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PLC Control Copper Wire Cable Making Machine
Extrusion Line From GF-65 to GF-200 With Full PLC Control
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Electrical and Electronic Wires Extrusion Line
Fine Gauge Insulation Line With Closed Loop OD Control
Product Overview
What This Product Is
This line insulates and optionally jackets fine-gauge copper and tinned copper conductors for electronic wire, control cable, signal wire and appliance wiring. It runs conductors from 0.12 mm² to 6 mm² at line speeds up to 800 m/min, with OD control accuracy of 0.02 to 0.05 mm when the closed-loop laser gauge is fitted and concentricity error held at 5 percent or better. It can be configured to produce wire to UL, JASO, ISO, VDE, IEC and EN standards.
Machine and Parts
Key Benefits
What It Gives Your Production Line
Speed Where the Wire Is Thin
Up to 800 m/min depending on conductor size, which is where fine-gauge economics are made.
OD Held by Closed Loop Feedback
A laser diameter gauge feeds back to extrusion speed, giving 0.02 to 0.05 mm accuracy on insulation thickness.
Insulation Adhesion Managed Upstream
Induction or infrared conductor preheating improves polymer adhesion and reduces microvoids.
Configurable for International Standards
UL1007, UL1015, UL1569, UL2464, AV, AVSS, FLRY-A/B, H05V-K, H07V-K, H03VV-F and RoHS, REACH and CE production support.
Application Scenarios
Where It Is Used
- Low-voltage electronic wiring
- Internal appliance wiring
- Automotive cable harnesses
- Communication and signal transmission wire
- Control and instrumentation cables
Who It Is For
Who Buys It
- Electronic wire makers supplying appliance and equipment manufacturers
- Automotive harness wire producers
- Plants certifying to UL, VDE or JASO standards
Problems It Solves
The Reasons Buyers Move To This Product
Insulation Thickness Drifts
Manual control wastes compound and fails spec. Closed-loop OD feedback corrects while the line runs.
Pinholes Found by the Customer
A 3 to 15 kV spark tester with discharge alarm catches pinholes and insulation breakdowns in-line.
Poor Adhesion Causes Rejects
Conductor preheating and straightening before the die head deal with the root cause rather than the symptom.
Technical Features
Construction And Materials
- High-speed pay-off with reel sizes Ø400–800 mm, constant or dancer-controlled tension
- Wire straightener removing torsional strain before the die head
- Conductor preheater using induction or infrared heating
- Main extruder with temperature-zoned barrel heating
- Crosshead die, fixed or adjustable, with optional stripe co-extrusion
- Vacuum or water cooling trough, stainless steel, 6–12 m
- Laser diameter gauge with closed-loop feedback (optional but recommended)
- High-frequency spark tester with discharge detection alarm
- Caterpillar capstan with servo-controlled pulling speed
- Automatic take-up or coiler with programmable tension and winding modes
Certifications And Compliance
- Line configurable for RoHS, REACH, UL, VDE or ISO/TS 16949 certified production
Specifications
Published Figures
| Conductor Diameter | 0.12 mm² – 6 mm² |
|---|---|
| Extrusion Materials | PVC, PE, XLPE, SR-PVC, LSZH, TPE, FEP and others |
| Line Speed | Up to 800 m/min depending on conductor size |
| OD Control Accuracy | ±0.02–0.05 mm with closed-loop OD gauge |
| Extruder Sizes | 30 mm, 45 mm, 60 mm, 70 mm, 90 mm screw diameters |
| Screw L/D Ratio | 25:1 or 30:1 |
| Temperature Control Zones | 4–7 heating zones with PID closed-loop control |
| Concentricity Error | ≤ 5% with precision die and OD monitoring |
| Spark Tester | 3–15 kV AC/DC with discharge detection alarm |
| Cooling Trough | Stainless steel, 6–12 m |
| Typical Output Voltage Rating | 300 V, 600 V, 1000 V depending on insulation |
Figures are the published specification for this product. Values outside this table are confirmed in writing before order rather than estimated.
Manufacturing And Quality Control
How It Is Produced And Checked
Machines are assembled and tested against the published model specification before dispatch, and commissioning support plus overseas service engineers are available after installation.
Specification Agreement
Model selected from conductor range and required output before anything is built.
Assembly
Line assembled to the agreed configuration, including instrumentation and control system.
Test Run
Machine tested against the published model specification before dispatch.
Documentation
Model parameters and component list supplied with the machine.
After Sales
Warranty, long-term maintenance and engineers available to service machinery overseas.
Customisation Options
What Can Be Changed
- Co-extrusion head for skin, stripe, double-layer insulation or shielding layer integration
- Inkjet printer for cable specs, logos, meter marking and traceability codes
- Gravimetric dosing system for automatic material feeding and colour masterbatch ratio control
- Closed-loop OD feedback with extrusion speed adjustment
- PLC and HMI full line automation with recipe management, alarm diagnostics and Ethernet or Industry 4.0 support
Use Guide
Working With It On Your Line
- Commission the OD gauge and its feedback loop before production; without it the accuracy figures do not apply.
- Set PID zones per compound and save them as recipes so changeovers are repeatable.
- Verify spark tester voltage against the insulation rating being produced.
- Check concentricity on first-article samples with the precision die installed.
Comparison
How It Compares Within The Range
Electrical and Electronic Wires Extrusion Line sits inside the Machine and Parts range. The products below are the closest alternatives or the parts most often ordered alongside it — compare the published specification tables rather than the descriptions when the choice is close.
Read Next
Applications Solutions And Guides
FAQ
Electrical and Electronic Wires Extrusion Line FAQ
What conductor range does this line handle?
0.12 mm² to 6 mm², covering fine-gauge electronic, automotive and appliance wire.
How fast does it run?
Up to 800 m/min depending on conductor size.
How accurate is the OD control?
±0.02 to 0.05 mm with the closed-loop OD gauge, and concentricity error of 5 percent or better with a precision die.
Which product standards can it be configured for?
UL and CSA wires such as UL1007, UL1015, UL1569 and UL2464, JASO and ISO automotive wires including AV, AVSS and FLRY-A/B, and VDE, IEC and EN wires such as H05V-K, H07V-K and H03VV-F.
Can marking be added in-line?
Yes, an optional inkjet printer applies cable specifications, logos, meter marking or traceability codes in real time.
Request A Quotation For Electrical and Electronic Wires Extrusion Line
Send the construction, grade and quantity you need. We confirm the specification in writing before quoting.