PE-Coated Steel Wire Rope Extrusion Line

PE-Coated Steel Wire Rope Extrusion Line

The PE-coated steel wire rope extrusion production line is a specialized automated complete set of equipment used to continuously and uniformly coat a layer of polyethylene (PE) plastic sheath onto the surface of bare steel wire rope. Its core process utilizes a plastic extruder to tightly coat molten PE material onto the steel wire rope moving at a constant speed. After cooling and setting, the final PE-coated steel wire rope product is formed.
Compared to PVC coating, the PE (especially High-Density Polyethylene HDPE) coating layer offers unique performance advantages:
Excellent Chemical Corrosion Resistance: Offers exceptional resistance to chemicals such as acids, alkalis, and salts, making it particularly suitable for harsh chemical environments.
Outstanding Wear Resistance: The wear resistance of PE is generally superior to PVC, making it especially suitable for frequently abraded applications.
Low Coefficient of Friction: The smooth surface reduces resistance when the wire rope passes through pulleys.
Excellent Low-Temperature Resistance: Maintains good flexibility in low-temperature environments and is less prone to embrittlement.
Higher Strength and Environmental Stress Crack Resistance: Offers better mechanical strength and a longer service life.
Seawater Corrosion Resistance: An ideal choice for marine applications.

Production Line Composition

A complete PE-coated steel wire rope extrusion production line primarily consists of the following seven systems working together:
Pay-off System
Core Equipment: Pay-off stand.
Function: Supports and releases the bare steel wire rope from the carrier reel.
Key Requirement: Provides stable and adjustable pay-off tension (typically using a torque motor or magnetic particle brake) to ensure the wire rope enters the extruder head straight and stable.
Pre-treatment System
Core Equipment: Cleaning device, Pre-heater.
Function:
Cleaning: Removes oil, moisture, and dust from the steel wire rope surface.
Pre-heating: Uses medium-frequency induction heating or electric heating tubes to heat the steel wire rope to a suitable temperature (typically 100-160°C).
Importance: Removes moisture and enhances the bonding strength between the PE melt and the steel wire rope, preventing bubbles or debonding in the coating layer.
Extrusion System
Core Equipment: Plastic extruder, Extrusion die (Head).
Function: Melts and plasticizes PE plastic pellets, then extrudes and uniformly coats them onto the steel wire rope surface.
Extruder: Composed of a screw, barrel, heating bands, and drive system. The screw structure needs specialized design considering the properties of PE.
Head (Die): This is the technical key. The steel wire rope passes through the center, and the molten PE forms a coating layer around it inside the head. The precision design of the die directly determines the thickness uniformity and concentricity of the coating layer.
Cooling and Setting System
Core Equipment: Cooling water tank.
Function: Rapidly cools and solidifies the high-temperature PE coating layer, setting it into the final product.
Process: Employs staged cooling (e.g., initial spray cooling followed by water bath) to avoid internal stress caused by rapid quenching, which could lead to PE layer deformation or cracking.
Pulling System
Core Equipment: Puller (typically a dual-caterpillar type).
Function: Provides continuous and stable pulling force for the entire production line, drawing the steel wire rope forward at a constant speed.
Key Requirement: The pulling speed must be strictly synchronized with the extrusion speed, pay-off, and take-up speeds. This is crucial for ensuring uniform thickness of the PE coating layer.
Take-up System
Core Equipment: Take-up stand.
Function: Winds the finished PE-coated steel wire rope neatly and tightly onto a carrier reel.
Type: Usually an active take-up, equipped with a traverser to achieve automatic, neat winding and maintain constant winding tension.
Electrical Control System
Core Equipment: PLC, Touchscreen (HMI), Temperature control modules, Frequency converters, etc.
Function: The "brain" of the entire production line. Centrally controls parameters such as temperature, speed, and tension for all sections, enabling automated production and monitoring.

PE-Coated Steel Wire Rope Extrusion Line Datasheet

Model	30	40	50	60	70	80	90
Screw Diameter (mm)	φ30	φ40	φ50	φ60	φ70	φ80	φ90
Screw L/D Ratio	25:1	25:1	26:1	26:1	26:1	26:1	26:1
Extrusion Amount (kg/hr)	25	40	70	100	140	200	250
Outlet Wire (mm)	0.2-1	0.4-3	0.8-5	1-8	2-15	3-25	5-35
Total Power (KW)	18	20	25	33	40	55	63
Traction Power (KW)	2.2	2.2	4	4	4	5.5	5.5
Production Speed (m/min (Max.))	600	600	600	500	500	300	300
Take-up Spool (mm)	φ200-400	φ300-500	φ400-630	φ400-630	φ500-630	φ800-1000	φ1000-1250

PE-Coated Steel Wire Rope Extrusion Line Application

The PE-coated steel wire rope extrusion production line is a technology-intensive continuous production system specifically designed for manufacturing high-performance PE-coated steel wire ropes. Its products combine the high strength of steel wire rope with the excellent chemical corrosion resistance and wear resistance of polyethylene, playing an irreplaceable role in marine, fisheries, mining, and various harsh industrial environments. It is the preferred solution for modern applications involving heavy corrosion and high wear conditions.
PE-coated steel wire ropes are widely used in the following fields due to their exceptional corrosion resistance, wear resistance, and low-temperature performance:
Marine Engineering and Shipping
Mooring ropes: Used for ship mooring at ports and offshore platforms.
Marine aquaculture: Fixed cables and main ropes for aquaculture nets.
Towing and traction ropes: Resistant to seawater corrosion with a long service life.
Fishing Industry
Fishing net main ropes: Main ropes for large fishing nets such as trawls and purse seines, offering high strength, seawater resistance, and extreme wear resistance.
Construction Engineering and Mining
Mining cables: Used for mine hoisting and transportation, offering corrosion and wear resistance.
Construction cables: Cables for construction elevators used in corrosive environments (e.g., mines, coastal construction sites).
Industrial and Agricultural Fields
Industrial conveyor belt skeleton material: Provides high strength and wear resistance.
Agricultural greenhouse tie-down cables: Weather-resistant with a long service life.
Underwater facilities: Trash barriers, positioning cables, etc., in lakes and rivers.
Special Environment Applications
Chemical industrial parks: Used for lifting and traction, resistant to chemical corrosion.
Low-temperature environments: Various cables used in cold regions, maintaining good flexibility.