YJLV Power Cable Extrusion Line

YJLV Power Cable Extrusion Line

YJLV Cable Full Name: Aluminum Core XLPE Insulated PVC Sheathed Power Cable. YJLV is a very common and economical power cable in electrical systems.
Letter Meanings:
YJ: Represents the cable's insulation material, which is cross-linked polyethylene (XLPE).
L: Represents the cable's conductor material, which is aluminum.
V: Represents the cable's sheath material, which is polyvinyl chloride (PVC).
Operating Temperature:
Long-term allowable operating temperature: ≤90°C (same as YJV, thanks to XLPE insulation).
Short-circuit temperature (max. 5s duration): ≤250°C.
Main Characteristics:
Advantages:
Low cost: The price of aluminum conductors is much lower than that of copper conductors, giving YJLV cables a significant advantage in initial procurement costs. They are the preferred choice for large projects aiming to reduce costs.
Light weight: The density of aluminum is about 30% that of copper, making the overall cable lighter, which facilitates transportation and installation.
Good performance: Inherits all the advantages of XLPE insulation, such as good heat resistance (90°C), excellent electrical performance, and high mechanical strength.
Disadvantages:
Poor conductivity: The resistivity of aluminum is about 1.68 times higher than that of copper. This means that for transmitting the same current, YJLV requires a larger conductor cross-section than YJV.
Lower mechanical strength: Aluminum has lower mechanical strength than copper. Poor crimping at joints or exposure to severe vibration can easily lead to increased contact resistance and heating issues, requiring higher installation craftsmanship.
Prone to oxidation: Aluminum surfaces easily oxidize, forming a resistive oxide film. If special terminals (such as tin-plated copper-aluminum transition terminals) and treatment processes are not used, this can easily cause poor contact.
Contains halogens: Like YJV, the PVC sheath releases black smoke and toxic gases when burned.

YJLV Power Cable Extrusion Line

The YJLV low-voltage power cable extrusion production line is a complete set of equipment specifically designed for manufacturing insulated cores and protective sheaths of power cables rated at 0.6/1 kV and below. Its core process involves melting solid plastics (such as PVC or XLPE) through heating and pressurization, then continuously and uniformly coating conductors (copper/aluminum wires) or assembled cable cores. After cooling and solidification, a smooth, dense, and uniformly thick insulating layer or protective sheath is formed.

Core Components

The YJLV power cable extrusion production line is a highly coordinated automated system, primarily consisting of the following major components:
Pay-off Unit:
Supports and releases the conductor or cable core, providing stable and controllable tension to prevent thinning or twisting of the conductor.
Preheater:
Heats the conductor before it enters the die head to remove moisture, reduce internal stress, and improve adhesion between the plastic and the conductor.
Extruder:
Screw: Conveys, compacts, melts, and homogenizes the plastic.
Barrel: Heats and cools the plastic.
Drive Motor: Provides power to the screw.
Die Head: Connects the extruder to the die.
Die (Tip and Die): Determines the thickness, concentricity, and shape of the extruded layer.
Cooling Trough:
Rapidly cools and solidifies the high-temperature cable. Typically features segmented temperature control to ensure material stability and avoid internal stress.
Haul-off Unit:
Provides the driving force for the production line. Its speed must be extremely stable, as it is critical for ensuring uniform extrusion thickness.
Spark Tester:
An online quality inspection device that applies high voltage to the insulating layer to detect defects such as pinholes or impurities, triggering alarms and marking the locations.
Take-up Unit:
Winds the finished cable neatly onto a reel, maintaining constant tension and synchronizing with the haul-off speed.
Control System:
Uses a PLC / industrial computer to centrally control all parameters (temperature, speed, tension, etc.), ensuring stable and reproducible production.

YJLV Power Cable Extrusion Line Datasheet

Model	70	80	90	100	120
Screw Diameter (mm)	φ70	φ80	φ90	φ100	φ120
Screw L/D Ratio	26:1	26:1	26:1	25:1	25:1
Extrusion Amount (kg/hr)	140	200	250	320	450
Outlet Wire (mm)	2-15	3-25	5-35	8-60	10-80
Total Power (KW)	40	55	63	120	165
Production Speed(Max., m/min)	300	200	200	100	80
Take-up Spool	500/800	800/1250	800/1600	1000/2000	2000/2500
Storage Length	240 m	200 m	180 m	0	0

YJLV Power Cable Extrusion Line Application

The YJLV low-voltage power cable extrusion production line is a complete set of equipment specifically designed for producing YJLV cables & other insulation cores and sheaths of power cables with rated voltage of 0.6/1kV and below. The details are as follows:

Conductor Insulation

Function: Extrudes insulating material onto copper or aluminum conductors to form the primary insulation layer.
Common Materials: Cross-linked polyethylene (XLPE), polyethylene (PE), polyvinyl chloride (PVC), etc.
Requirements: Uniform thickness, high concentricity, absence of impurities, and no microvoids. The insulation extrusion process for high-voltage cables demands the highest technical precision.

Sheathing Extrusion

Function: Extrudes a protective sheath over the assembled cable core.
Purpose: Provides mechanical protection, corrosion resistance, moisture resistance, UV resistance, flame retardancy, etc.
Common Materials: Polyvinyl chloride (PVC), polyethylene (PE), polyolefins, etc.