In medium-voltage power cable manufacturing, the continuous vulcanization process is decisive for transforming high-quality rubber compounds into insulation and sheathing with consistent dielectric strength, mechanical robustness, and long service life. Our horizontal steam-heated CV lines are purpose-engineered for the efficient production of rubber insulated power cables rated 6 kV to 35 kV.
These systems integrate precision triple co-extrusion with a common crosshead, enabling simultaneous application of conductor screen, primary insulation, and insulation screen in a single, controlled operation. The half-catenary configuration, combined with optimized heating and cooling sections, ensures uniform cross-linking under superheated steam while maintaining excellent core concentricity and layer adhesion.
Designed with the engineering principles valued in leading international equipment — stable process control, flexible layer configurations, and durable construction — these lines deliver reliable daily performance and support manufacturers serving utility, industrial, infrastructure, and renewable energy projects. They are particularly suited for EPR and other high-performance rubber compounds where flexibility, chemical resistance, and electrical integrity are critical.
Key Technical Advantages
Our horizontal CV lines are built for process stability, product quality, and operational flexibility:
- Triple Co-Extrusion Capability — Three dedicated extruders feeding a single three-layer crosshead enable precise, simultaneous extrusion of inner semiconductive screen, rubber insulation, and outer screen. This reduces handling steps, improves interfacial bonding, and achieves superior concentricity essential for reliable MV performance.
- Optimized Steam Vulcanization — Controlled superheated steam environment (typically 18–24 bar) in stainless steel tubing delivers uniform cross-linking. The division of vulcanization (~42 m) and cooling sections (~36 m) is engineered for efficient curing while minimizing thermal stress on the cable.
- Excellent Dimensional Control — State-of-the-art extrusion technology and synchronized drives maintain tight tolerances on insulation thickness and conductor centering across a wide range of conductor sizes and wall thicknesses.
- Flexible Layer & Product Configurations — Support for single-layer, two-layer, or full triple extrusion, plus options for skin layers, stripes, and even flat cable production with specialized tooling. Overheated steam capability available for sensitive compounds or combined Rubber/XLPE operation.
- Advanced Line Control & Synchronization — Modern PLC-based systems (Siemens platform options) with PROFIBUS communication, precise temperature regulation, non-contact sag control, and real-time monitoring of all critical parameters. Drives allow synchronous or independent operation with full safety interlocks.
- Robust & Maintainable Design — Nitrided barrels and screws, stainless steel tubes and splice boxes, independent heating/cooling circuits, and modular construction for long service life and reduced maintenance. Pin-type extruder options available for enhanced compound mixing and homogenization where required.
- High Productivity with Quality — Line speeds up to 40 m/min depending on cable design, supported by optimized heating/cooling ratios and multiple water overflow adjustments for different rubber compounds.
- Comprehensive Safety & Monitoring — Multiple emergency stops, acoustic-optical alarms, TV surveillance at key positions, and interlocked systems protect both personnel and process integrity.
المواصفات الفنية
Voltage Class 6–35 kV rubber insulated power cables
Conductor Range Copper: 25–630 mm² Aluminum: 35–800 mm²
Cable Construction Conductor screen: 0.5–1.5 mm Insulation (EPR or equivalent rubber): 1.2–10.5 mm Insulation screen: 0.5–1.5 mm Maximum finished cable diameter: 60 mm Maximum cable weight: 9 kg/m
Line Performance Line speed: 0–40 m/min (adjustable) Vulcanization section: approx. 42 m (stainless steel tube) Cooling section: approx. 36 m Extruder configuration: φ65 mm (screen) + φ120 mm (insulation) + φ90 mm (screen) — triple recommended
Utilities Installed capacity: approx. 500 kVA Water: 0.2–0.6 MPa, ~15 m³/h circulating (softened) Compressed air: 0.6–0.8 MPa Superheated steam: working pressure ~1.8 MPa, consumption ~240 kg/h (user-supplied boiler ≥2 t @ 2.5 MPa)
Control System Siemens S7-series PLC with PROFIBUS DP, PARKER or equivalent DC drives, real-time displays for speed, position, temperature, pressure, and accumulation. Non-contact sag controller with automatic synchronization.
