Polyester Elastomer-Coated Steel Wire Rope Extrusion Line

Polyester Elastomer-Coated Steel Wire Rope Extrusion Line

A polyester elastomer-coated steel wire rope extrusion production line is a specialized automated equipment used for uniformly and continuously coating the surface of a steel wire rope with a layer of polyester elastomer (such as TPEE) polymer material. This production line combines the steel wire rope with high-performance polyester elastomer through processes such as melt extrusion, precision coating, cooling shaping, and winding. It endows the product with excellent resistance to bending fatigue, wear resistance, weather resistance, oil resistance, and high elasticity, while protecting the internal steel wire rope from corrosion, wear, and impact.
This coated steel wire rope combines the high strength of the steel wire rope with the flexibility and protective properties of the polyester elastomer. It is widely used in high-end machinery, automotive, aerospace, and other fields as transmission, traction, or load-bearing components.

Equipment Composition

This production line is an integrated system, mainly composed of the following major parts:
Unwinding System
Function: Used to carry and release the steel wire rope to be coated.
Features: Typically equipped with a tension control system (such as a magnetic powder brake or servo tension control) to ensure constant, stable, and smooth tension of the steel wire rope as it enters the extruder head, preventing jittering or slack, which is crucial for ensuring coating uniformity.
Pre-heating System
Function: Preheats the steel wire rope before coating.
Purpose: Removes moisture from the surface of the steel wire rope and increases its surface temperature, enabling better adhesion between the molten polyester elastomer and the steel wire rope surface, reducing internal stress, and improving bond strength.
Plastic Extruder
Function: The core of the entire production line, responsible for plasticizing, melting, and stably extruding the polyester elastomer (TPEE) pellet raw material.
Key Components:
Barrel and Screw: Specially designed for the processing characteristics of TPEE (such as its narrow processing temperature range and susceptibility to hydrolysis), often using high-efficiency mixing screws.
Heating and Cooling System: Precisely controls the temperature of each zone to ensure uniform melting of the material without degradation.
Drive Motor: Provides stable torque to ensure stable extrusion pressure.
Extrusion Die and Head
Function: This is the core component for the coating formation. The molten TPEE passes through the head, forming a uniform coating layer around the steel wire rope.
Types: Typically uses a "crosshead" or "right-angle" coating die to ensure the material uniformly wraps the steel wire rope 360 degrees without dead angles. The flow channel and die design are crucial, directly determining the coating thickness, concentricity, and surface quality.
Cooling and Sizing System
Function: Rapidly cools and solidifies the freshly extruded, molten coating from the die, shaping it into the final product.
Method: Typically uses a multi-stage cooling water tank with adjustable water temperature. Gradual cooling avoids excessive internal stress, deformation, or surface defects caused by rapid quenching.
Haul-off/Puller System
Function: Provides stable forward power for the production line, clamping and pulling the coated steel wire rope at a constant speed.
Features: Usually uses a caterpillar or wheel-type haul-off unit, synchronized with the tension control of the unwinding system to ensure stable and synchronized line speed. This is key to ensuring consistent product dimensions.
Take-up System
Function: Winds the finished product onto spools or coils for storage and transportation.
Features: Equipped with a traversing mechanism for neat winding; uses torque motors or servo motor control to achieve constant tension or taper tension winding, preventing product deformation.
Control System
Function: Integrates PLC (Programmable Logic Controller) and a touchscreen HMI (Human-Machine Interface) for centralized monitoring and precise control of parameters such as temperature, speed, and tension across the entire production line.
Advanced Features: Can be equipped with an online diameter gauge for real-time monitoring and feedback control of the coating outer diameter; includes fault diagnosis, data recording, and other functions.

Polyester Elastomer-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

Polyester Elastomer-Coated Steel Wire Rope Extrusion Line Application

The polyester elastomer-coated steel wire rope manufactured by this production line is widely used in the following fields due to its excellent comprehensive performance:
Automotive Industry:
Window Regulators: Used as lifting cables, offering smooth operation, low noise, and long service life.
Throttle Control: Used as control cables, transmitting precise displacement.
Parking Brakes: Used as handbrake cables, offering corrosion resistance and good feel.
Mechanical Transmission and Control Systems:
Used in push-pull flexible shafts, manipulator control cables, etc., in various industrial equipment to achieve flexible power transmission.
Furniture and Home Furnishings:
Lifting cables in high-end office chairs and sofas, ensuring smooth and durable adjustment.
Sports Equipment and Outdoor Products:
Bicycle brake cables, shift cables, and other flexible transmission components requiring high strength and fatigue resistance.
Other Precision Fields:
Any application scenario that requires transmitting rigid push/pull force through a curved path and demands high reliability, long service life, and good protection is a potential application area.