UL1015 Electronic Wire Extrusion Line

UL1015 Electronic Wire Extrusion Line

UL1015 is a widely used internal connecting wire in electronic and electrical equipment. Like UL1007, it belongs to a specific "Style" within the UL AWM (Appliance Wiring Material) standard.
Core Characteristics
Rated Voltage: 600 Volts. This is twice that of the common UL1007 (300V), enabling its use in applications with higher voltage requirements.
Rated Temperature: 105°C (221°F). This refers to the maximum ambient temperature at which the wire can operate safely long-term, which is higher than UL1007's 80°C rating.
Conductor:
Material: Usually annealed bare copper wire, ensuring excellent conductivity.
Structure: Composed of multiple fine copper strands stranded together, providing good flexibility.
Insulation:
Material: The standard material is PVC (Polyvinyl Chloride).
Thickness: The insulation thickness of UL1015 is significantly greater than that of UL1007. This is a key design feature enabling it to withstand higher voltage and temperature, and also makes the wire body thicker and stiffer.
Certification Markings: Compliant wires are periodically printed with permanent markings, typically including:
UL AWM STYLE 1015 600V 105°C
VW-1 or FT1 flame retardant rating, indicating it has passed stringent vertical flame tests.
Manufacturer's name or trademark.
May also include other certification marks such as CSA (Canadian Standards Association).
Main Advantages
Higher Electrical Rating: The 600V rated voltage and 105°C rated temperature make it suitable for more demanding electrical and environmental conditions.
Stronger Mechanical Protection: The thicker insulation provides better abrasion resistance, crush resistance, and mechanical strength.
Excellent Flame Retardancy: Passing the VW-1 test effectively prevents flame spread, ensuring equipment safety.
Good Chemical Resistance: The PVC insulation layer has a certain resistance to common chemicals, solvents, and oils.
Standardized Sizes: Adheres to the American Wire Gauge (AWG) standard, with a complete range of specifications. Common sizes range from 20AWG to 10AWG (or even thicker), facilitating design and procurement.

UL1015 Electronic Wire Extrusion Line

The UL1015 electronic wire extrusion production line is a complete set of automated equipment specifically used for manufacturing wires that comply with the UL 1015 standard. Its core process (extrusion) involves melting PVC plastic pellets and uniformly coating them onto a copper conductor to form a thicker insulation layer that meets the UL1015 standard.

Core Components

A standard UL1015 extrusion production line mainly consists of the following eight core components, arranged in the order of the process flow:
Pay-off Unit
Function: Used to pay off and supply the copper conductor.
Requirement: Equipped with a precise tension control system to ensure smooth pay-off and prevent the conductor from being thinned or broken.
Preheater
Function: Heats the conductor before it enters the extrusion die head.
Purpose: Removes moisture from the conductor surface, enhances the adhesion between the PVC and the conductor, reduces internal stress, thereby ensuring the concentricity (uniform thickness) and roundness of the insulation layer.
Extruder System
Function: The "heart" of the production line, responsible for plasticizing, melting, and steadily conveying the PVC material.
Key Features:
Screw Design: Often uses a gradual compression screw designed for PVC to ensure uniform plasticization of the material at the 105°C processing temperature and avoid decomposition.
Temperature Control Precision: Requires extremely high precision in the heating and cooling systems, with strict control of temperatures in each zone.
Specification: Depending on output, extruders with specifications such as φ65mm or larger are often selected to handle the larger extrusion volume required for the thicker insulation layer.
Die Head and Tooling
Function: Molten PVC is directed here and uniformly coats the conductor to form the insulation layer.
Key: Uses extrusion-type tooling. Due to the thick insulation layer, the precision fit between the tip and die is crucial, directly determining the quality of the insulation layer's concentricity.
Cooling Trough
Function: Rapidly cools and sets the high-temperature cable.
Characteristics: Requires a longer cooling length (usually over 10 meters) or segmented cooling control to ensure the thick insulation layer cools evenly from the inside out, avoiding bubbles, shrinkage, or internal stress.
Online Detection System
Spark Tester: Essential equipment. Applies high voltage (e.g., 3500V) to the cable to detect defects like pinholes or scratches in the insulation layer online, ensuring 100% electrical safety.
Diameter Gauge (Optional): Monitors the insulation outer diameter in real time and automatically adjusts the haul-off and extrusion speed via a closed-loop control system to ensure dimensional tolerance.
Caterpillar Haul-off / Puller
Function: Provides stable pulling force to draw the cable through the entire line at a constant speed.
Type: A robust caterpillar-type haul-off that must be precisely synchronized with the extruder output to control the insulation layer thickness.
Take-up Unit / Spooler
Function: Winds the finished cable neatly and tightly onto a reel.
Requirement: Uses active take-up with constant and controllable tension to avoid damaging the wire or uneven winding.
Central Control System
Function: The "brain" of the production line. Integrates a PLC and touchscreen to centrally monitor and adjust all parameters, such as temperature, rotation speed, tension, and speed, enabling automated and intelligent production.

Process Flow

Pay-off → Preheating → Extrusion → Cooling → Spark Testing → Haul-off → Length Counting → Take-up

UL1015 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

UL1015 Electronic Wire Extrusion Line Application

The UL1015 electronic wire extrusion production line is high-demand equipment designed to meet higher electrical safety standards (600V, 105°C). It emphasizes production stability, precise temperature control, and uniformity of the insulation layer. It is a key piece of equipment for manufacturing high-performance, high-reliability internal connecting wires, widely used in high-end fields such as industrial control and appliance manufacturing. Details are as follows:
Manufacturing UL1015 Standard Electronic Wire
Produces various specifications of UL1015 single-core wire, ranging from 20 AWG to 10 AWG (or even thicker).
By changing the molds and adjusting process parameters (such as extrusion volume and haul-off speed), the insulation thickness for different wire specifications can be precisely controlled.
Manufacturing Similar Thick-Insulation Cables
By replacing the PVC material (e.g., 105°C flame-retardant PVC) and adjusting process parameters, this production line can also be used to produce other wires with similar standards, for example:
UL 1007 wire (80°C, 300V) - requires adjustment of insulation thickness.
UL 1032 and other higher temperature grade cables - requires changing to high-temperature resistant materials.
Its principle is applicable to the manufacturing of all single-core PVC wires requiring a thick insulation layer.
Downstream Industries
The UL1015 wire manufactured by this production line, due to its high voltage and temperature resistance, is widely used in:
Industrial Automation: Power wiring and control connections inside PLC control cabinets, frequency converters, servo drives, and large machinery.
Household Appliances: Wiring in high-temperature or high-power areas inside washing machines, dryers, dishwashers, air conditioners, etc.
Power Equipment: Internal connecting wires in uninterruptible power supplies (UPS), inverters, and transformers.
Commercial and Medical Equipment: Internal wiring for equipment requiring high safety levels.
Lighting Field: Internal wiring for high-temperature industrial and mining lights, and high-power lighting equipment.