1. Project Background & Requirements

The Armenian client, METAL WORLD LLC, required an insulation solution for their drawn copper wires. The project demanded equipment capable of processing multiple insulation materials while ensuring uniform thickness at high line speeds.

• Applicable Wire Diameter: 1.36mm - 3.48mm.

• Finished Outer Diameter: 2.5mm - 5.5mm and 1.2mm - 3.3mm.

• Processed Materials: Soft PVC, PE, Low-Smoke Halogen-Free (LSZH) materials, etc.

• Production Efficiency: Design line speed up to 400 m/min.

2. Technical Support & Parameterized Evidence

To ensure the consistency of the extrusion process, the unit integrates the following core technologies:

• High-Volume Extrusion: The main extruder (70 unit) achieves a maximum extrusion volume of 180 KG/H for soft PVC, ensuring material supply stability during high-speed operation.

• Precision Control System: Features Siemens PLC and frequency converters, paired with a Kunlun Tongtai touchscreen HMI. The system includes a reserved Ethernet interface for host computer communication.

• Multi-Stage Temperature Control: Equipped with WINPOUND temperature controllers for independent zone control of the barrel and head. It includes alarms for temperature runaway and linked fan cooling to prevent material degradation.

• Automated Auxiliary Units: Includes 500/630 active pay-off, dual-wheel tension stands, and a vacuum drying/suction system. The take-up unit supports dual-spool (φ500mm-φ630mm) automatic operation for continuous production.

• Smart Monitoring: An integrated smart meter allows real-time display of power consumption, current, and voltage on the touchscreen, facilitating precise cost analysis.

3. Equipment Composition & Specifications

The 45-meter production line consists of:

• Core Extrusion Units: WDL-70 main extruder and WDL-35 vertical co-extruder for color stripping.

• Cooling & Detection: A 3.5m constant temperature water trough and a 20m telescopic cooling trough.

• Drive & Power: Main unit powered by Innomotics motor.

• Electrical Components: Major low-voltage switches and contactors are supplied by Chint, ensuring reliable performance and high energy efficiency.