H05V-K Electronic Wire Extrusion Line

H05V-K Electronic Wire Extrusion Line

H05V-K is a very common, harmonized European standard polyvinyl chloride (PVC) insulated flexible wire. Known for its good flexibility, wide applicability, and economical price, it has become a standard choice for internal wiring in equipment, household appliances, low-voltage control cabinets, and other fields.

Meaning Analysis

H: Stands for "Harmonized Standard". This indicates that the wire complies with the unified CENELEC (European Committee for Electrotechnical Standardization) standards of the European Union, ensuring its consistency and recognition within the European Economic Area.
05: Represents the rated voltage grade. 05 indicates a voltage grade of 300/500V. Specifically:
300V refers to the rated voltage between the wire and ground.
500V refers to the rated voltage between the conductors of the wire.
V: Indicates that the insulation material is Polyvinyl Chloride (PVC).
K: Denotes that the conductor type is a finely stranded copper conductor. This is a key point; the "K" signifies the flexibility of the conductor. It is much more flexible than standard solid conductors (denoted by "U") or more coarsely stranded conductors, making it highly suitable for applications requiring bending or movement.

H05V-K Electronic Wire Extrusion Line

An H05V-K electronic wire extrusion production line is a dedicated automated complete set of equipment for manufacturing H05V-K type flexible wires. Its core process is "extrusion," which involves melting PVC plastic at high temperatures and uniformly and densely coating it onto a continuously moving copper conductor to form an insulation layer. This is followed by cooling, detection, printing, and other processes, ultimately winding the finished wire onto reels. The core task of the production line is to efficiently and stably produce H05V-K electronic wires that meet the requirements of standards such as VDE, IEC, and GB/T, ensuring that conductor resistance, insulation thickness, outer diameter, voltage withstand performance, flexibility, and markings all meet specified standards.

Main Components

A standard H05V-K extrusion production line consists of the following equipment arranged in sequence according to the process flow:
Pay-off Unit
Function: To carry and release the copper conductor (finely stranded copper wires).
Types:
Passive Pay-off: Relies on the pulling force from downstream equipment; simple structure, used for low-speed or low-demand production.
Active Pay-off: Equipped with a motor and tension control system, capable of maintaining constant pay-off tension. It is standard for high-speed, high-quality production lines and prevents conductor stretching or breaking.
Preheater
Function: To appropriately heat the conductor before it enters the extruder head.
Purposes:
Remove Moisture: Eliminate moisture on the conductor surface.
Improve Adhesion: Reduce the temperature difference between the conductor and the hot PVC plastic, enhancing the bonding force between the insulation layer and the conductor, preventing insulation shrinkage or blistering.
Improve Quality: Achieve more uniform cooling inside and outside the insulation layer, reducing internal stress.
Extruder
Function: To melt, plasticize, compact, and continuously extrude PVC insulation compound granules.
Key Components:
Screw: The core component. Designed for the thermal sensitivity of PVC, typically a gradual compression screw, performing feeding, compression, melting, and metering functions.
Barrel: Houses the screw, externally equipped with heating bands and cooling fans for precise control of processing temperature.
Drive System: Provides stable rotational speed for the screw.
Die Head and Tooling (Mold): Determine the forming quality of the insulation layer. The cooperation between the tip and die causes the molten PVC to form a ring shape, uniformly coating the conductor.
Cooling Trough
Function: To rapidly cool and set the wire coated with high-temperature insulation.
Characteristic: Typically segmented (long trough), with water temperature controllable in zones (e.g., warm water first, then cold water) to achieve "gradual cooling," avoiding excessive internal stress, surface roughness, or embrittlement of the insulation layer caused by rapid cooling.
Spark Tester
Function: Online, 100% inspection of the integrity of the insulation layer. The wire passes through a high-voltage electric field. If there are pinholes, thin spots, or other defects in the insulation, it will be broken down by the high voltage, generating a spark, and the equipment will immediately alarm or stop.
Importance: Ensures every inch of the wire has good electrical insulation performance, constituting a safety bottom line.
Diameter Monitoring and Control System
Function: Uses laser or ultrasound for non-contact real-time measurement of the wire's outer diameter.
Working Principle: Compares the measured value with the set value. If there is a deviation, it automatically sends feedback signals to the capstan or extruder to fine-tune the speed, ensuring the outer diameter remains constant within the tolerance range, saving material and ensuring stable quality.
Printing Device
Function: To continuously and clearly print permanent markings on the insulation surface, such as type (H05V-K), specification, certification number, manufacturer name, etc. This is a mandatory standard requirement.
Types: Commonly used types include hot embossing printing (type wheel) and inkjet printers.
Capstan (Puller)
Function: To provide stable pulling force, pulling the entire line synchronously. Its speed must be precisely matched with the extruder's output.
Type: The mainstream type is the caterpillar capstan, which holds the wire steadily without damage via rubber tracks.
Take-up Unit
Function: To wind the finished wire neatly and tightly onto a reel.
Type: Modern production lines generally use active take-up, equipped with PID tension control systems and traversers to ensure neat winding, suitable for high-speed production. Gantry-type take-ups are common.
Control System
Function: Integrates PLC (Programmable Logic Controller) and Touch Screen (HMI) to centrally control parameters like temperature, speed, and tension for the entire line, enabling automated production, data recording, and fault diagnosis.

H05V-K 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

H05V-K Electronic Wire Extrusion Line Application

The H05V-K electronic wire extrusion production line is a specialized equipment system with mature technology, high degree of automation, and strict quality control. The application of this production line is very specific and extensive, as follows:
Main products: PVC insulated flexible wires specifically designed for the production of H05V-K (300/500V) and H07V-K (450/750V) series. By changing the mold and adjusting the process, other single core wires with similar structures can also be produced.
Target industry: Serve all wire and cable manufacturing enterprises. The H05V-K wires produced are widely used in:
Mechanical equipment: Power distribution and control wiring inside CNC machine tools and automation equipment.
Household appliances: Internal power and control cables for washing machines, refrigerators, air conditioners, etc.
Low voltage distribution cabinet: Control circuit, signal line, indicator light connection line.
Electronic devices: Internal wiring for speakers, power adapters, etc.
Capacity and specifications: The production line can adapt to different production needs according to configuration (such as extrusion machine screw diameter, host power), and efficiently produce various specifications of electronic wires.