Zip Line Steel Cable Extrusion Line

Zip Line Steel Cable Extrusion Line

The zip line steel cable extrusion production line is a technology-intensive, high-end composite production line specifically designed for manufacturing sheathed steel cables dedicated to zip line applications. Its core lies in applying a wear-resistant, weather-resistant polymer sheath (typically high-density PE, nylon, or specially modified PVC) over an ultra-high-strength galvanized steel cable core through a precision extrusion process.
This "sheath-core structure" product combines the absolute strength of the steel cable with the protective function of the polymer sheath, aiming to meet the extreme demands of zip line equipment for life safety, durability, and reliability. The production line seamlessly integrates processes such as steel cable pay-off, polymer melting and extrusion, concentric coating, cooling, setting, and take-up to achieve fully automated continuous production.

Main Components of the Production Line

Compared to ordinary coating lines, this line has extremely stringent requirements for synchronization control accuracy, tension control, and coating quality.
Steel Cable Pay-off and Pre-treatment System
Function: To carry and feed heavy, large-diameter steel cable cores, and to clean and preheat them.
Pay-off: Uses high-tonnage active pay-off stands to ensure constant tension, no jitter, and prevent cable twisting.
Pre-treatment: Includes cleaning (removing oil, moisture) and preheating, aimed at thoroughly improving the adhesive interface between the steel cable and the polymer, preventing the risk of "debonding" during use.
Composition:
Large-capacity Active Pay-off Stand: Equipped with a precision servo tension control system.
Cleaning Device and Preheating Oven: Ensures the steel cable surface is clean and reaches the optimal bonding temperature.
High-Performance Extrusion System
Function: To melt and plasticize engineering plastic pellets and uniformly, concentrically coat the high-speed moving steel cable through a dedicated die.
Composition:
High-Power Extruder: Ensures stable melting and conveying of high molecular weight materials.
Precision Crosshead Coating Die: The core and technical key of the production line. Its flow channel design must ensure the melt converges evenly from all sides, precisely wrapping the steel cable in the center position, achieving perfect concentricity and ensuring uniform circumferential coating thickness.
Precision Cooling and Sizing System
Function: To gradually and uniformly cool and solidify the high-temperature coated cable, and precisely control its final outer diameter.
Composition:
Multi-stage Cooling Water Trough: Can be tens of meters long, implementing gradient cooling (e.g., hot water - warm water - cold water) to eliminate internal stress and avoid shrinkage voids, deformation, or residual stress in the coating.
Vacuum Sizing Tank: During the initial cooling stage, uses vacuum suction to tightly adhere the molten coating to the sizing sleeve, thereby precisely controlling the outer diameter size and roundness.
High-Torque Haul-off System
Function: To provide powerful, smooth, and precisely synchronized pulling force for the entire line, moving the heavy steel cable through the whole production line. Speed stability is crucial for ensuring consistent coating thickness.
Composition: Ultra-heavy-duty multi-caterpillar haul-off machine, providing immense clamping force and traction torque, absolutely preventing slippage.
Large-Capacity Take-up System
Function: To wind the finished zip line cable, which can be thousands of meters long, orderly onto extra-large spools.
Composition:
Adjustable Spool Diameter Take-up Machine: Adapts to spools of different capacities.
PID Tension Control: Ensures the winding process tension is linearly adjustable, resulting in neat and tight coils.
Fully Automated Integrated Control System
Function: The "nerve center" of the production line. Achieves millisecond-level synchronous control of all main units and monitors the entire process parameters.
Composition:
Multi-PLC Network and Industrial Touchscreen: Centrally controls all process parameters.
Laser Diameter Gauge: Monitors the coating outer diameter online in real-time and provides feedback to control extrusion or haul-off speed.
Synchronous Servo Drives: Ensure the speeds of the four main hosts—pay-off, extrusion, haul-off, and take-up—are strictly matched. This is the fundamental guarantee for achieving uniform coating thickness over kilometer-long lengths.

Zip Line Steel Cable 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

Zip Line Steel Cable Extrusion Line Application

The zip line steel cable extrusion production line is high-end manufacturing equipment integrating mechanical engineering, polymer materials science, and automation control technology. What it produces is not just a cable, but a safety line, a lifeline concerning lives. The products output from this line are the core safety components of zip line projects, and their performance is directly related to life and property safety.
Main Load-Bearing Zip Line Cable
Application: Serves as the primary load-bearing track for passengers or cargo gliding in zip line projects.
Requirements:
Extremely high breaking force: The core steel cable must have a very high safety factor (typically >5:1 or even higher).
Exceptional fatigue resistance: Able to withstand countless cycles of rolling and bending from the trolley.
Top-level weather resistance: The sheath must long-term resist UV, ozone, rain, snow, and extreme temperature differences, without cracking or powdering.
Excellent wear resistance: The sheath effectively resists abrasion from the trolley, protecting the internal steel cable from damage.
Emergency Safety Backup Cable
Application: In dual-cable systems, serves as the backup safety rope in case the main cable fails.
Requirements: Possesses safety performance and durability equal to the main cable, ensuring absolute redundant safety for the system.
Forestry and Special Transport Zip Lines
Application: Used in industrial fields such as forestry yarding and mountain material transport.
Requirements: While meeting basic safety requirements, greater emphasis is placed on the cut resistance and chemical corrosion resistance of the coating.