Ø70+90 Double-Layer Insulation Tandem Extrusion Production Line for Photovoltaic Cables

1. Equipment Purpose
This equipment is suitable for producing solar photovoltaic cables, low-smoke halogen-free cables, irradiated cables, and XL-PE cross-linked polyethylene cables; it is also applicable for conventional plastic extrusion such as PVC and PE.

● Cable Types Produced: Solar photovoltaic cables, low-smoke halogen-free cables, irradiated cables, XL-PE cross-linked polyethylene cables, etc.
● Extrusion Material: Low-smoke halogen-free irradiated material.
● Finished Wire Diameter: MAX Ф8mm.
● Design Line Speed: 0～250m/min (line speed depends on wire diameter).
● Extrusion Capacity: 380+200kg (die head open, flexible PVC).
● Center Height: 1000mm.
● Power Supply: 380V±10%, 50HZ, three-phase five-wire system.
● Operation Direction: Facing the operation - Left-hand machine (right pay-off → left take-up) □; Right-hand machine (left pay-off → right take-up) □.
● Machine Color: Overall exterior - Blue orange texture RAL5015 (color card provided by customer).
● Electric Cabinet Exterior: RAL7035 gray-white corrugated paint.
● Safety Color: Yellow (as shown in the image).

630 Double-head Swing Drum Pay-off Rack
● Suitable reel diameter: Ф630mm;
● Suitable wire diameter: Ф0.5-4.0mm;
● Maximum applicable line speed: 800m/min;
● Drive power: 400W geared motor;
● Motor power: 0.75KW motor;
● Mobile trolley with electric reel lifting;
● Frame made of stainless steel with double-layer sound insulation;
● Noise level during normal operation: ≤80dB (tested at 1.5m away);
● Two wire ends can be spliced to realize non-stop reel change;
● Suitable for high-speed continuous pay-off of extruders, no need to stop for reel change, and automatic stop when wire breaks;
● Tension control: Closed-loop tension control via displacement, adjustable tension.

Semi-enclosed Magnetic Powder Tensioner

• Tension control: Magnetic powder brake for tension control, adjustable tension;
• Wire inlet/outlet guide wheel grooves with ceramic spraying;
• Semi-enclosed wheels made of high-quality alloy steel with hard chrome plating on the surface.

Straightening Table

• Model: ZZA-60;
• Straightening direction: Single direction;
• Straightens the pay-off wire, adjustable up and down as needed;
• Equipped with a die toolbox; center height: 1000mm.

70-26D High-speed Extruder Main Machine

• Screw structure: Refer to the most advanced European screw structure, with large extrusion capacity and good plasticizing effect; screws processed by professional screw manufacturers using 3D CNC machines, ensuring high processing accuracy and linearity;
• Screw and barrel: Underwent double nitriding treatment with nitriding time >100 hours for long service life;
• Gearbox: Hard-tooth-surface gearbox with widened gear surfaces to improve gearbox strength and operation stability;
• Screw thrust bearing: Enlarged model to increase equipment safety factor and improve screw speed stability, ensuring uniform screw discharge and thus uniform cable extrusion thickness;
• Connection: Screw connected to gearbox gear via spline, ensuring uniform and stable screw speed and easy installation;
• Power: 37KW AC motor;
• Reduction gearbox: Model ZLYJ200, precision ground, with forced oil lubrication and cooling, featuring wear resistance and low noise; box body: Square castings, annealed, material HT200-300; gear teeth: High-frequency quenched and ground, noise level <75dB;
• BM screw (ensures uniform and dense plasticization of coating materials):
  • Diameter: Φ70;
  • Length-diameter ratio: 26:1;
  • Rubber extrusion capacity: 200KG/HR (die head open, flexible PVC);
  • Maximum speed: 120r/min;
  • Material: 38CrMoAlA with nitriding treatment (nitriding depth: 0.6), surface hardness ≥HV950;
  • Screw roughness: 0.8;
• Barrel:
  • Material: 38CrMoAlA with nitriding treatment (nitriding depth: 0.6);
  • Surface treatment: Nitriding;
  • Hardness: HRC60-63;
  • Special heat dissipation groove design at the connection between barrel and reduction gearbox to greatly extend the service life of the screw and gearbox;
  • Barrel roughness: 0.8;
• Heating:
  • Temperature measurement points: 8 positions (4 sections on the machine body, 1 section on the lock clamp, 1 section on the die head flange, 2 sections on the die head);
  • Machine body heating: Far-infrared heaters, which have shorter heating time than conventional cast aluminum heaters and save 25-30% energy;
  • Control: Temperature controller for automatic adjustment within 0～399℃; when the actual temperature exceeds the set temperature, the temperature controller automatically cuts off the power of the heating element and turns on the cooling fan power;
• Cooling: 4 high-pressure centrifugal fans (power 250W), one per barrel section; water cooling for the feeding section;
• Lock clamp type: Two-piece split type with 2-section heating, heated by stainless steel heating rods; new-type flange with double-sided screw locking and chain-driven upper/lower synchronous opening/closing, easy and quick to assemble/disassemble;
• Unit center height: 1000mm.

