UL1007 Electronic Wire Extrusion Line

UL1007 Electronic Wire Extrusion Line

UL1007 is a very common and versatile internal connecting wire for electronic equipment. It belongs to the UL Style (Style) cable category, and its specifications are strictly defined by Underwriters Laboratories. UL1007 is not a brand but an industry standard, meaning that any wire produced by any manufacturer that meets the requirements of this standard can be called a UL1007 wire.
Core Characteristics
Rated Voltage: 300 Volts. This is its most commonly used voltage rating, suitable for most low-voltage electronic equipment.
Rated Temperature: 80°C (176°F). This refers to the maximum ambient temperature at which the wire conductor can operate normally long-term.
Conductor:
Material: Usually annealed bare copper wire, which has good conductivity.
Structure: Composed of multiple fine copper strands stranded together, making it very flexible, easy to bend and route.
Insulation:
Material: The standard material is PVC (Polyvinyl Chloride).
Thickness: The UL standard clearly specifies the minimum insulation thickness, ensuring good electrical insulation performance and certain mechanical strength.
Certification Markings: Wires complying with the UL standard are periodically printed with relevant information, typically including:
UL AWM Style 1007 (AWM stands for Appliance Wiring Material).
Voltage and Temperature Rating: 300V 80°C.
VW-1 or FT1 flame retardant rating (this is a key safety indicator).
Manufacturer's name or logo.
Possibly other certification marks such as CSA (Canadian Standards Association) or CE.
Main Advantages
Good Flexibility: The multi-strand conductor makes it very suitable for wiring within the confined spaces of equipment.
Excellent Electrical Performance: Provides reliable insulation, preventing short circuits.
Flame Retardancy: Passes the VW-1 vertical flame test, offering good flame retardant properties, effectively preventing flame spread, and enhancing equipment safety.
Resistance to Solvents and Oils: Its PVC insulation layer has a certain resistance to common acids, alkalis, and oils.
Standardized Sizes: Adheres to the American Wire Gauge (AWG) standard, with unified sizes. Common specifications range from 30 AWG (very fine) to 16 AWG (thicker), facilitating engineer selection.

UL1007 Electronic Wire Extrusion Line

The core process of the extrusion production line for UL1007 cable is to melt PVC plastic pellets and uniformly coat them onto the copper conductor to form an insulation layer that complies with the UL1007 standard regulations. This is a continuous production line.

Main Components

A standard UL1007 extrusion production line mainly consists of the following major components:
Pay-off Unit
Function: Used to pay off the copper conductor (usually stranded copper wire).
Type: Typically uses active or passive pay-off with a tension control system to ensure smooth pay-off and constant tension, preventing conductor thinning or breakage.
Preheater
Function: Preheats the conductor before it enters the die head.
Purpose: Removes moisture from the conductor surface, improves adhesion between the conductor and molten PVC plastic, prevents internal stress caused by excessive temperature difference between the conductor and insulation layer, and improves the roundness and surface quality of the insulation layer.
Extruder
Function: The "heart" of the production line, responsible for plasticizing, melting, compacting, and conveying the PVC material to the die head.
Key Parameters:
Specification: Commonly used single-screw extruders based on production requirements, such as φ45mm, φ55mm, φ65mm, etc.
Length-to-Diameter Ratio (L/D): Typically 20:1 or 25:1. A longer L/D ratio facilitates sufficient plasticization and mixing of the plastic.
Cooling System: The barrel requires air or water cooling to control temperature and prevent overheating.
Screw Structure: A gradual compression screw is often used for PVC properties to avoid shear overheating.
Die Head and Tooling
Function: Molten PVC is guided here and uniformly coated onto the conductor.
Type: Extrusion-type tooling is typically used for UL1007 insulation layer extrusion.
Composition:
Tip: The conductor passes through it.
Die: Determines the outer diameter and surface finish of the insulation layer.
Key: The precision fit between the tip and die is crucial, directly affecting the concentricity (uniformity of thickness) of the insulation layer.
Cooling Trough
Function: Rapidly cools and sets the high-temperature cable after the insulation layer is applied.
Structure: Usually segmented, with a length that can reach over 10 meters.
Requirement: Water temperature needs to be controlled (usually ambient or chilled water), with smooth water flow to prevent cable deformation, bubble formation, or internal stress caused by uneven or excessive cooling.
Caterpillar Haul-off / Puller
Function: Provides stable pulling force to draw the cable through the entire production line at a constant speed.
Type: Usually a caterpillar-type haul-off.
Key: The haul-off speed must perfectly match the extruder's output rate; otherwise, it can lead to oversized diameter (slow pulling) or undersized diameter (fast pulling), or even break the conductor.
Length Counter / Meter Counter
Function: Precisely measures and controls the production length of the cable.
Type: Can be wheel-type or encoder-type.
Take-up Unit / Spooler
Function: Winds the finished cable neatly onto a reel.
Type: Includes active take-up (tension control) and passive take-up. Modern lines typically use active take-up controlled by a torque motor or inverter to ensure even winding tension and neat coiling.
Control System
Function: The "brain" of the production line, integrating a PLC (Programmable Logic Controller) and a touch-screen HMI (Human-Machine Interface).
Control Parameters: Centrally controls and monitors all key parameters such as extruder temperature zones, screw speed, haul-off speed, pay-off/take-up tension, and length count.

Process Flow

Pay-off → Preheating → Extrusion → Cooling → Drying → Haul-off → Length Counting → Take-up.

UL1007 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

UL1007 Electronic Wire Extrusion Line Application

The UL1007 cable extrusion production line is a complete set of automated equipment specifically used for manufacturing electronic wires that comply with the UL 1007 standard. The application of this production line is highly specialized and clear:
Manufacturing UL 1007 Standard Electronic Wire
Produce various specifications of UL1007 single-core wire, ranging from very fine 30 AWG to thicker 16 AWG.
By changing the molds and adjusting process parameters, products with different wire diameters can be produced.
Manufacturing Similar Types of Equipment Internal Wire
Simply by changing the plastic material and adjusting the process (mainly temperature), this production line can also be used to produce PVC-insulated wires meeting other standards, for example:
UL 1015 wire (105°C, thicker PVC insulation layer).
UL 1061 wire (hook-up wire), etc.
Its basic principle is applicable to the extrusion of all single-core wires using PVC as the insulating material.
Downstream Industries
The UL1007 wire produced by this line is widely used in:
Household Appliances: Internal wiring of refrigerators, air conditioners, washing machines.
Office Equipment: Internal connecting wires for printers, computers.
Industrial Control: Wiring for PLC control cabinets, sensors, instruments.
Automotive Electronics: Wiring for low-voltage non-core areas (e.g., audio systems).
Lighting Industry: Internal connecting wires for LED lamps, light strips.