AVR Electronic Wire Extrusion Line

AVR Electronic Wire Extrusion Line

AVR is a Chinese standard PVC insulated installation flexible wire. Its core feature is the use of multiple strands of fine twisted copper wire as a conductor, making it very soft. It is mainly used for low-voltage connection wires inside electronic and electrical equipment, similar to the "H05V-K" or "H07V-K" wires in international standards, but following China's own standard system.
Meaning Analysis
A: Represents' installation line '. This indicates that wires are mainly used for electrical installation inside equipment and appliances, rather than for large-scale power transmission in the power system.
V: The representative insulation material is polyvinyl chloride (PVC).
R: The representative conductor is a soft conductor, which is composed of multiple strands of thin copper wire twisted together. This is the fundamental difference between it and "hard wire" (usually represented by "BV", where the conductor is a single or multiple strands of thick hard copper wire).

AVR Electronic Wire Extrusion Line

AVR Electronic Wire Extrusion Production Line is a set of automated equipment specifically used for producing the AVR series of PVC-insulated installation flexible wires. Its core process is "extrusion," where molten PVC plastic is uniformly coated onto a continuously moving ultra-fine stranded copper conductor via an extruder to form an insulation layer. The wire then undergoes cooling, detection, winding, and other processes to become the final product.

Core Components

A precision AVR electronic wire extrusion production line mainly consists of the following equipment arranged in process order:
Pay-off Device
Function: To carry and release the ultra-fine stranded copper conductor. This is the critical starting point of production.
Special Requirement: Must use a high-precision active pay-off device equipped with an extremely sensitive tension control system. Due to the extreme fineness of the conductor, any minor tension fluctuation can cause the conductor to be stretched thin or even break.
Preheater
Function: To precisely preheat the ultra-fine conductor.
Purpose: To remove moisture from the conductor surface and reduce the temperature difference with the hot PVC, which is crucial for ensuring the adhesion and surface smoothness of the ultra-thin insulation layer.
Extruder
Function: To melt, plasticize, and continuously extrude PVC pellets.
Key Characteristics:
Miniaturization: Typically uses small-diameter screws to adapt to the production of small-diameter wires with low extrusion volume, ensuring uniform plasticization and precise temperature control.
High-Precision Temperature Control: The temperature control for each zone of the barrel must be very precise and stable due to the thermal sensitivity of PVC.
Precision Mold: The matching accuracy of the tip and die must be extremely high to ensure uniform micron-level insulation thickness and good concentricity.
Cooling Trough
Function: To rapidly and uniformly cool and set the fine wire coated with the insulation layer.
Characteristic: Utilizes segmented warm water cooling to avoid excessive internal stress or deformation of the insulation layer caused by rapid cooling.
Spark Tester
Function: 100% online detection of the insulation layer's integrity. Even for such fine wires, high voltage must be applied to detect defects like pinholes or thin spots, ensuring safety.
Diameter Monitoring and Control System
Function: Uses laser to monitor the wire's outer diameter in real-time.
Importance: Due to the fine wire diameter and thin insulation layer, a tiny deviation in the outer diameter signifies a significant proportional change in insulation thickness. This instrument can automatically provide feedback for adjustment, ensuring product consistency.
Printing Device
Function: To continuously and clearly print markings on the fine insulation layer surface.
Type: Typically uses high-precision hot embossing or micro inkjet printers to ensure the markings are clear and wear-resistant.
Haul-off Machine
Function: To provide extremely smooth pulling force, synchronously moving the entire line.
Type: Uses dual-wheel belt-type haul-off machines or miniature caterpillar haul-off machines, which provide uniform and gentle gripping force without crushing the fine wires.
Take-up Device
Function: To wind the finished fine wire neatly and tightly onto small reels.
Special Requirement: Must use active take-up equipped with precise PID tension control and a traverse system, ensuring constant winding tension and neat winding, adapting to high-speed production.
Control System
Function: The "brain" of the production line. Integrates PLC and a touch screen to centrally control all parameters, enabling automated production and allowing quick response to subtle process fluctuations.

AVR Electronic Wire 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

AVR Electronic Wire Extrusion Line Application

The AVR electronic wire extrusion production line is a set of high-precision and high stability specialized equipment. It focuses on producing ultra-fine and flexible installation wires for internal connections of electronic appliances. The specific applications are as follows:
Main products: Chinese standard PVC insulated installation flexible wires specifically designed for the production of AVR and AVR-105 (high temperature resistance of 105 ° C) series.
Target industry: Serving wire and cable manufacturing enterprises, especially manufacturers specializing in fine small wires. The AVR wires produced are widely used in:
Household appliances: computer board connection wires, sensor wires, indicator light wires inside washing machines, air conditioners, refrigerators, etc.
Electronic devices: Low voltage wiring and signal lines inside speakers, televisions, computer motherboards, and power adapters.
Office equipment: Fine connections inside printers and copiers.
Automotive electronics: Internal connections in low-voltage areas such as in car entertainment systems and instrument panels (specific standards should be noted).
Security equipment: Connection wires inside the camera.
Technical features: This production line represents the manufacturing level in the field of fine small wires, and its requirements for tension control, temperature control, mold accuracy, and operational stability are more stringent than those for producing ordinary power cords.