U14 Alignment-free Square Die Head

• Die head: Alignment-free square die head;
• Applicable outer diameter: φ1-φ10mm;
• Applicable forms: Single-layer extrusion, 30% color stripe extrusion, double-layer extrusion;
• Features: New flow channel design concept, uniform pressure, no dead ends, simple structure and easy operation;
• Suitable extrusion materials: PVC;
• Electric heating: 2 temperature measurement points, built-in heating rods, natural cooling;
• Material: Heat-resistant and corrosion-resistant materials;
• Processing technology: Rough and fine machining with quenching and tempering, overall hard chrome plating after fine machining, and final grinding.

50KG Dryer

• Maximum loading capacity: 50kg;
• Power: 3.9kw;
• Rated fan power: 0.18kw;
• Voltage: 380V;
• Hopper volume: 80L.

240KG Suction Feeder

• Maximum conveying capacity: 240kg/hr;
• Power: 1.1kw;
• Voltage: 380V;
• Hopper volume: 10L.

Control System A - With Boom

• Power supply: 380V+10%, 50HZ, three-phase five-wire system;
• System control: Equipped with an electrical cabinet, controlled by Siemens PLC, with distributed IO structure; all drives and testing instruments adopt bus communication, full digital control process, programmed with WINCC;
• Cantilever operation cabinet at die head: All operations of the main machine and traction can be completed without moving during wire threading;
• Main control synchronous display: Key parameters (e.g., outer diameter, line speed) and common operations (e.g., stop, synchronous acceleration, synchronous deceleration) displayed on the touch screen via PN bus;
• Power control: Controlled by main switch and branch switches; with total voltage display and total current display;
• Motor operation control: Drives controlled by frequency converters respectively;
• Automatic process control: Siemens PLC controls the entire production process, supporting single-action control and linkage control;
• Linkage control of auxiliary accessories: Auxiliary accessories such as diameter measuring instruments and spark testers are fully integrated into the system, with high automation;
• Indicator control: Temperature controllers accurately control each temperature zone; ammeters display heater current to better reflect heater working status;
• Electric heating temperature controller: Digital temperature controller with PID automatic control, accurately controlling the set temperature of each temperature zone's measurement points within ±1℃ to meet different process requirements with different temperature settings;
• Cooling fan control: Controlled by temperature controllers to keep the temperature curve flat.

2.5m Movable Water Tank (Letter-type)

• Main function: Rapid cooling and shaping of cables;
• Cooling method: Water immersion;
• Center height: 1000mm;
• Tank length: 2.5m;
• Moving range: 0.5m;
• Tank material: High-quality 304 stainless steel; thickness: 2.0mm;
• Blowing drying device installed at the end of the water tank (with cover); noise level: approx. 80dB.

Muffler Blowing Dryer Box

• Box material: High-quality 304 stainless steel; thickness: 2.0mm;
• Type: Flip-top;
• Blowing heads: Built-in two square compressed air water blowers;
• Noise sealing: Sandwich design with built-in sound-absorbing cotton for noise reduction.

Outer Diameter Measuring Instrument

• Power supply: AC220V±10%, 50-60HZ;
• Operating temperature: 5-45℃;
• Air humidity: ≤80%;
• Maximum measurement range: d=20mm;
• Recommended measurement range: d=0.05-16mm;
• Measurement accuracy: ±0.003mm;
• Measurement resolution: 0.001mm;
• Peripheral interface: RS485 communication interface.

4m Double-layer Fixed Water Tank

• Main function: Rapid cooling and shaping of cables;
• Cooling method: Water immersion;
• Center height: 1000mm;
• Tank length: 4+4m;
• Tank material: High-quality 304 stainless steel; thickness: 2.0mm;
• Sewage outlets at the bottom of both ends of the tank; water inlet pipe: 1 inch; water return pipe: 2 inches;
• Blowing drying device installed at the end of the water tank (with cover); noise level: approx. 80dB;
• Equipped with a rotary box.

