Drawing, SFS Insulation Tandem Line
Product Details
Nowadays, the world has already entered the information society. LAN, the basic unit of high-speed information network, its transmission rate is getting faster with the development of society.
The data cable is one of the most important transmission media of the LAN, and the development of the LAN is also driving the rapid growth of the data cable. In the future for a long time, data cables will be used widely .
In order to meet the high-speed information transmission requirements of today's social networks, data cables have evolved from the lower transmission rates like Cat.3, Cat.5e, and Cat.6 to higher transmission rates of Cat.6A, Cat.7, and Cat. 7A and even the highest category Cat.8.
With the development of communication networks, Cat.6A and higher categories of data cables have become the mainstream products of network wiring systems. In order to achieve better transmission performance, such data cables no longer use traditional solid insulation, but must use foam insulation type. In order to ensure that the insulated wire core reaches a highly precise geometric size and the best quality. At present, the extrusion of Cat.6A and above categories adopts a drawing skin-foam-skin insulation tandem extrusion production line.
Insulation extrusion is the most critical production process for data cables. The quality of the insulation is directly related to the performance indicators of the entire data cable product. Our company has many years of experience in research and development and manufacturing of data cable production equipment. Our drawing-skin foam skin insulation tandem extrusion production line has many core technologies, which are suitable for Cat.6A, Cat.7, Cat.7A, Cat.8 production of foam insulation. The test performance of the finished cable products can meet the requirements of ISO 11801, IEC 61156, ANSI / TIA 568 and other standards.
1. Features
1) Adopting drawing, continues annealing, pre-heating integrated machine to make copper conductor and insulation adhere well;
2) The main extruder adopts the most advanced gas injection foaming screw in the world, with stable discharge and uniform foaming;
3) The inner and outer skin extruder adopts frequency conversion and vector control to make the inner and outer skin thickness uniform and consistent;
4) Adopting German high-precision nitrogen pressurized gas injection system and precision gas needle to produce fine and even bubbles;
5) Adopting automatic dual take-up and bobbin change, which can realize automatic bobbin change without stopping, which greatly improves production efficiency;
6) Full line industrial computer control, online control of copper wire diameter, insulation outer diameter, water capacitance, concentricity, foaming degree, etc.
The drawing, annealer, pre-heating insulation tandem extrusion production line provided by our company has more than 80% market share in China, and is also exported to various countries in the world. Choosing us means not only chose the world-class data cable foam insulation production line, but also chose first-class technical support and after-sales service. This production line has extremely high commissioning difficulty, but we have a professional technical team that can assist customers to successfully complete the installation and commissioning of the production line, provide customers with professional technical training, and enable customers to truly master foam production technology. At the same time, according to the size of the wire produced by the customer, the design of the wire drawing dies and the foam extrusion dies can be free for the customer.
2. Main Technical Parameters
|
Max.inlet dia. of copper wire (mm) |
2.6 |
|
Outlet dia. of copper wire (mm) |
0.40～0.65 |
|
Max. completed outer diameter of insulation |
3.0 |
|
Applicable insulation materials |
LDPE、MDPE、HDPE |
|
Applicable insulation type |
Skin-foam-skin |
|
Insulation concentricity (%) |
≥95 |
|
The highest degree of foaming (%) |
70 |
|
Production speed (m/min) |
Solid PE: max.1200 Skin-foam-skin PE: max.1000 |
|
Operating direction |
From left to right / right to left |
3. Production Effect
Main Components
Pay-off unit, drawing-annealing-preheating integrated machine, extruder (including inner skin extruder, foaming extruder, outer skin extruder, crosshead, etc), automatic vacuum suction machine, masterbatch mixer, high pressure gas injection system, cooling water tank, cooling device with traction wheel, wire drying device, sparker, zumbach online control system (including copper wire diameter gauge, water capacitance tester, laser diameter gauge / eccentricity tester), fully automatic dual take-up unit, electrical control system, etc.
1. Drawing-annealing-preheating Integrated Machine
This production line adopts the integrated drawing-annealing-preheating equipment, which has a compact structure and effectively reduces the area of the production line.
