YJLLW02 EHV Power Cable Extrusion Line

YJLLW02 EHV Power Cable Extrusion Line

YJLLW02 is a power cable mainly used in the field of ultra-high voltage transmission.
Meaning of Letters:
YJ: Insulation is cross-linked polyethylene (XLPE)
L: The metal sheath is made of aluminum
L: The type of metal sheath is Welded and Corrugated - note: the repeated use of L here to represent "aluminum" and "wrinkles" is a specific rule for Chinese models.
W: Non magnetic (W often represents this meaning in some standards, but in this model, it is more essential to combine with the later 02)
0: Code
2: The outer sheath is made of polyvinyl chloride (PVC)
Structural Analysis:
Conductor: Copper or aluminum conductor, usually a segmented conductor structure with a large cross-section to reduce skin and proximity effects.
Conductor shielding: extruded semiconducting layer.
Insulation: The ultra pure cross-linked polyethylene (XLPE) insulation layer is the core of the cable and can withstand extremely high electric field strength.
Insulation shielding: extruded semiconducting layer.
Water blocking tape: Usually wrapped around an insulation shield to achieve longitudinal water blocking.
Metal sheath: Wrinkled aluminum sheath. This is the key to this model, made using argon arc welding technology, providing excellent radial waterproof barriers and mechanical protection (pressure resistance, impact resistance).
Inner lining layer: Optional, protective metal sleeve.
Armor: Typically, non-magnetic metal strips (such as stainless steel strips) or non-magnetic metal wires (such as stainless steel wires) are used for armor. This is the important meaning of the "02" section, which provides strong mechanical protection and can avoid eddy current losses in single core cables.
Outer sheath: Polyvinyl chloride (PVC) sheath, providing anti-corrosion, weather resistance, and ultimate protection.
Main Features:
Ultra high voltage level: Designed specifically for voltage levels of 110kV, 220kV, and even 500kV.
Excellent radial waterproofing: The wrinkled aluminum sleeve is a completely impermeable barrier, ensuring that the insulation system is not affected by moisture.
Powerful mechanical protection: The structure of aluminum sleeve and non-magnetic armor enables it to withstand extreme mechanical pressure, extrusion force, and tension, making it suitable for harsh installation environments.
No eddy current loss: Non magnetic armor ensures that it will not overheat due to hysteresis and eddy currents during operation in AC systems, ensuring current carrying capacity.
Suitable for complex laying methods: Can be directly buried or laid in tunnels or pipelines, especially suitable for situations that require significant external forces.

YJLLW02 EHV Power Cable Extrusion Line

The YJLLW02 EHV cable extrusion production line is a special equipment used for manufacturing the core part of high-voltage and extra-high-voltage power cables (usually referring to voltage levels of 110kV and above). Its core process involves extruding and coating specific functional plastic or rubber layers onto the conductor (copper or aluminum) layer by layer, forming the insulation and shielding layers of the cable, thereby ensuring the cable can withstand extremely high electric field strength and operate safely and stably. This production line is a technology-intensive system with extremely high precision requirements, representing the highest level in the wire and cable manufacturing industry.