9m Horizontal Wire Storage Rack

• Type: Horizontal;
• Track structure: 9m H-beam + medium-carbon square steel bars (tempered and hardened);
• Power: 2.2KW geared motor with speed ratio 1:30;
• Transmission: Multi-core steel cable;
• Wire storage length: 10M-150M;
• Guide wheels: Diameter Φ300mm, material: aluminum alloy; number of wheels: 10 pairs + 11 pairs;
• Speed control: A set of displacement detectors feeds back to the take-up motor; when the wire storage volume is large, the take-up speed increases automatically; when the wire storage volume is small, the take-up speed decreases automatically; during normal operation, the wire storage wheel remains stable at a specific position; only momentary displacement occurs during reel change, and it automatically returns to the specific position immediately;
• Guide wheel material: ADC12 aluminum alloy with surface hardening;
• Anti-collision: Nitrogen buffer pressure spring with adjustable pressure;
• Double detection device: Potential balance tension control, full-process signal detection by precision angle detector;
• Safety device: Limit switches at front and rear ends, synchronous stop control when wire breaks;
• Control box: Located at the wire inlet steering wheel of the wire storage rack; controls: forward/reverse control of 2.2KW power motor, switch tension adjustment VR, tension ammeter, power indicator.

Pneumatic Wire Clamp

600 Double-wheel Traction Machine

• Power: 5.5KW motor;
• Type: Double-wheel fully enclosed;
• Traction line speed: Max 400m/min;
• Traction wheels: Material aluminum alloy; driving wheel Φ600mm, driven wheel Φ500mm;
• Groove type: Flat groove with 4 grooves vs. 3 grooves;
• Box body: Steel plate welding + 304 stainless steel sealed water tank;
• Traction door frame: Equipped with exquisite aluminum alloy fire-rated rolling shutter door.

Powder Coating Machine

• Structure: Composed of steel plates and profiles; built-in spiral blades for powder mixing, brushes for powder removal, and heating plates for heating and dehumidifying stone powder (talcum powder); fully enclosed working chamber with no powder flying; equipped with a powder falling guide plastic pipe connected to a powder collection box for powder collection; no powder flying, and the collected powder can be returned to the working chamber for reuse;
• Transmission: Motor drives the worm gear reducer via V-belt, then drives the spiral blade shaft via chain transmission for powder mixing; electric heating plates for talcum powder heating with adjustable temperature (function: keep copper wire or core wire dry and smooth);
• Geared motor: Global temperature controller (Japan RKC);
• Double-thread spiral blade mixing; single-phase 220V 90W 1:20 reducer.

Straightening Table

• Model: ZZA-60;
• Straightening direction: Single direction;
• Straightens the pay-off wire, adjustable up and down as needed;
• Equipped with a die toolbox; center height: 1000mm.

90-26D High-speed Extruder Main Machine

• Screw structure: Refer to the most advanced European screw structure, with large extrusion capacity and good plasticizing effect; screws processed by professional screw manufacturers using 3D CNC machines, ensuring high processing accuracy and linearity;
• Screw and barrel: Underwent double nitriding treatment with nitriding time >100 hours for long service life;
• Gearbox: Hard-tooth-surface gearbox with widened gear surfaces to improve gearbox strength and operation stability;
• Screw thrust bearing: Enlarged model to increase equipment safety factor and improve screw speed stability, ensuring uniform screw discharge and thus uniform cable extrusion thickness;
• Connection: Screw connected to gearbox gear via spline, ensuring uniform and stable screw speed and easy installation;
• Power: 90KW AC motor;
• Reduction gearbox: Model ZLYJ280, precision ground, with forced oil lubrication and cooling, featuring wear resistance and low noise; box body: Square castings, annealed, material HT200-300; gear teeth: High-frequency quenched and ground, noise level <75dB;
• BM screw (ensures uniform and dense plasticization of coating materials):
  • Diameter: Φ90;
  • Length-diameter ratio: 26:1;
  • Rubber extrusion capacity: 380KG/HR (die head open, flexible PVC);
  • Maximum speed: 100r/min;
  • Material: 38CrMoAlA with nitriding treatment (nitriding depth: 0.6), surface hardness ≥HV950;
  • Screw roughness: 0.8;
• Barrel:
  • Material: 38CrMoAlA with nitriding treatment (nitriding depth: 0.6);
  • Surface treatment: Nitriding;
  • Hardness: HRC60-63;
  • Special heat dissipation groove design at the connection between barrel and reduction gearbox to greatly extend the service life of the screw and gearbox;
  • Barrel roughness: 0.8;
• Heating:
  • Temperature measurement points: 10 positions (5 sections on the machine body, 1 section on the lock clamp, 1 section on the die head flange, 2 sections on the die head, 1 section on the die);
  • Machine body heating: Far-infrared heaters, which have shorter heating time than conventional cast aluminum heaters and save 25-30% energy;
  • Control: Temperature controller for automatic adjustment within 0～399℃; when the actual temperature exceeds the set temperature, the temperature controller automatically cuts off the power of the heating element and turns on the cooling fan power;
• Cooling: 5 high-pressure centrifugal fans (power 750W), one per barrel section; water cooling for the feeding section;
• Lock clamp type: Three-piece split type with 2-section heating, heated by stainless steel heating rods;
• Unit center height: 1000mm.

