This MV CCV line is typically designed for triple extrusion of XLPE insulated medium voltage
cables for use at voltages ranging from 6kV to 35kV. By absorbing world's advanced catenary
continuous vulcanization (CCV) technology, Baicheng Miracle has developed and manufactured this
three-layer extrusion dry cure cross-linking line in-house, which was the first in the domestic
market.
Our independently developed three-layer crosshead has obtained national patent, due to its
great convenience and ease of alignment. Furthermore, the patented control technology in catenary
line is characterized by high resistance against interference, ensuring an exceptional stability.
Medium voltage cables manufactured by this extrusion line are supplied in diverse sizes,
diameters, lengths, layer thickness and other technical specifications. Depending on applications,
the produced XLPE insulated power cables can be laid directly in the ground or buried in
underground ducts, also suitable for submerged under water and working on overhead transmission
systems.
Features
Triple extrusion process for XLPE insulated cables of voltages up to 35kV;
Capable of manufacturing power cables used for a variety of applications;
Computer control, touch screen operation, Siemens TIA Portal software, and high-resolution HMI
interface;
Triple crosshead provides great convenience and ease of alignment;
Customer-specific modified versions are available, which deviate from the standard version in
speed adjustment by control of CV tube temperature;
Φ80 extruder for conductor screen Φ175 extruder for cross-linked
polyethylene (XIPE) Φ100 extruder for insulation screen
Electricity
Installation capacity 1050kVA
380V ±10% 50Hz±1%
3 phase 4 wire
Water
Water pressure 0.2-0.6MPa
Water consumption 15m3/h (circulating water from reservoir)
Compressed air
0.6-0.8MPa
Air consumption 0.8m3/min
Nitrogen
Pressure 2.0-2.5MPa
Purity 99.5%
Consumption 1-2m3/h
Nitrogen storage tank
≥6m3 (1 pc)×2
Extruder & Crosshead
Extruder
Three-layer Crosshead
Triple extrusion lines have three extruders connected to one common three-layer crosshead for the
simultaneous extrusion of conductor screen layer, insulation layer and insulation screen layer.
Technical Data of Extruders
65/20D Extruder
Max. screw speed: 46.5rpm
Gear reduction ratio: 32:1
Extrusion output: 35kg/h
Used for extruding conductor screen layer (inner semiconductor layer)
90/20D Extruder
Max. screw speed: 41.5rpm
Gear reduction ratio: 36:1
Extrusion output: 60kg/h
Used for extruding insulation screen layer (outer semiconductor layer)
150/25D Extruder
Max. screw speed: 40rpm
Gear reduction ratio: 37.5:1
Extrusion output: 250kg/h
Used for extruding insulation layer
Technical Data of Three-layer Crosshead
Technical Parameters
Conductor diameter: 6-34mm
Max. cable diameter: 70mm
Extrusion thickness:
First layer: 0.5-2.0mm
Second layer: 2.0-12mm
Third layer: 0.5-2.0mm
Heating method: oil or water heating
Features
Designed with circulating distribution flow channel and restrictor ring, the length of
flow distributors and crosshead is greatly shortened in contrast to other three-layer
crosshead, thus reducing its weight;
Easy to disassemble for convenient cleaning;
Providing great convenience and ease of alignment during extrusion process;
Control System
Highly resistant to interference, minimum fluctuation of cables in tube, ensuring stable
running and easy to
maintain;
Control system is placed at the middle part of heating zone, it can protect cables from
contacting the tube wall
during heating process;
When the control receives the signal of cable position, the rotation speed of lower
capstan (pulling) will be
adjusted accordantly;
Details
Portal Upper Beam Travelling Pay-Off Stand
Features
Gantry structure with mechatronic design, achieving reciprocating motion while keeping the alignment of center line when paying off;
Shaftless pay-off reel moves up and down between two posts, driven by AC motor;
Dancer is adopted for speed control;
Pay-off stand can achieve rotation in both positive and negative directions;
Touch screen allows operator to input technical parameters easily and conveniently;
The pay-off stand is independently controlled;
Specifications
Drum diameter: 1600-2500mm (GB4004-84, PN Type)
Drum width: 1180-1900mm
Drum weight: Max.16t
Pay off tension: 5000N
Main drive: 5.5kW DC motor, 4 quadrant, Parker 590P (original Eurotherm)
Dancer: used for speed control, keeping the cable aligned with center line when paying off
Used for pulling cable conductors from lower level to desired height;
Belt wrap capstan (or caterpillar capstan) operates synchronously in CCV line;
Conductor positioning unit ensures the cable conductors of different sizes placed in alignment with the center of the crosshead;
Transmission unit adopts fixed base, spiral bevel gear reducer and DC motor;
Specifications
Pulling method: belt wrap capstan
Capstan wheel diameter: 2000mm
Adjusting range: 0-30m/min (four gear shifts)
Pulling force: max. 30kN
Belt contact length: 3m or above
Cable diameter: up to 100mm
Speed sensor equipped with line speed meter
Main drive: 11kW DC motor, Parker 590P drive
Belt-type Twister with Angle Adjustment
Specifications
Twister weight: 650kg
Overall dimensions: 1525mm×975mm×1243mm
26 grooved passive wheels are mounted on both sides. The distance between wheel sets on both sides is adjustable ranging from 2 to 200mm. The wheel sets move on both sides.
The rollers on both sides can be adjusted by ±50mm, which is calibrated by the caliper. Max. wire diameter passing through is 70mm.
The center height is 1m. (If the height is not consistent with the outlet of end seal, cut off the footing to change the center height.)
The twister comes with a welded machine body, a passive transmission mechanism, and a semi-enclosed stainless steel cover.
It’s installed between the end seal and pull-out capstan.
Extruder
Three-layer Crosshead
