the annealed copper wire from oxidation, and have bright appearance.
The preheating temperature can up to 140℃, and no additional conductor preheater is needed, so that the copper wire and insulation layer have good adhesion.
The lubricating liquid circulation cooling and copper powder emulsion filtering device of the wire drawing machine ensure that copper powder will not stick to the outlet dies and copper wire. It not only extends the service life of drawing dies, but also ensures the surface quality of copper wire.
2. Extruding machine
The extruding machine includes main extruder, crosshead, dies, etc.
The main extruder is placed horizontally, using the most advanced BM high-speed screw, with stable discharging and uniform insulation outer diameter.
The crosshead adopts Swiss-made MICRODIA high precision self-centering crosshead, which can be fine-tuned to achieve high insulation concentricity.
3. Zumbach on line control system
Zumbach on line control system includes copper wire diameter gauge system, integrated data processing controller, no-contact eccentricity/outside diameter gauge system, etc.
The system can realize continuous monitoring and recording of copper wire diameter, insulation outer diameter and insulation concentricity after drawing and annealing, so that the whole production state can be monitored.
The system has intelligent control, friendly operation interface, multiple languages available for choosing, and a large capacity of product information database, which can view the production process data records.
Commercial Parts
1. The AC motor adopts Siemens or ABB brand.
2. The inverter adopts Siemens brand.
3. The DC motors adopts China well-known brand.
4. The DC motor controller adopts Parker brand.
5. The PLC adopts Omron brand.
6. The main low-voltage electrical appliances adopt Schneider, Siemens and other brands.
7. The display screen adopts Schneider brand.
8. The main bearings adopts NTN, NSK brand.
Auxiliary Equipment
1. Pointing and stringing machine
In actual production, the max diameter of the copper wire can reach to 2.6mm. In order to make it pass through the die hole of wire drawing dies, the copper wire needs to be sharpened. This pointing and stringing machine is a special equipment for large-size wire passing through smaller die holes.
The pointing and stringing machine is mainly composed of two rollers with eccentric holes. When the roller rotate, the holes change from large to small, and then change from small to large, and reciprocate periodically at an Angle of 180°. When the hole shape is the largest, the wire is pushed forward. With the change of the hole shape, the uniform change of the wire cross-section decreases, and it is withdrawn by the roller.
This production line is equipped with wire pointing and stringing machine , which does not need additional preparation from customers. The machine is installed on the wire drawing host. This installation method not only effectively reduces the equipment footprint, but also greatly facilitates the rolling head and threading of the inlet copper wire. It not only makes the operator easy to operate, but also improves the efficiency of dies threading.
FAQ
Q: Can I visit your factory?
A: All the customers from both home and abroad are warmly welcomed to visit our company and factory.
Q: Do you supply the installation and commissioning?
A: Yes, we do as followings:
-As soon as customer informed us the machines are put in the right place, we will send both mechanical and electrical engineer for machine start up.
-No-load testing: After machine installed completely, we make no-load testing first.
-With-load testing: Usually we will can produce 3 different wires to make load testing.
-Acceptance report: After the buyer confirms that machine can reach all specification under contract, the acceptance report will be signed for our record that machine will be in guarantee period.
Q: What information should I offer to get a detailed quotation from you?
A: For single machine: Usually we need to know inlet wire size, outlet wire size to be produced, productivity, pay off and take up size to choose the right machine.
For new cable plant or new cable production line, we need to know the datasheet of cables to be produced, the productivity, the standards to be followed, etc to design all machines needed.
Q: Can you supply the auxiliary equipment along with the machines?
A: Yes, definitely.
We has supplied heat exchanger, copper/aluminum powder filter machine, cooling tower, chiller, air compressor, drawing dies, pointing machine, cold welders, bobbins etc. with our machines.
Q: Could you do the design for the whole plant?
A: Yes, this is our advantage.
With the data sheet of cable to be produced, the standard your cables should follows, the productivity you expected. Our engineer on production technology and machinery will make design of production machines, test equipment, accessories like bobbins, dies, rewinding lines and materials needed.
Q: How can I know the status of my order?
A: We have our OA system on tracking the production.
For any of your request we can send photos and videos of your order, also we can use FACETIME to let you know the production.
Q: How do you work on the inspection before delivery?
A: We will make dynamic balance testing, levelness testing, noise testing, etc. during production.
After production finished, usually we make no-load running of each machine before delivery. Customers are welcomed to attend the inspection.
Q: What exhibitions will you attend, can we meet in the fair?
A: Dusseldorf International Wire and Cable Fair;
Wire South America Fair;
International Wire and Cable Fair in Shanghai;
International Istanbul Wire Fair, etc.
wire Southeast Asia Fair, etc.