U14 Alignment-free Square Die Head

• Die head: Alignment-free square die head;
• Applicable outer diameter: φ1-φ10mm;
• Applicable forms: Single-layer extrusion, 30% color stripe extrusion, double-layer extrusion;
• Features: New flow channel design concept, uniform pressure, no dead ends, simple structure and easy operation;
• Suitable extrusion materials: PVC;
• Electric heating: 2 temperature measurement points, built-in heating rods, natural cooling;
• Material: Heat-resistant and corrosion-resistant materials;
• Processing technology: Rough and fine machining with quenching and tempering, overall hard chrome plating after fine machining, and final grinding.

100KG Dryer

• Maximum loading capacity: 100kg;
• Power: 5.4kw;
• Rated fan power: 0.18kw;
• Voltage: 380V;
• Hopper volume: 160L.

450KG Suction Feeder

• Maximum conveying capacity: 450kg/hr;
• Power: 1.5kw;
• Voltage: 380V;
• Hopper volume: 15L.

Control System B - With Boom

• Power supply: 380V+10%, 50HZ, three-phase five-wire system;
• System control: Equipped with an electrical cabinet, controlled by Siemens PLC, with distributed IO structure; all drives and testing instruments adopt bus communication, full digital control process, programmed with WINCC;
• Cantilever operation cabinet at die head: All operations of the main machine and traction can be completed without moving during wire threading;
• Main control synchronous display: Key parameters (e.g., outer diameter, line speed) and common operations (e.g., stop, synchronous acceleration, synchronous deceleration) displayed on the touch screen via PN bus;
• Power control: Controlled by main switch and branch switches; with total voltage display and total current display;
• Motor operation control: Drives controlled by frequency converters respectively;
• Automatic process control: Siemens PLC controls the entire production process, supporting single-action control and linkage control;
• Linkage control of auxiliary accessories: Auxiliary accessories such as diameter measuring instruments and spark testers are fully integrated into the system, with high automation;
• Indicator control: Temperature controllers accurately control each temperature zone; ammeters display heater current to better reflect heater working status;
• Electric heating temperature controller: Digital temperature controller with PID automatic control, accurately controlling the set temperature of each temperature zone's measurement points within ±1℃ to meet different process requirements with different temperature settings;
• Cooling fan control: Controlled by temperature controllers to keep the temperature curve flat;
• Equipped with an intelligent communication electricity meter, data integrated into the PLC system, enabling real-time recording and display of equipment power consumption and energy consumption;
• Preset industrial Ethernet interface; interface data can be easily connected to workshop-level or company-level Ethernet switches, with real-time, stable data signals and resistance to industrial environment interference.

2.5m Movable Water Tank (Letter-type)

• Main function: Rapid cooling and shaping of cables;
• Cooling method: Water immersion;
• Center height: 1000mm;
• Tank length: 2.5m;
• Moving range: 0.5m;
• Tank material: High-quality 304 stainless steel; thickness: 2.0mm;
• Blowing drying device installed at the end of the water tank (with cover); noise level: approx. 80dB.

Muffler Blowing Dryer Box

• Box material: High-quality 304 stainless steel; thickness: 2.0mm;
• Type: Flip-top;
• Blowing heads: Built-in two square compressed air water blowers;
• Noise sealing: Sandwich design with built-in sound-absorbing cotton for noise reduction.

Outer Diameter Measuring Instrument

• Power supply: AC220V±10%, 50-60HZ;
• Operating temperature: 5-45℃;
• Air humidity: ≤80%;
• Maximum measurement range: d=20mm;
• Recommended measurement range: d=0.05-16mm;
• Measurement accuracy: ±0.003mm;
• Measurement resolution: 0.001mm;
• Peripheral interface: RS485 communication interface.