Compatible Rubber Materials
These lines process a wide range of compounds, including:
- EPR/EPDM — Ethylene propylene rubber (excellent electrical and weathering properties)
- CR — Polychloroprene (good flame retardancy and chemical resistance)
- NR — Natural rubber
- NBR, CSM, CPE and other specialty elastomers as required
- Semiconductive rubber compounds for screens
Different compounds may require specific curing/cooling profiles, which the line’s adjustable water overflows and temperature zoning readily accommodate.
Main Equipment Composition
Typical configuration includes mobile pay-off stands, horizontal accumulator, metering capstan, triple extrusion group with crosshead, motorized splice box, vulcanizing tube with sag control, cooling tube system, pull-out caterpillar, mobile take-up stands, full electrical and utilities control cabinets, and complete tooling set.
Production Process
Conductor is fed from pay-off through the accumulator and metering capstan into the triple crosshead, where the three layers are applied simultaneously. The cable then enters the pressurized steam vulcanization tube under precise sag and tension control, followed by controlled water cooling. Synchronized drives maintain stable speed and catenary geometry throughout. The finished cable is taken up on drums ready for testing and further processing.
Quality Assurance & Standards
The equipment is designed to produce cables meeting or exceeding the requirements of relevant international and national standards (IEC 60502, GB/T 12706, and equivalent). Trial production and acceptance testing typically cover representative sizes to verify compliance on dimensions, electrical properties, and mechanical performance.
Customization & Optional Configurations
We work closely with clients to tailor each line to specific production goals:
- Alternative extruder sizes or single/twin configurations
- Overheated steam capability and combined Rubber/XLPE operation for maximum flexibility
- Extended tube lengths, additional temperature zones, or turnaround autoclave for space-constrained layouts
- Enhanced data logging, recipe management, and Industry 4.0 connectivity
- Flat cable tooling and special product adaptations
- Integration with existing plant infrastructure and upstream/downstream equipment
Why Choose Our CV Line Solutions
These horizontal CV lines combine proven engineering principles with practical, robust execution. They deliver the process control and product quality demanded in modern MV cable production while offering the flexibility and customization expected from an experienced equipment partner. Our focus remains on reliable performance, ease of operation, and long-term value through responsive technical support, training, and spare parts availability.
Ready to enhance your rubber cable manufacturing capability?
Whether you are planning a new line, upgrading existing capacity, or seeking a technically sound solution for specific rubber compounds and voltage classes, we are prepared to provide detailed specifications, layout proposals, and process recommendations.
استفسر الآن — Contact our technical team today to discuss your project requirements. We are committed to delivering reliable, high-performance equipment and long-term partnership support that helps you achieve consistent quality and sustainable production success.
Frequently Asked Questions
What is the main difference between horizontal CV and catenary CCV lines?
Horizontal lines are typically preferred for smaller diameters and lighter cables with lower wall thicknesses. For heavier cables or larger conductor sizes, catenary (CCV) configurations provide better support and are often recommended.
Can the line produce both rubber and XLPE cables?
Yes. Combined configurations with dual curing circuits (steam and nitrogen) and appropriate extruder setups are available for maximum production flexibility.
How do you ensure consistent insulation quality across different rubber compounds?
Through precise temperature and pressure control, adjustable curing/cooling ratios via multiple water overflows, non-contact sag monitoring, and recipe-based process parameters tailored to each compound.
What after-sales support is provided?
We offer installation supervision, operator training, process optimization assistance, spare parts supply, and ongoing technical consultation to maximize equipment uptime and performance.
CV Lines for the Production of Rubber Cables - Reliable Cable
Engineered for precision and reliability, our horizontal continuous vulcanization lines deliver high-quality rubber insulated medium-voltage power cables up to 35 kV. Advanced triple co-extrusion, controlled steam cross-linking, and robust automation ensure excellent tolerances, process stability, and long-term cable performance. Customized solutions with full technical support. Inquiry Now.
رمز تعريف SKU للمنتج.: CV lines
العلامة التجارية للمنتج: شركة آر إل بي للآلات
عملة المنتج: دولار أمريكي
سعر المنتج: اتصل بنا للحصول على عرض سعر
المنتج متوفر في المخزون: في الأوراق المالية
المراجعات
لا توجد مراجعات بعد.