PVC-Coated Steel Wire Rope Extrusion Line

PVC-Coated Steel Wire Rope Extrusion Line

A PVC-coated steel wire rope extrusion production line is a specialized industrial system designed to apply a continuous, uniform, and adherent layer of Polyvinyl Chloride (PVC) onto the surface of a bare steel wire rope. This process transforms the standard wire rope into a durable, versatile, and corrosion-resistant product.
The core principle involves pulling a clean and pre-heated wire rope through a cross-head extrusion die, where molten PVC is applied under pressure. The coated rope is then immediately cooled to solidify the plastic layer, resulting in a finished product that combines the high tensile strength of steel with the protective and functional properties of PVC.
Key Characteristics of the PVC Coating:
Excellent Corrosion Resistance: Protects the underlying steel from rust and degradation caused by moisture, salt water, and many chemicals.
Good Abrasion Resistance: The PVC layer reduces wear from friction with pulleys, drums, and other surfaces, extending service life.
Weather and UV Resistance: Specially formulated PVC compounds can withstand prolonged exposure to sunlight and varying weather conditions.
Electrical Insulation: Provides a non-conductive barrier.
Flexibility and Durability: The coated rope remains flexible and resistant to cracking.
Color and Safety: PVC can be easily colored, allowing for product identification or high-visibility safety applications.
Smooth Surface: Improves handling comfort and prevents dirt buildup.

Key Components

A complete PVC-coated wire rope production line consists of several integrated subsystems:
1. Pay-off System
Function: Holds and feeds the bare steel wire rope from a large spool into the line.
Key Feature: Equipped with a tension control device (e.g., magnetic powder brake) to ensure steady, controlled pay-off without slack or over-tightening.
2. Pre-treatment System
Function: Prepares the wire rope surface for optimal PVC adhesion.
Components:
Cleaning Unit: Uses brushes and/or air blowers to remove dust, oil, and rust.
Pre-heater: Heats the wire rope (typically to 80-150°C) using induction or electrical resistance heating. This removes moisture and raises the surface temperature, promoting a stronger bond with the PVC melt.
3. Extrusion System
Function: The heart of the line, where the PVC coating is applied.
Components:
Extruder: Consists of a motor-driven screw inside a heated barrel. It feeds, melts, compresses, and homogenizes PVC compound, then delivers the molten PVC at a consistent pressure and rate.
Extrusion Die (Cross-head): The molten PVC is directed around the moving wire rope inside this precision-machined die, forming a continuous, concentric coating layer.
4. Cooling System
Function: Solidifies the molten PVC coating quickly and uniformly.
Component: A multi-stage cooling water tank.
Process: Often uses progressive cooling (e.g., mist spray, then warm water, then cold water) to prevent internal stresses, voids, or deformation in the PVC layer.
5. Pulling System
Function: Provides the primary driving force to pull the wire rope through the entire production line at a constant speed.
Component: A synchronized dual-caterpillar haul-off unit.
Critical Requirement: Speed must be perfectly synchronized with the extruder's output and the take-up system to maintain consistent coating thickness.
6. Take-up System
Function: Winds the finished PVC-coated wire rope onto a spool for storage and shipment.
Component: A motorized take-up stand with a traversing mechanism.
Key Feature: Provides controlled winding tension to ensure a tight, even, and organized coil.
7. Control System
Function: The operational brain of the production line.
Components: PLC (Programmable Logic Controller), HMI (Human-Machine Interface/Touchscreen), temperature controllers, and drives.
Role: Integrates and automates all components, allowing for precise control and monitoring of temperatures, speeds, and tensions.

PVC-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

PVC-Coated Steel Wire Rope Extrusion Line Application

PVC-coated steel wire ropes are widely used across various industries due to their protective qualities and longevity.
Marine & Offshore:
Ship mooring lines
Fishing net headlines and purse lines
Aquaculture cage mooring and grid lines
Dock and harbor fender lines
Construction & Architecture:
Barrier and guardrail cables
Curtain wall support systems
Cable for construction elevators and gondolas
Sports & Leisure:
Tennis and badminton racket strings (core)
Yacht rigging and control lines
Zip line cables
Suspension bridge cables in parks
Industrial & Agricultural:
Control cables and push-pull wires
Reinforcing core for utility cables
Greenhouse support wires and bracing
Conveyor belt reinforcement
Consumer Goods:
Clotheslines
Pet leashes and tie-outs