6m Double-layer Fixed Water Tank

• Main function: Rapid cooling and shaping of cables;
• Cooling method: Water immersion;
• Center height: 1000mm;
• Tank length: 6+6m;
• Tank material: High-quality 304 stainless steel; thickness: 2.0mm;
• Sewage outlets at the bottom of both ends of the tank; water inlet pipe: 1 inch; water return pipe: 2 inches;
• Blowing drying device installed at the end of the water tank (with cover); noise level: approx. 80dB;
• Equipped with a rotary box.

12m Horizontal Wire Storage Rack

• Type: Horizontal;
• Track structure: 12m H-beam + medium-carbon square steel bars (tempered and hardened);
• Power: 2.2KW geared motor with speed ratio 1:30;
• Transmission: Multi-core steel cable;
• Wire storage length: 10M-200M;
• Guide wheels: Diameter Φ300mm, material: aluminum alloy; number of wheels: 10 pairs + 11 pairs;
• Speed control: A set of displacement detectors feeds back to the take-up motor; when the wire storage volume is large, the take-up speed increases automatically; when the wire storage volume is small, the take-up speed decreases automatically; during normal operation, the wire storage wheel remains stable at a specific position; only momentary displacement occurs during reel change, and it automatically returns to the specific position immediately;
• Guide wheel material: ADC12 aluminum alloy with surface hardening;
• Anti-collision: Nitrogen buffer pressure spring with adjustable pressure;
• Double detection device: Potential balance tension control, full-process signal detection by precision angle detector;
• Safety device: Limit switches at front and rear ends, synchronous stop control when wire breaks;
• Control box: Located at the wire inlet steering wheel of the wire storage rack; controls: forward/reverse control of 2.2KW power motor, switch tension adjustment VR, tension ammeter, power indicator.

Pneumatic Wire Clamp

Electronic Length Counter

• Components: Mechanical bracket, upper/lower double wheels, encoder, etc.;
• Type: Double-wheel (vertical structure);
• Length counter wheel diameter: 190.98mm;
• Length measurement range: 9999m;
• Length counter wheel circumference: 600mm;
• Length measurement accuracy: 0.3%;
• Material: Aluminum alloy wheel circumference;
• Counting method: Encoder-based length counting;
• Length counter wheel and pressure wheel adopt one-way bearings, allowing only forward wire movement (no backward movement) for accurate length counting;
• Length counter wheel surface: Electroplated; pressure wheel: Rubber wheel to prevent wire damage; length counter wheel circumference: 600mm.

600 Double-wheel Traction Machine

• Power: 5.5KW motor;
• Type: Double-wheel fully enclosed;
• Traction line speed: Max 400m/min;
• Traction wheels: Material aluminum alloy; driving wheel Φ600mm, driven wheel Φ500mm;
• Groove type: Flat groove with 4 grooves vs. 3 grooves;
• Box body: Steel plate welding + 304 stainless steel sealed water tank;
• Traction door frame: Equipped with exquisite aluminum alloy fire-rated rolling shutter door.

Ink Printing Machine (Brand: Xinhua)

• Maximum printing speed: 500m/min, with beautiful and clear printing;
• Matching printing wheel: φ100mm;
• Applicable wire diameter: φ0.75mm～φ12mm.

15kv Power Frequency Spark Tester

• Output voltage: 1.0-15.0kV;
• Voltage indication error: <5%;
• Detection sensitivity: <600µA;
• Detection resolution: 0.05s;
• Transient breakdown current: 100mA;
• Steady-state short-circuit current: <20mA;
• Maximum detection speed: 500m/min;
• Outer diameter of tested cable: ≤30mm.

1000-1250 Double-disk Shaftless Take-up Machine

• Suitable reels: φ1000-1250mm;
• Reel inner hole: Φ80, Φ125;
• Reel loading type: Pneumatic/electric lifting for loading/unloading;
• Power: 7.5KW AC motor, 7.5KW frequency converter (linked with wire storage rack);
• Cable arrangement: Polished rod cable arrangement;
• Length counting: Automatic length counting, automatic stop when set length is reached;
• Operation control box;
• Pneumatic reel clamping, free switching between left and right reels;

Waste Collection Box

• Function: Collects waste generated during extruder start-up (start-up discharge) and shutdown (screw cleaning) of the extrusion production line;
• Specification: 400400180.

Molding Die

Spare Tools