Fitness Equipment Steel Wire Pulling Rope Extrusion Line

Fitness Equipment Steel Wire Pulling Rope Extrusion Line

The fitness equipment steel wire pulling rope extrusion production line is a highly specialized composite production line used for manufacturing pulling ropes with a "sheath-core structure". Its core lies in tightly coating the exterior of a high-strength steel wire rope core (providing tensile strength and durability) with a layer of polymer material (usually TPE, PVC, or rubber, providing feel, color, and protection). This product combines the strength of steel wire with the flexibility and aesthetics of the polymer, and is widely used in high-end fitness equipment.
The production line integrates processes such as steel wire rope pay-off, polymer melting and extrusion, coating, cooling, setting, and take-up through precise synchronous control to achieve continuous automated production.

Main Components

Compared to ordinary elastic rope production lines, this line adds a system for handling the steel wire rope core, requiring higher technical specifications.
Steel Wire Rope Pay-off and Preheating System
Function: Stores and steadily feeds the steel wire rope core, and preheats it.
Pay-off: Must ensure constant tension to prevent the steel wire rope from slipping, twisting, or accumulating.
Preheating: Heating the steel wire rope helps remove surface moisture and enhances the adhesive strength between the rope and the molten polymer, preventing later debonding.
Composition:
Active Pay-off Stand: Equipped with a tension control system.
Preheating Device: Typically uses electric heating tubes or a hot air box.
Extrusion System
Function: Melts and plasticizes plastic or rubber pellets, and uniformly coats the moving steel wire rope core through a special die.
Composition:
Extruder: Same as in ordinary production lines, responsible for plasticizing the raw material.
Special Coating Die: This is the core key of the production line. Typically uses a crosshead, where the material flow direction is 90 degrees to the steel wire rope travel direction, ensuring the melt evenly wraps the steel wire rope from all sides without gaps or core deviation.
Cooling and Setting System
Function: Rapidly cools the high-temperature product after coating, solidifying the outer plastic/rubber layer and setting it into the final product.
Composition:
Multi-stage Cooling Water Tank: Usually divided into several sections with adjustable water temperatures for gradual cooling, avoiding internal stresses and surface defects caused by rapid cooling.
Sizing Sleeve: Ensures precise and consistent outer diameter of the product during the initial cooling stage.
Haul-off System
Function: Provides smooth and powerful pulling force to drag the entire steel wire rope and its coating through the entire production line. The haul-off speed must be strictly synchronized with the extrusion speed and pay-off speed.
Composition: Heavy-duty caterpillar haul-off machine with strong clamping force to prevent slipping.
Take-up System
Function: Winds the finished product into coils.
Composition:
Spool Take-up Machine: Used for long-length winding.
Tension Control System: Ensures tight and neat winding.
Electrical and Control System
Function: The "brain" of the production line. Requires higher precision synchronous control.
Composition:
PLC and Touch Screen: Integratively control pay-off tension, extruder speed, haul-off speed, take-up tension, etc.
Synchronization Controller: Ensures the precise matching of the speed ratios of the four main units: pay-off, extrusion, haul-off, and take-up. This is key to ensuring uniform coating thickness.

Fitness Equipment Steel Wire Pulling 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

Fitness Equipment Steel Wire Pulling Rope Extrusion Line Application

The products produced by this line are mainly used in fitness equipment that demands extremely high safety, durability, and smoothness.
High-end Power Rack Pulling Ropes
Application: Used as the weight stack cables for cable crossover machines, lat pulldown machines, rowing machines, etc.
Requirements:
Very low elongation rate: Ensures direct and accurate force transmission.
Ultra-long service life: The steel wire rope core withstands repeated stretching and pulley friction, while the outer coating prevents rust, wear, and reduces noise.
Smooth feel: The coating allows the rope to run quietly and smoothly through the pulleys.
Special Ropes for Heavy-duty Pulling Machines and Rowers
Application: Used for high-load pulling training equipment.
Requirements:
Extremely high breaking strength: The core steel wire rope must withstand huge pulling forces to ensure safety.
Wear-resistant surface: The coating needs to have good wear resistance to cope with long-term friction against pulleys and guide channels.
Other Special Applications
Adjustable Dumbbells: The internal lifting systems of some high-end adjustable dumbbells use this type of coated steel wire rope.
Physical Therapy Equipment: Some rehabilitation equipment also requires such high-strength, durable pulling ropes.