Cable Drawing Insulation Tandem Line

What are the main process flows of Cable Drawing Insulation Tandem Line?

Overall Process Overview

1. Wire Drawing

High-precision multi-segment drawing rollers are used to uniformly reduce the original copper wire diameter to the required specification, ensuring wire diameter consistency.

Real-time tension monitoring is used during the drawing process to prevent wire breakage and improve the yield rate of finished products.

2. Annealing

After drawing, the wire enters an annealing furnace for softening treatment using a controllable temperature (±1°C), restoring the metal's ductility.

The annealing temperature is precisely controlled by a Siemens PLC to ensure uniform metal structure and improve the quality of subsequent extrusion.

3. Preheating

The annealed wire is preheated before entering the extrusion section to make the insulation material flow more easily and reduce extrusion resistance.

The preheating zone uses a frequency-controlled AC motor and a Eurotherm DC controller to achieve rapid temperature response.

4. Extrusion

Using a high-precision extrusion die, insulating material is evenly coated onto the metal wire core to form an insulation layer.

The outer diameter (maximum 3.0mm) and foam content (maximum 65%) are monitored simultaneously during the extrusion process to ensure that the product dimensions and performance meet standards.

5. Take-up

The finished wire is automatically taken up on the continuous production line. The coil diameter and tension are adjusted in real time to prevent the wire from being too loose or too tight.

A 15-inch full-color touchscreen HMI provides a one-button operation interface, allowing operators to quickly switch production parameters.

What are the advantages of a tandem cable drawing and insulation line compared to a traditional single-machine drawing-insulation line?

What are the common causes of malfunctions or downtime in cable drawing and insulation lines?

1. Extrusion die or abnormal plastic supply
When the extrusion section lacks plastic, the entire line will stop due to material shortage.

2. Wire breakage or surface defects: Common problems with linear wire drawing machines, such as wire breakage, surface scratches, and uneven dimensions, can cause bottlenecks in subsequent processes.

3. Temperature control deviation: Temperatures exceeding ±1°C in the annealing or preheating zone can cause abnormal metal stress or poor insulation viscosity, leading to quality fluctuations.

4. PLC/electrical faults: Communication interruptions or relay failures in Siemens PLCs or Schneider low-voltage components can cause the entire production line to stop abruptly.

5. Variable frequency drive malfunctions: Incorrect parameters in AC variable frequency motors or Eurotherm DC controllers can cause unstable speeds, thus affecting the balance of wire speed and tension.

Frequently Asked Questions (FAQ)
Q1:What are the main functions of the Cable Drawing Insulation Tandem Line?

A:This production line integrates drawing, annealing, preheating, and insulation processes, achieving continuous cable stretching and insulation coating. It can complete multiple processes in one operation, improving production capacity and product consistency.

Q2:What is the market share of this line?
A:The company's drawing-annealing-insulation tandem line has a market share exceeding 80% in China and has been exported to several countries.

Q3:What are the technical challenges of the product and what support does the company provide?
A:This line is difficult to commission, but the company has a professional technical team that can provide on-site installation, commissioning, training, and follow-up technical services to help customers successfully start production.

Q4:What is the production capacity range of the LAN cable production line?

A:LAN cable production lines can be configured according to customer needs. Common production capacities range from 5km/day to 30km/day, depending on the equipment specifications.