The wire drawing machine can draw up to 17 dies. By adjusting the number of dies, it can draw copper wires with different wire diameters. It is easy to change the dies and has a wide range of wire diameter.
The annealing current of the annealing machine is adjustable and the drawing speed is automatically synchronized, which effectively guarantees the consistency and uniformity of the copper wire drawing performance after annealing. After annealing, the elongation of copper wire can reach up to 18% ～ 28%.
The annealing machine does not need additional injection of steam, the equipment can generate steam autonomously to protect the annealed copper wire from oxidation and bright appearance.
The preheating temperature can be up to 140℃, and no additional conductor preheater is needed, so that the copper wire has good adhesion to the insulating layer.
The lubricating fluid circulating cooling and copper emulsion filter device of the wire drawing machine ensure that no copper powder will stick to the outlet dies and the copper wire. Not only prolongs the service life of the drawing dies, but also ensures the surface quality of the copper wire.
2. Extruder
Extruders include inner skin extruder, main extruder, outer skin extruder and crossheads.
The main extruder is placed horizontally, and the inner and outer skin extruders are vertically connected to the crossheat to realize the three-layer co-extrusion of skin-foam-skin with the main extruder.
The main extruder adopts the most advanced gas injection foaming screw in the world, with stable discharge and uniform foaming. The inner and outer skin extruders adopt frequency conversion and vector control to make the inner and outer skin thickness uniform and consistent;
The crossheads adopt the high-precision self-centering crosshead from Swiss-made MICRODIA, which can be fine-tuned to obtain higher insulation concentricity.
3. High-pressure Nitrogen Injection System
High-precision nitrogen pressurized gas injection system and precision gas needle made in Germany are used to inject high-pressure nitrogen evenly into the main extruder to produce fine and uniform bubbles. The amount of gas injection is adjustable according to the degree of foaming, and the gas injection is uniform.
4. Zumbach Online Control System
The zumbach online control system includes copper wire diameter gauge, water capacitance tester, laser diameter gauge / eccentricity tester and control system, etc.
The system can realize continuous monitoring statistics and recording of copper wire diameter, insulation outer diameter, insulation concentricity, and water capacitance after drawing annealing, so that the entire production status is unobstructed.
The system has intelligent control, friendly operation interface, multiple languages to choose from, and a large-capacity 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 use China well-known brand;
4. The DC motor controller adopts American Parker brand;
5. The PLC adopts Siemens brand;
6. The main low-voltage electrical appliances adopt Schneider and China well-known brand;
7. The display screen adopts Siemens brand;
8. The main bearings adopt Japanese NTN and NSK brands.
Auxiliary Equipment
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 the wire drawing die, 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.
This machine is mainly composed of two rollers with eccentric pass. When the roller rotates, the pass shape is changed from large to small, and then small to large, and the reciprocating is performing a periodic movement at an angle of 180°. When the hole shape is the largest, the wire is pushed forward. With the change of the hole shape of the roller, the uniform change of the wire cross-section decreases, and it is withdrawn by the roller.
This production line is equipped with pointing and stringing machine and does not require additional preparation by the customer. 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 incoming copper wire. It not only makes the operator easy to operate, but also improves the efficiency of dies threading.
Installation and Commissioning
14 days before the inspection before delivery, the customer shall inform the plan schedule of installation, commissioning and test run to us. The both party will finalize this plan during the period of inspection visit. The customer is liable to carry out the installation of the equipment at the plant in accordance with our instructions.
Our three specialists for commissioning (checking the wire and cable connections, water supply, air supply, etc. and make corrections), adjustment of the equipment and start-up of test run will leave for customer’s site within 15 days after the installation complete. Test runs shall be carried out immediately after the end of the commissioning. The specialists shall demonstrate during the test runs that the individual machine of the equipment have been properly installed and tested. The test runs shall be conducted by the specialist with the help of customer’s workers and technical staff.
The customer shall provide, free of charge, facilities for the tests such as material, utilities and apparatus that may reasonably be required for carrying out such tests.
The commissioning and test run duration is max. 30 working days.
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.
