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Extrusion Line for Lifting and Hoisting Wire Ropes

Extrusion Line for Lifting and Hoisting Wire Ropes

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  • Model 30-90
  • Screw Diameter φ30-90 mm
  • L/D Ratio 26:1/25:1
  • Extrusion Output 25-250 kg/h
  • Main Motor 18-63 KW
  • Outlet Diameter 0.2-35 mm
  • Speed 10-600 m/min
  • Application Extrusion line for lifting and hoisting wire ropes
  • Extrusion Line for Lifting and Hoisting Wire Ropes

    An extrusion production line for lifting and hoisting wire ropes is specialized automated equipment used to produce wire ropes coated with plastics (such as PVC, PE, PU, etc.). This production line works by melting plastic at high temperatures and continuously extruding it to form a uniform coating over a pre-treated wire rope core. The coated rope is then cooled and shaped into the final product.
    Core Purpose and Product Features:
    Core Purpose: To add a sturdy, wear-resistant, and corrosion-resistant plastic protective layer to bare wire ropes.
    Product Features:
    Corrosion Resistance: Effectively isolates moisture, chemicals, and salt spray, significantly extending the service life of the wire rope in harsh environments.
    Abrasion Resistance: The plastic layer reduces friction and wear between the wire rope and sheaves, drums, or other wire ropes.
    Identification: Different colored plastics can be used to color-code the wire ropes according to specification, load capacity, or usage area, enhancing safety.
    Reduced Stress Concentration: The flexible plastic coating helps create a smooth surface, reducing stress concentration points.
    Safer Handling: The smoother surface is less prone to producing burrs, making it easier and safer for operators to grip and handle.
    This coated wire rope is widely used in lifting, hoisting, and material handling applications where high safety and durability are critical.

    Line Composition

    A complete wire rope extrusion production line is a continuous, automated system integrating pay-off, preheating, extrusion, cooling, pulling, and take-up. Its main components are as follows:
    1. Pay-off Unit
    Function: Supports and unwinds the spool of bare, uncoated wire rope.
    Type: Typically uses active or passive pay-off systems equipped with tension control to ensure constant, stable tension as the wire rope enters the line, preventing over-tightening or slack.
    2. Pre-heating System
    Function: Heats the wire rope before it enters the extrusion die.
    Purpose:
    Removes moisture from the wire rope surface.
    Raises the core temperature of the wire rope, allowing the molten plastic to adhere and plasticize better upon contact, enhancing the bond strength (adhesion) between the coating and the wire rope, and preventing delamination during later use.
    3. Plastic Extruder
    Function: The "heart" of the production line. It heats and melts plastic pellets (e.g., PVC) into a uniform viscous fluid and conveys it to the die via a screw.
    Key Components:
    Hopper: Stores and feeds plastic pellets.
    Barrel and Screw: Melt, mix, and homogenize the plastic pellets through electrical heating and shear heat generated by the rotating screw.
    Temperature Control System: Precisely controls the temperature in different zones of the barrel to ensure proper plasticization of the plastic.
    4. Extrusion Die
    Function: The "forming organ" of the production line. Mounted on the front of the extruder, it shapes the molten plastic into a uniform, concentric coating around the moving wire rope.
    Type: Typically uses a "crosshead" or "right-angle" die, ensuring the wire rope passes through the center and plastic envelops it evenly from all sides.
    5. Cooling Trough
    Function: Rapidly cools and sets the freshly extruded, hot molten plastic coating on the wire rope.
    Form: One or multiple tandem troughs filled with circulating cooling water.
    Purpose: Gradual cooling prevents internal stresses, sink marks, or deformation in the plastic layer caused by rapid quenching, ensuring a round, dimensionally stable coating.
    6. Puller
    Function: The "power source" of the production line. It provides stable, adjustable pulling force, gripping and drawing the coated wire rope at a constant speed through the entire line.
    Characteristics: Usually employs a caterpillar or wheel-type structure with variable speed control. Its speed directly determines the line speed and the outer diameter of the product.
    7. Take-up Unit
    Function: Winds the finished coated wire rope neatly and tightly onto a reel or spool.
    Type: Can be active or passive take-up. Modern lines are often equipped with a traverser that moves automatically side-to-side to ensure neat winding. It also includes tension control to guarantee winding quality.
    8. Control System
    Function: The "brain" of the production line. Typically uses a PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface).
    Control Content: Integrally controls the start/stop of the entire line, speed coordination, zone temperatures, tension, length measurement, etc., enabling automated production, parameter storage, and fault diagnosis.

    Extrusion Line for Lifting and Hoisting Wire Ropes 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

    Extrusion Line for Lifting and Hoisting Wire Ropes Application

    Coated steel wire ropes produced by extrusion lines are widely used in the following lifting and hoisting fields due to their excellent properties:
    1. Port Machinery and Shipping
    Application Scenarios: Quay cranes, yard cranes, gantry cranes, shipboard cranes, etc.
    Advantages: The coating effectively resists corrosion in the high-salt, high-humidity marine environment, significantly extending wire rope replacement cycles, reducing maintenance costs, and ensuring operational safety.
    2. Construction Tower Cranes
    Application Scenarios: Hoist ropes and luffing ropes for tower cranes.
    Advantages: Good abrasion resistance reduces wear against sheaves; bright colors facilitate inspection and identification; capable of withstanding outdoor exposure to sun and rain.
    3. Mining and Metallurgical Industries
    Application Scenarios: Mine hoists, metallurgical cranes, etc.
    Advantages: Strong wear and corrosion resistance, capable of withstanding harsh working conditions (e.g., dust, moisture, chemicals).
    4. Engineering Machinery Equipment
    Application Scenarios: Mobile cranes such as truck cranes, mobile cranes, crawler cranes, etc.
    Advantages: Enhances wire rope durability, reduces equipment maintenance frequency, and ensures reliability in mobile operations.
    5. Other Industrial Fields
    Application Scenarios: Elevators (certain types), cableways, large amusement park rides, fishing, etc.
    Advantages: Provides safe, durable, low-maintenance lifting and traction solutions.
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