YJLV62 Power Cable Extrusion Line

YJLV62 Power Cable Extrusion Line

YJLV62 is a cross-linked polyethylene insulated power cable with non-magnetic armor, aluminum core, and polyvinyl chloride outer sheath.
Name Resolution:
YJ: Cross linked polyethylene (XLPE) insulation. Excellent electrical and heat resistance performance, with a long-term allowable working temperature of 90 ℃.
L: Aluminum conductor. This is the core difference from YJV62, where the conductor material is aluminum instead of copper.
V: Polyvinyl chloride (PVC) inner sheath (or lining).
6: The first "6" represents non-magnetic metal strip (usually stainless steel strip) or non-magnetic metal wire armor. This is the most critical feature of this model.
2: The second "2" represents a polyvinyl chloride (PVC) outer sheath.
Key Features:
Non magnetic armor: Using stainless steel tape or wire as the armor layer avoids eddy current losses in AC power systems, which can cause cable heating and energy loss. This is the fundamental difference between it and YJV22 (steel belt armor).
Aluminum conductor: The conductor is made of aluminum material, which makes the overall weight of the cable lighter and the cost lower. But the conductivity of aluminum is about 61% of that of copper, and a larger cross-sectional area of the conductor is required to transmit the same current. The mechanical properties (such as tensile strength and ductility) are also inferior to copper.
High mechanical protection: The armor layer provides excellent compressive and impact resistance.
Corrosion resistance: The PVC outer sheath provides excellent resistance to chemical corrosion and environmental erosion.
Main Purpose:
Mainly used in AC single circuit transmission systems that require avoiding eddy current losses caused by magnetic armor, especially in high current and single core cable laying scenarios.
The outgoing lines of power stations and substations.
High voltage and ultra-high voltage transmission systems.
In situations where direct burial, pipe laying, and potential mechanical external threats are required.
Projects that have high requirements for cable weight and cost, and can meet the current carrying capacity requirements of aluminum conductors.

YJLV62 Power Cable Extrusion Line

The YJLV62 medium-voltage power cable extrusion production line is a complete set of equipment specifically designed for manufacturing the core components of medium-voltage power cables rated at 3.6/6 kV to 26/35 kV. This production line applies molten plastic to the conductor in a high-temperature, high-pressure, and continuous manner, ensuring uniform coating. Subsequent cross-linking processes endow the cable with excellent electrical, thermal, and mechanical properties. Given that the products are used in medium- and high-voltage applications, the requirements for the purity, uniformity, and defect-free nature of the insulation layer are extremely high. As a result, medium-voltage production lines are technologically more complex, require higher precision, and involve greater investment compared to low-voltage production lines.

Main Components

The YJLV62 medium-voltage powder cable extrusion line primarily consists of the following components, arranged according to the process flow:
Pay-Off Device
Function: Supports and feeds copper or aluminum conductors. Provides stable and adjustable tension control to prevent thinning or抖动 of the conductor.
Types: Active pay-off (powered) or passive pay-off (unpowered, controlled by braking).
Conductor Pre-Heater
Function: Heats the conductor to a certain temperature (e.g., above 90°C) before extrusion.
Purpose:
Removes moisture from the conductor surface to prevent bubble formation ("microvoids") during extrusion.
Reduces the temperature difference between the conductor and the molten insulation material, minimizing internal stress and improving interfacial bonding quality.
Two or More Layers Co-Extrusion System
This is the technological core of the medium-voltage production line, typically consisting of two or more extruders and a shared die head.
Online Detection and Control System
Laser Diameter Gauge: Monitors the insulation outer diameter in real-time without contact and feeds data back to the control system to automatically adjust the extruder or traction speed, ensuring minimal thickness tolerance.
Eccentricity Gauge: Ensures the insulation layer is uniformly coated on the conductor without core shift.
Spark Tester: Detects defects such as pinholes or breaks in the insulation layer online (applicable only to cores with an outer shield, which must be grounded).
Industrial Computer/PLC: The "brain" of the entire production line, centrally controlling parameters such as temperature, speed, tension, and pressure for all equipment.
Traction Device
Function: Provides the driving force for the production line, pulling the cable forward at a constant or programmable speed. Requires extremely stable speed without vibrating.
Types: Caterpillar haul-off or dual-wheel capstan.
Take-Up Device
Function: Winds the cooled and set finished insulated core neatly onto large reels.
Requirements: Synchronized with the traction speed, constant and adjustable tension, and neat winding.

