Automotive AV Low-voltage Wire Extrusion Line

Automotive AV Low-voltage Wire Extrusion Line

AV wire (A : Low-voltage wires for automobiles, V : Vinyl) is a type of low-voltage electrical wire for automobiles based on Japanese Industrial Standards (JIS), which is widely used in the low-voltage electrical systems of traditional fuel vehicles and some hybrid models. 

Typical Application of AV Wire

Vehicle Electrical System
Lighting system: Connecting wires for headlights, taillights, and turn signals (0.5~1.5 mm2);
Sound system: Speaker, radio antenna harness (0.3~0.75 mm2);
Comfort system: Power windows, central locking control cable (0.5~2.0 mm2).
Sensors and Signal Transmission
Low speed signal wire: Speed sensor, temperature sensor (twisted pair unshielded type);
Grounding wire: black identification, used for ECU and frame grounding (1.5~4.0 mm2).
Low Voltage Auxiliary System for New Energy Vehicles
48V mild hybrid system low-voltage wiring harness (must comply with JASO D618 halogen-free requirements);
Battery Management System (BMS) signal acquisition wire.

The automotive AV low-voltage wire extrusion line is a specialized equipment for producing PVC insulated low-voltage automotive wires that comply with JIS standards (such as JIS C 3306). Its core features are high precision, high efficiency, and stable production of ultra-thin insulation layers.

Composition of Production Line

The automotive AV low-voltage wire extrusion line mainly includes the following core equipment:
Pay off Stand: Release copper conductors to maintain stable tension.
Preheating Unit: Heat the conductor to improve insulation adhesion.
Extruder: Melt PVC coat the conductor.
Cooling Tank: Segmented cooling and shaping insulation layer.
Haul off: Control the speed of the production line.
Take-up Reel: Automatic winding of finished wires.
Testing Equipment: Spark tester, laser diameter measuring system, etc.

Process Flow

Pay-off → Preheating → Extrusion coating → Cooling and shaping → Spark detection → Printing → Take-up.

Automotive AV Low-voltage Wire Extrusion Line Datasheet

Model	50	60	70
Pay-off Type	Active or passive	Active or passive	Active or passive
Screw Diameter	φ50 mm	φ60 mm	φ70 mm
Screw L/D Ratio	25:1	26:1	26:1
Extrusion Amount	70 kg/hr	110 kg/hr	160 kg/hr
Outlet Wire	φ0.75-4 mm	φ0.8-8 mm	φ1.5-12 mm
Main Motor	11 KW	18.5 KW	37 KW
Cooling Device	U type	U type	U type
Storage Rack	Horizontal	Horizontal	Horizontal
Traction Power	4 KW	4 KW	4 KW
Production Speed	500 m/min (Max.)	450 m/min (Max.)	400 m/min (Max.)
Take-up Spool	φ400-630 mm	φ400-630 mm	φ500-630 mm
Coiling Method	Automatic	Automatic	Automatic

Automotive AV Low-voltage Wire Extrusion Line Application

The automotive AV low-voltage wire extrusion line is an automated equipment specifically designed for producing PVC insulated low-voltage automotive wires that comply with JIS standards (such as JIS C 3306). The details are as follows:
1. Used for producing connecting wires for headlights, taillights, and turn signals;
2. Used for producing speaker and radio antenna wiring harnesses;
3. Used for producing electric car windows and central locking control wires;
4. Used for producing low-speed signal wires for speed sensors and temperature sensors:;
5. Used for producing grounding wires;
6. Low voltage wiring harness for 48V mild hybrid system used in the production of low-voltage auxiliary systems for new energy vehicles;
7. Used for producing signal acquisition wires for battery management systems.