UL1061 Electronic Wire Extrusion Line

UL1061 Electronic Wire Extrusion Line

UL1061 is a common internal connecting wire for equipment, belonging to a "Style" defined within the UL AWM (Appliance Wiring Material) standard. UL1061 is also commonly classified as Hook-up Wire. Its design aims to provide reliable electrical connections between circuit boards, components, and power supplies inside electronic equipment.

Core Characteristics

Rated Voltage: 300 Volts. This is its most common voltage rating, suitable for typical low-voltage electronic circuits.
Rated Temperature: 80°C (176°F). Refers to the maximum ambient temperature at which the wire can operate normally long-term.
Conductor:
Material: Usually annealed bare copper, providing excellent conductivity.
Structure: Composed of multiple fine copper strands stranded together, giving it good flexibility for bending and routing inside equipment.
Insulation:
Material: The standard material is PVC (Polyvinyl Chloride).
Thickness: The UL standard clearly specifies its minimum insulation thickness to ensure sufficient electrical insulation strength and mechanical protection. Its insulation thickness is typically between that of UL1007 and UL1015.
Certification Markings: Compliant wires are periodically printed with permanent markings, typically including:
UL AWM STYLE 1061 300V 80°C
VW-1 or FT1 flame retardant rating, which is a key safety indicator.
Manufacturer's name or trademark.
May also include other certification marks such as CSA.

Main Advantages

Good Balance: UL1061 achieves an excellent balance between electrical performance, mechanical strength (such as abrasion resistance), and flexibility.
Excellent Flame Retardancy: Passing the VW-1 test ensures safety inside the equipment.
Standardized Sizes: Adheres to the American Wire Gauge (AWG) standard, with common specifications ranging from 28 AWG to 10 AWG.

UL1061 Electronic Wire Extrusion Line

UL1061 electronic wire extrusion production line is a complete set of automated equipment specifically used for manufacturing wires that comply with the UL 1061 standard. Its core process (extrusion) involves melting PVC plastic pellets and uniformly coating them onto a copper conductor to form an insulation layer that meets UL1061 standard requirements.

Core Components

A standard UL1061 extrusion production line mainly consists of the following core components:
Pay-off Unit
Function: Used to pay off and supply the copper conductor (such as stranded copper wire).
Requirement: Equipped with a tension control system to ensure smooth pay-off and prevent conductor stretching or breaking.
Preheater
Function: Heats the conductor before it enters the extrusion die head.
Purpose: Removes moisture from the conductor surface, improves adhesion between the PVC and conductor, reduces internal stress, and ensures uniform insulation thickness (concentricity) and a smooth surface.
Extruder System
Function: The core of the production line, responsible for plasticizing, melting, and steadily conveying the PVC material to the die head.
Key Features:
Screw Design: Uses a gradual compression screw designed for PVC to ensure uniform plasticization of the material at the 80°C processing temperature.
Temperature Control Precision: Requires precise temperature control to prevent PVC decomposition.
Specification: Single-screw extruders with specifications such as φ45mm, φ55mm, or φ65mm are commonly selected based on production output requirements.
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. The precision fit between the tip and die directly determines the concentricity quality of the insulation layer.
Cooling Trough
Function: Rapidly cools and sets the high-temperature cable after the insulation layer is applied.
Characteristics: Requires sufficient length (typically 6-10 meters) to ensure the cable is fully and evenly cooled, avoiding deformation or internal stress.
Online Detection System
Spark Tester: Essential equipment. Applies high voltage (e.g., 2500V) to the cable to detect defects like pinholes or scratches in the insulation layer online, ensuring electrical safety.
Diameter Gauge (Optional): Monitors the insulation outer diameter in real time to assist in controlling the dimensional tolerance.
Caterpillar Haul-off / Puller
Function: Provides stable pulling force to draw the cable through the entire line at a constant speed.
Type: Caterpillar-type haul-off, which must be precisely synchronized with the extrusion speed 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 tension to ensure neat winding.
Central Control System
Function: The control center of the production line. Integrates a PLC and touchscreen to centrally monitor and adjust parameters such as temperature, rotation speed, and tension, enabling automated production.

Process Flow

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

UL1061 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

UL1061 Electronic Wire Extrusion Line Application

The UL1061 electronic wire extrusion production line is a technologically mature and highly versatile automated equipment. It emphasizes production stability and precise process control, serving as key equipment for manufacturing balanced-performance, highly reliable internal connecting wires (Hook-up Wire). It is widely used in various electronic and industrial manufacturing fields. Details are as follows:
Manufacturing UL1061 Standard Electronic Wire
Produces various specifications of UL1061 single-core wire, ranging from 28 AWG to 10 AWG.
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 Standard Cables
This production line offers great flexibility. By adjusting the PVC material formula and process parameters, it can also be used to produce other similar standard PVC-insulated wires, for example:
UL 1007 wire (300V, 80°C) - the insulation thickness is slightly different.
Other AWM cables with 300V, 80°C ratings.
Its basic principle is applicable to the manufacturing of most standard-grade PVC electronic wires.
Downstream Industries
The UL1061 wire manufactured by this production line, due to its balanced performance and reliability, is widely used in:
Electronic Equipment: Internal wiring of computer mainframes, servers, televisions, and audio equipment.
Office Equipment: Internal connections in printers, copiers, and scanners.
Industrial Control: Wiring in CNC machine tools, measuring instruments, and control cabinets of automated equipment.
Communication Equipment: Low-voltage wiring inside network equipment and communication base stations.