Core Components

The complete YJLLW02 EHV  cable extrusion production line typically consists of the following major systems:
Pay-off System
Function: To smoothly release the conductor (such as copper core) and maintain constant tension.
Features: Usually equipped with dual pay-off stands (one active, one standby) to enable continuous production without stopping. It includes a precision tension control system to prevent the conductor from being stretched or damaged.
Preheating System
Function: To heat the conductor before it enters the extruder head.
Purpose: To remove moisture from the conductor surface and bring the conductor temperature close to that of the molten plastic, reducing the temperature difference between the inner and outer layers, preventing inner layer cracking due to thermal stress, and improving the adhesion between the plastic and the conductor.
Extrusion System
This is the core part, typically adopting the "two ore more layers co-extrusion" mode, where two or more extruders work simultaneously to extrude different materials into a common head, forming two or more layers in one step.
Cooling System
Function: To gradually and slowly cool down the cable after cross-linking is completed.
Features: Segmented cooling is adopted, with water temperature precisely controlled from high to low. Rapid cooling can cause internal stress and microvoids in the insulation layer, affecting the cable's lifespan, so slow cooling is essential.
Pulling System
Function: To provide power for the entire production line, pulling the cable forward at a constant or synchronized speed.
Features: Dual pulling (e.g., belt-type puller + drum-type puller) or multi-stage pulling is used to provide strong pulling force and maintain extremely stable speed. Any speed fluctuation can cause uneven insulation layer thickness.
Take-up System
Function: To neatly wind the finished cable onto large cable reels.
Features: Take-up tension must be precisely controlled, and winding must be neat and tight. It is usually equipped with an online diameter measuring instrument and a spark tester (for medium and low-voltage sheaths) for online quality inspection.
Central Control System
Function: The "brain" of the production line. Integrated with PLC and industrial computers, it monitors, records, and performs closed-loop control of hundreds of parameters throughout the production process (such as temperature zones, extruder speed, pulling speed, pressure, nitrogen flow, cooling water temperature, etc.).

YJLLW02 EHV Power Cable Extrusion Line Datasheet

Model	200+120
Screw Diameter (mm)	φ200+φ120
Screw L/D Ratio	25:1
Extrusion Amount (kg/hr)	φ200: ≤1000 kg/h, φ120: ≤500 kg/h
Inlet Wire (mm)	55-160
Outlet Wire (mm)	70-180
Traction (N)	≤32000
Production Speed(Max., m/min)	30
Pay-off Spool (mm)	φ2000-φ4200
Take-up Spool (mm)	φ2000-φ4200

Core Components List

Ø200~Ø4200 Rail-mounted Motorized Pay-off Stand	2 sets
3200kg Auxiliary Caterpillar Puller	1 set
Asphalt Coating Unit	1 set
Ø200 Extruder	1 set
Ø120 Extruder	1 set
Dual-layer Extrusion Head and Cart	2 sets
Extrusion Head Vacuum Unit	1 set
Mobile Water Trough and Hot Water Tank	1 set
Stainless Steel Cooling Trough	1 set
Cable Air Wiping / Drying Unit	1 set
Length Counter / Meter Counter	1 set
3200kg Main Caterpillar Puller / Haul-off	1 set
Graphite Coating Unit	1 set
Ø200~Ø4200 Rail-mounted Motorized Take-up Stand	2 sets
Spark Tester	1 set
Electrical Synchronous Control System	1 set

YJLLW02 EHV Power Cable Extrusion Line Application

YJLLW02 cable is used in the most critical ultra-high voltage power transmission scenarios due to its ultra-high mechanical strength and reliable waterproof performance
Urban underground transmission backbone network: as the core ring network or important transmission line of the city.
Incoming and outgoing lines of power stations and substations: connecting generators, transformers, and the power grid.
Large scale cross river and cross sea bridge transmission projects require cables to withstand mechanical tension and vibration.
Tunnels, direct burial, and other situations that require significant mechanical external forces, such as burial under highways and railways.
The transmission lines of renewable energy power plants (such as large wind farms and photovoltaic bases).

YJLLW02 EHV Power Cable Extrusion Line

The YJLLW02 EHV cable extrusion production line is a complex system engineering that integrates mechanical, electrical, material, thermodynamic, and automatic control technologies. The core of its technology lies in the "two or more layers co extrusion". Through ultra clean environment and extremely precise control system, it ensures that the produced cable insulation layer has the characteristics of no impurities, no micropores, high uniformity, and perfect interface, thus meeting the safe operation requirements of the power grid for high reliability and long life. This production line is mainly used for the following occasions:
1. Used for manufacturing cross-linked polyethylene insulated (XLPE) power cables with voltage levels of 110kV, 220kV, 500kV and above.
2. The cable core used to manufacture submarine high-voltage cables.
3. Used to produce high-voltage special cables for special purposes.