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Silicone Sheath Extrusion Line

Silicone Sheath Extrusion Line

Silicone Sheath Extrusion Line is a non-standardized equipment with customization. The main machine model is generally 50-120mm. It is suitable for high-temperature silicone cross-linked wire sheath extrusion. The temperature of SILICON extrusion is low. The extruded material has no mechanical strength. After being irradiated in a high-temperature sintering pot, the internal molecules of the rubber material are cross-linked and solidified. The cross-linked sheath layer has high elasticity, high-temperature resistance, friction resistance, and other properties. A desirable sheathed extruder has the following characteristics: continuous and stable extrusion of material by screw, sufficient cooling of the material feeding tube without being heated up, smooth feeding without stagnation, convenient and quick adjustment of machine head deviation, energy-saving and heat-insulating sintering pot, and automatic lifting and lowering of the sintering pot to save labor, smooth sheath surface without mold closing marks, and smooth surface without particles, smooth guide wheel with no damage to the wire, stable wire diameter and tolerance, stable tension of the pay-off and take-up, changing reels of take-up and pay-off without stopping the machine, saves labor take-up structure, and beautiful wire griding of take-up, etc. Different users will have different needs when ordering this machine. Our company can support personalized customization according to user needs. In terms of hardware, we can provide a variety of models and core accessories brands for users to choose from. In terms of electrical control software, we can also provide economical and practical or the advanced electrical control methods. Due to different overall configurations, the price of this machine also varies greatly. Therefore, the main factor that determines the price of this machine is the user's product configuration level positioning. In addition, because this product is non-standardized customized equipment with only a small lot of production, it takes a longer period for the design, manufacturing, installation, and debugging cycle is long. Users must reserve sufficient procurement cycles to achieve desirable product delivery.

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Product Details

COMPONENTS

● Tension stand
● Straightening stand
● Preheater
● Main extruder
● Extruder head
● Circulating water cooling system
● Percussion furnace
● Sintering Oven
● Cooling water tank
● Printer
● Air blow nozzle
● Capstan
● Wire accumulation stand
● Meter counter
● Laser diameter gauge
● Industrial frequency spark tester
● Take-up
● Electricity Control Box