YJLV62 Power Cable Extrusion Line Datasheet

Model	120+100	200+120
Screw Diameter (mm)	φ120+φ100	φ200+φ120
Screw L/D Ratio	25:1	25:1
Extrusion Amount (kg/hr)	φ120: ≤450 kg/h, φ100: ≤320 kg/h	φ200: ≤1000 kg/h, φ120: ≤500 kg/h
Inlet Wire (mm)	/	55-160
Outlet Wire (mm)	10-80	70-180
Traction (N)	/	≤32000
Production Speed(Max., m/min)	80	30
Pay-off Spool (mm)	φ1000-φ2500	φ2000-φ4200
Take-up Spool (mm)	φ1000-φ2500	φ2000-φ4200

Core Components List

Rail-mounted Motorized Pay-off Stand	2 sets
Auxiliary Caterpillar Puller	1 set
Asphalt Coating Unit	1 set
Ø200 Extruder / Ø120 Extruder	1 set
Ø120 Extruder / Ø100 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
Main Caterpillar Puller / Haul-off	1 set
Graphite Coating Unit	1 set
Rail-mounted Motorized Take-up Stand	2 sets
Spark Tester	1 set
Electrical Synchronous Control System	1 set

YJLV62 Power Cable Extrusion Line Application

YJLV62 cable is a type of cross-linked polyethylene insulated power cable with non-magnetic armor, aluminum core, and polyvinyl chloride (PVC) outer sheath. It is primarily used in the following scenarios:
Power Transmission and Distribution Systems
Power plants and substation lead-out lines: Transmitting electricity from generator outlets or the low-voltage side of transformers to the distribution network. Its non-magnetic armor characteristic is crucial here.
Urban power grids and regional distribution: Serving as main or branch lines for voltage levels of 35kV and below, used for long-distance transmission and distribution of electrical energy.
Power supply trunk lines for large industrial parks: Delivering high-voltage electricity to various factories or facilities within the park. The cost advantage of aluminum conductors is particularly significant in scenarios requiring large quantities of cables.
Single-Core Cable Installation Scenarios
Single-circuit AC system installation: When single-core cables are used to transmit alternating current, magnetic materials (such as ordinary steel tape) for armor can form a closed magnetic circuit, generating significant eddy currents. This may cause severe cable heating, surging energy consumption, or even burnout.
Projects with Strict Requirements for Cable Weight and Cost
Large infrastructure projects: Such as subways, railways, airports, and ports, where cable usage is extensive. YJLV62 can significantly reduce engineering material and transportation costs.
Long-distance power transmission projects: The lighter weight of aluminum cables makes transportation and installation (especially traction installation in mountainous or challenging terrains) more convenient and economical.
Budget-constrained projects: Where YJLV62 serves as an economical alternative to more expensive copper-core cables (e.g., YJV62), provided current-carrying capacity and voltage drop requirements are met.
Environments with Mechanical External Forces or Pressure for Direct Burial
Direct burial in soil: The armor layer can resist soil pressure and potential impacts from sharp stones, protecting the insulated cable core from damage.
Anti-termite and anti-rodent biting: The stainless steel tape armor layer effectively prevents damage from rodent or termite bites.
Occasions with Certain Corrosion Resistance Requirements
Humid environments: Such as tunnels or cable trenches, where the PVC outer sheath provides excellent moisture resistance and chemical corrosion protection.
Mildly chemically polluted areas: Capable of resisting corrosion from certain levels of acids, alkalis, salts, and other chemical substances.

YJLV62 Power Cable Extrusion Line

The YJLV62 medium-voltage extrusion line is specifically used to manufacture the core parts (insulated wire cores) of the following products:
Power transmission and distribution: Producing various medium voltage levels (such as 8.7/10kV, 8.7/15kV, 26/35kV) of transmission and distribution cables is the "main artery" of urban power grids, industrial parks, and large building power supply systems.
Specific industry requirements:
Flame retardant/fire-resistant cables: By using special materials such as halogen-free low smoke flame-retardant polyolefins, safe cables are produced for use in densely populated areas such as subways, airports, and shopping malls.
Waterproof cable: Produce longitudinal waterproof cables with a metal waterproof layer for use in rainy, humid areas or direct burial.
Mining cables: Produce mining armored cables with high mechanical strength and wear resistance.
Subsequent deep processing: The insulated wire cores produced from the CV line will also be sent to a cable forming machine for twisting (such as three core cable), and then extruded with inner sheath, armor layer (such as steel strip, steel wire) and outer sheath on the sheath line, ultimately forming a complete structure of the cable.