SATA Data Cable Extrusion Line

SATA Data Cable Extrusion Line

SATA data cables are data transmission cables used to connect computer motherboards to storage devices (such as HDDs, SSDs, and optical drives). They represent the next-generation standard that replaced the older PATA (Parallel ATA) cables.

Main Features

Point-to-Point Connection: Each SATA port can connect to only one device. This eliminates the complexity of configuring master/slave drives required with older PATA cables and removes the performance bottleneck of multiple devices sharing a single cable.
Higher Transfer Speeds: SATA technology has undergone multiple iterations, with speeds far exceeding PATA (max 133 MB/s). The latest SATA Revision 3.0 (i.e., SATA 6Gb/s) offers a theoretical bandwidth of up to 600 MB/s.
Smaller Physical Size: SATA cables are very thin, with a width of only about 1 cm. This design improves internal chassis airflow, aids cooling, and enables cleaner, tidier cable management.
Hot-Swapping Support: The SATA standard supports hot-swapping (which may need to be enabled in the motherboard BIOS), allowing users to connect or disconnect devices while the computer is running, enhancing convenience.
Longer Connection Distance: SATA cables can be up to 1 meter in length, whereas PATA cables were typically limited to 45 cm. This provides greater flexibility for device layout within the chassis.
L-Shaped Right-Angle Connectors: Many SATA data cables feature L-shaped right-angle connectors on one or both ends. This allows the cable to sit closer to the device, saving space, which is particularly beneficial in compact chassis environments.

SATA Data Cable Extrusion Line

SATA Data Cable Extrusion Production Line is an automated, high-precision production system used for manufacturing the core part of SATA data cables—the internal differential signal wires. Its core process is "extrusion," which involves uniformly coating the conductor copper wire with molten insulating plastic at high temperatures to form precise core wires with specific electrical characteristics. Because SATA is a high-speed serial data transmission protocol, the cables have extremely high requirements for characteristic impedance (typically 100Ω ±10%), attenuation, and signal integrity. Therefore, compared to ordinary power cable production, the SATA cable extrusion line demands stricter precision, stability, and cleanliness.

Core Components

A complete SATA data cable extrusion production line consists of the following systems in the order of the process flow:
Pay-off System
Function: Smoothly releases multiple strands of very fine tinned or bare copper wires as conductors.
Requirements: Must use active tension control to ensure the tension of each copper wire strand is constant and minimal. Uneven tension will cause wire diameter fluctuations, seriously affecting final impedance control.
Preheating System
Function: Precisely heats the copper wires before they enter the extruder head.
Purpose: Removes surface moisture and brings the copper wire temperature close to the molten plastic temperature, reducing internal stress in the insulation layer and significantly improving the adhesion and concentricity between the plastic and the conductor.
Extruder System - Core Unit
a. Extruder:
Composition: Includes the drive motor, precision screw, barrel, and heating and cooling systems.
Function: Heats and melts solid insulating plastic pellets into a uniform fluid.
Requirements: The screw design must be suitable for the specific material. Temperature control accuracy must be within ±1°C to ensure proper plasticization and absence of bubbles.
b. Die Head and Mold:
Die Head: The key area where the molten plastic and conductor copper wires meet.
Mold: Includes the tip and die. Their precise coordination determines the thickness and concentricity of the insulation layer. High concentricity is key to ensuring stable impedance.
Cooling System
Function: Rapidly cools and sets the core wires coated with molten plastic.
Form: Uses a segmented cooling water tank where water temperature can be controlled in zones. Gradual cooling is crucial for preventing crystallization of the insulating material and reducing internal stress.
Online Diameter Gauge
Function: Uses laser principles to monitor the outer diameter of the core wire in real-time, thousands of times per second.
Purpose: Instantly feeds the measurement data back to the control system to achieve closed-loop control, ensuring wire diameter fluctuations are controlled at the micron level, thereby precisely managing the characteristic impedance.
Spark Tester
Function: Applies high voltage to the cooled core wires.
Purpose: Detects defects in the insulation layer such as pinholes or scratches, ensuring the insulation integrity of the product. It automatically alarms or stops upon detecting defects.
Capstan / Puller
Function: Provides smooth and constant pulling force to draw the core wires through the entire production line.
Requirements: The speed must be strictly synchronized with the extruder's output speed. Any lack of synchronization will cause uneven wire diameter or breakage. Dual-wheel capstans are often used to prevent slipping.
Take-up System
Function: Neatly winds the finished core wires onto spools.
Requirements: Take-up tension must be smooth, and winding must be even to avoid damaging the precision core wires.
Central Control System
Function: Integrates PLC and touchscreen to centrally monitor and adjust all parameters (temperature, speed, tension, etc.), enabling production automation, data recording, and fault diagnosis.

SATA Data 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

SATA Data Cable Extrusion Line Application

The SATA data cable extrusion production line is a technology-intensive, precision manufacturing system. Its core value lies in producing insulated core wires with highly consistent electrical parameters through high-precision control of mechanics, temperature, and tension. It is primarily used to produce various types of data cables. Details are as follows:
Main Products
SATA data cable inner cores: Produces the multiple independent insulated core wires inside a SATA cable. These cores subsequently undergo a twisting process, where two cores are twisted together at a specific pitch to form a differential pair, resisting electromagnetic interference.
Other high-speed data cable inner cores: This production line is versatile and equally suitable for manufacturing:
USB 2.0/3.0 cable inner cores
HDMI cable inner cores (requires even higher precision)
DisplayPort cable inner cores
Other internal ribbon cables, etc.
Production Line Type Breakdown
Depending on the structure of the SATA cable (typically containing 4 or 7 core wires), production usually adopts the following methods:
Single-spindle extrusion line: Produces one insulated core wire at a time. This is the most basic method. After all core wires are produced, a dedicated twisting machine is used to complete the pair twisting and cabling.
Multi-spindle extrusion line: A more efficient configuration. Multiple pay-off units and extruders work together to simultaneously produce multiple core wires and directly integrate subsequent twisting and cabling processes, significantly improving production efficiency and consistency.