TECHNICAL SPECIFICATIONS

Main technical parameters 65 Type 90 Type 120 Type
Suitable wire types Suitable for data cable, computer cable, high-frequency cable, electric-power cable, power cord, and other wire to be sheath extruded.
Core Range Ø1.2-6mm Ø2.5-12mm Ø6-22mm
Finished Outer Diameter Ø2.5-7mm Ø3.5-14mm Ø8-25mm
Wire Speed Range 10-200m/min 10-200m/min 10-200m/min
Machine Structure Take the extruder head as the central axis, all parts from pay-off to take-up are linearly distributed. The standard extrusion line has a center height of 1 meter and a total length of 20-25 meters
Wire Pay-off Type Shaftless pay-off stand, electric lifting. Pay-off power type can be customized to be active or passive, and pay-off stand type can also be customized such as shaft type/portal cradle type.
Pay-off Reel Specification Ø500/Ø630 Ø630/Ø800/Ø1000/Ø1250 Ø800/Ø1000/Ø1250/1600
Pay-off power 3.7KW motor + gearbox 5.5KW motor + gearbox
Pay-off Tension-type Vertical slide rail tension frame, customizable in other styles Shaft lever tension frame, customizable in other styles
Straightening Stand Five-wheel conductor straightening stand, the outer diameter of the conductor straightening wheel is Ø100, equipped with toolbox.
Preheater Electric vertical lift type drying oven, stainless steel heating tube, heating power of 24KW, capable of reaching a temperature from room temperature to a maximum of 800 degrees in less than 5 minutes, length of 1 meter, equipped with a communication-type temperature module, SCR control, aluminum silicate insulation layer, and an external stainless steel temperature insulation cover. It is used for drying and preheating the surface of the core wire or conductor, preventing surface bulging during subsequent heating cycles, and can be customized with infrared heating tubes.
Extruder Material Output 70kg/h 200kg/h 300kg/h
Extruder Power 22KW 37KW 55KW
Screw Parameter L/D:14:1, compression ratio:1.6
Temperature Control  Hopper1＋extruder body2＋extruder neck1＋extruder head1＋screw1
Hopper Cooling The external spiral water jacket of the barrel is water-cooled, and the internal screw is also water-cooled. The hopper is cooled by circulating water, and the temperature is controlled independently with a cooling unit to keep the temperature constant.
Circulating Water Cooling System Each section is equipped with independent water cooling, with water pumped in by a water pump. When the set temperature is exceeded, cold water is supplied, and the hot water flows back to the chiller for cooling to maintain a constant temperature.
Honeycomb Plate The machine is made of 316 stainless steel without electroplating. It has an internally guided flow structure, with flow holes interconnected by chamfers with no dead corners. The honeycomb plate and flange are sealed with a tapered sealant to prevent leakage.
Head type The water-cooled adjustable machine head. Hopper's specification is customized according to the diameter of the wire. It can be designed with single-layer/double-layer/single-injection/double-injection structures. It can also be customized to an auto-centering extruder head type.
Head Brand The machine head is made in China and can be customized to other brands such as EUROTEK, UNITEK, EUROCAB, and MICRODIA
Head Clamp There are two halves of a machine head clamp, with two up-and-down sets of screws rod clamp synchronized. A one-way wrench can be included, and other types of machine head clamps can be customized.
Head Height Level Adopting a head flange double locating pin structure, the height level of the head remains unchanged for a long time.
Percussion Furnace Electric upright lift type drying oven, infrared heating tubes, with a heating power of 24KW. It takes no more than 5 minutes to reach the highest temperature of 800 degrees from room temperature. It has a length of 1 meter. Equipped with a communication temperature module and SCR control, it features an alumina silicate insulation layer and an external stainless steel heat insulation cover. It is used for the rapid shaping of cable surfaces after extrusion, protecting against scratches and damages caused by subsequent supporting guide wheels.
Sintering Oven Electric upright lift type drying oven, stainless steel heating tubes, with a heating power of 12KW. It takes no more than 5 minutes to reach the highest temperature of 600 degrees from room temperature. It is segmented into 2-meter sections. Equipped with a communication temperature module and SCR control, it features an alumina silicate insulation layer and an external stainless steel heat insulation cover. The oven entrance and exit are equipped with adjustable baffles to reduce heat loss. The cables pass through the middle position of the oven.
Printer An electric stirring type inkjet printer can be customized with other printing styles or an additional droplet dilution injection device.
Cooling Water Tank The 10-meter single-layer U-shaped water tank incorporates circulating water cooling. Made of SUS304 material, it can be customized as a double-layer U-shaped water tank or with customized length.
High-Pressure Air Blowing Nozzle Flip-type air-blowing nozzle, made of POM material features a dual-stage blowing structure. It is installed at the cooling water tank and capstan, and other types of air-blowing nozzles can be customized.
Capstan Type Dual-wheel capstan Caterpillar capstan
Capstan Wheel Diameter Ø500 dual-wheel type Ø600 dual-wheel type 800KG Caterpillar capstan
Capstan Power 3.7KW servo motor + gearbox 5.5KW servo motor + gearbo
Wire Accumulation Tension Stand Horizontal wire accumulation tension stand, total length of 12 meters, 10 grooves + 9 grooves on the wire storage wheel, total wire storage of 180 meters, magnetic powder clutch tension, vertical or other types are customizable. 
Wire Accumulation Wheel Diameter Ø300, wheel diameter specification can be customized Ø400, wheel diameter specification can be customized Ø550, wheel diameter specification can be customized
Meter Counter Pressure wheel type meter counters, meter wheel circumference of 500mm, encoder detection, adjustable meter correction coefficient, and other types of meter counters are customizable. 
Take-up Type Dual-head shaftless wire take-up, electric lifting, other types are customizable. Portal ground type, other types are customizable. 
Take-up Reel Specifications Ø500/Ø630 Ø630/Ø800/Ø1000/Ø1250 Ø800/Ø1000/Ø1250/1600
Take-up Power 3.7KW motor + gearbox 5.5KW motor + gearbox
Laser Diameter Gauge Made-in-Chian single-axis diameter gauge, measuring accuracy of 0.001, other brands such as SIKORA/ZUMBACH/PROTON/TAKIKAWA can be customized. 
Industrial frequency Spark Tester Made-in-China bead-type high-voltage spark tester, voltage range 0-15KV, customizable other brands such as CLINTON/SIKORA/PROTON
Control Electrical Box Environmentally friendly flame-retardant paint-coated VICTOR electric cabinet, WEINVIEW 10” HMI, SIEMENS PLC, SCHEIDER switches, RKC temperature controller. Motor and frequency converter brands are customizable.
Gross Power 280KW 320KW 350KW


