Wire and cable extrusion machine works
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October 11 07:12:07, 2025
The compaction process for round stranded conductors involves three vertical pressing stages and four horizontal pressing stages. In this process, 80% of the pressing force is applied during the main compaction, while the remaining 20% is distributed across four rounding rollers that help shape the conductor into a more uniform form. Compared to non-compacted conductors, compacted ones can reduce the outer diameter by 2% to 17%, significantly improving the fill factor—from 75% in non-compacted versions up to 90% to 93% in compacted ones. For sector-shaped stranded conductors with cross-sectional areas between 25–50 mm², only one vertical pressing is required. However, for conductors of 70 mm² and above, a three-layer stranding and pressing method is typically used. In mining cables, the process includes vertical, horizontal, and vertical pressing in sequence, achieving a compaction level of about 85%. The second stage focuses on shaping both sides, while the third stage ensures a fully formed structure, resulting in a fill factor of 90% to 93% for compacted fan-shaped conductors.
**Comparison Between Pressed Conductors and Non-Compacted Conductors:**
- **Process Characteristics:** Pressed conductors offer improved efficiency, reduced material consumption, and a more stable structural integrity.
- **Electric Field Strength:** A pressed conductor provides a more uniform electric field distribution, which enhances performance and reduces electrical stress.
- **Flexibility:** There may be a slight reduction in flexibility compared to non-pressed conductors, especially in mining communication cables.
- **Material Usage:** The amount of structural material is reduced, with plastic cables saving approximately 8% in material usage due to better compaction.
**Extrusion Process Overview:**
An extruder operates by using a specially designed screw inside a heated rotating barrel. Raw plastic pellets are fed into the hopper, where they are gradually melted and uniformly plasticized through the action of the screw. This molten material is then forced through a die, which shapes it into the desired profile. The extrusion process consists of three main stages:
1. **Plasticization Stage (Compression Stage):** This occurs within the barrel as the screw rotates, transforming solid granules into a viscous, melt-like state.
2. **Forming Stage:** Located at the machine head, the viscous material is pushed forward by the screw’s rotation and pressure, passing through the die to take on its final shape. The die itself does not reshape the material but rather forms it.
3. **Setting Stage:** After exiting the die, the material enters a cooling tank, where it solidifies into its final, rigid form.
This process ensures consistent quality, efficient production, and precise control over the final product's dimensions and properties.