OPTIONAL CUSTOMIZATION ITEMS

Front capstan Ø500 double-wheel front capstan can be customized Ø600 double-wheel front capstan can be customized Ø800KG caterpillar front capstan can be customized
Open rubber refining mixer Open rubber refining mixer can be customized
Automatic rubber feeding machine An automatic rubber feeding machine can be customized, and installed above the main machine's feeding hopper, saving manual feeding operation.
Extruders for inject/inner layer extrusion/outer layer extrusion Extrusion machines for injection, inner layer extrusion, or outer layer extrusion can be customized, with a preferred V-shaped layout.
Pressure detection  A pressure sensor or explosion-proof safety valve can be added to the flange plate of the machine head.
Vacuum extractor Vacuum devices can be added to the inlet of the machine head.
Power machine Customizable option to add an electric stirring-type powder machine or electrostatic environmentally friendly powder machine.
Wire cutting machine Customizable option to add a wire-cutting machine.
Coiling plate Customizable options to add a simple or fast coiling plate.
Coiling machine Customizable option to add a coiling machine.
Air pump drying machine Customizable option to add an air pump drying machine.
Lump detector Customizable option to add lump detection features to the measuring instrument on Chinese brands diameter gauge, or customize other brands like SIKORA/ZUMBACH/PROTON/TAKIKAWA.
Inkjet printer IMAJE/KGK/LEIBINGER is customizable.
Eccentricity Measurement BETA/SIKORA/ZUMBACH/PROTON/TAKIKAWA is customizable.
Hanging electronic display board Customizable option to add a double-sided LED electronic screen or other types.
Intelligent recipe management system Customizable option to add an intelligent formula management system, storing data such as wire tension, preheating temperature, extrusion outer diameter, wire spacing, and air pressure in the PLC. Using Profinet bus communication mode, supporting MES data collection and import, one-click access to the production process, one-click start, and realizing digital intelligent production.
Peripheral auxiliary equipment Support for customizing additional peripheral auxiliary equipment or special customized extrusion line.
Electrical wiring 2.5-meter overhead cable trough stand, air pipes, signal wires, and power cable arranged with isolations, wire inlet from the top of the electrical control box, customizable alternative methods.
Safety regulations and standards Manufactured according to Chinese CCC safety standards, customizable according to CE/CSA/UL safety standards.
Power supply standards 3-phase 380V/50Hz, customizable for different voltages and frequencies in various countries and regions.




PRODUCT FEATURES

● Quick threading: Simply press the button to raise the heating chamber. The furnace chamber is lowered to seal and heated after threading the wire.

● Leak-proof design: The unique sealing and positioning structures ensure that the flange does not leak material, and the height level of the extrusion head remains stable even for long-term use.

● Fault protection: Equipped with a fault-tolerant function for the heating oven. In the event of partial damage to the heating elements, causing a temperature drop, the equipment will only sound an alarm, reduce the speed of operation, and continue to ensure normal production of long-length cables.

● Efficient and environmentally friendly: The entrance and exit of the oven are equipped with adjustable baffles to reduce heat loss. Additionally, the entrance and exit of the oven are equipped with smoke vents to maintain a clean production environment.

● Intelligent: An intelligent formula management system can be customizable. It has one-click access to the SOP formula, one-click start-up preparation, one-click start-up, and smart control.

● Easy maintenance: Customers outside of China can customize the use of the Profinet bus control system, which ensures fast and low-interference signal transmission. As long as there is a communication network in any country or region, remote fault detection, troubleshooting, and maintenance services can be quickly implemented.

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Gemwell Electrical Machinery Co., Ltd.
Founded in 2005, GEMWELL is a professional wire and cable equipment solution provider in design, manufacture and sales for the United States, Canada, Mexico, Germany, Italy, India, Thailand, Russia and etc. more than 40 countries in the world.

The success of customer is our goal to get success!

● Focus on technological innovation, quality stability, precision manufacturing and considerate service.
● Insist on making all in detail well, repay every customer with high quality.
● Take customer's success as the embodiment of our enterprise value.

The enterprise spirit of dedication, dedication, enterprise and exploration encourages us to innovate and transform the technology of wire and cable into advanced productive forces, in order to build GEMWELL into a new name card of China facing to the world.
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