ال MV CCV Line (Catenary Continuous Vulcanization Line) is a high-performance triple extrusion production system specifically engineered for the reliable and efficient manufacturing of 6-35kV XLPE insulated medium voltage power cables.
By integrating world-leading catenary continuous vulcanization technology with our independently developed and nationally patented three-layer crosshead, this line achieves exceptional layer bonding, precise concentricity, uniform insulation thickness, and stable cross-linking — ensuring the finished cables fully comply with IEC 60502, IEC 60840 and other international standards while delivering long-term electrical performance and mechanical reliability.
The intelligent 7+2+11 configuration is available in both 6-section and 9-section half-catenary layouts, giving you the flexibility to match different production capacities and cable specifications.
الميزات الرئيسية والمزايا التقنية
- True Triple Extrusion in Single Pass：Conductor screen, XLPE insulation, and insulation screen are extruded simultaneously, eliminating interface defects and ensuring perfect concentricity and strong bonding.
- Patented Three-Layer Crosshead：Nationally patented design offers superior alignment, centering accuracy, and quick changeover, significantly reducing setup time and operator dependency.
- Advanced Anti-Interference Catenary Control：Patented control technology provides high resistance to electromagnetic interference, guaranteeing outstanding process stability even at high line speeds.
- Siemens TIA Portal Full Automation：High-resolution HMI touch screen with complete computer control, real-time monitoring, data logging, and recipe management.
- Flexible Customization：Line speed, CV tube temperature zones, extruder configuration, and auxiliary systems can be fully tailored to your exact production needs.
Technical Parameters Comparison (6-Section vs 9-Section)
| المعلمة | 6-Section MV CCV Line | 9-Section MV CCV Line |
|---|
| Voltage Class | 6–35 kV XLPE | 6–35 kV XLPE |
| Conductor Size | Cu: 25–630 mm² / Al: 35–800 mm² | Cu: 25–630 mm² / Al: 35–800 mm² |
| Max. Cable Diameter | 70 mm | 70 mm |
| Max. Cable Weight | 10 kg/m | 10 kg/m |
| Line Speed | 0–30 m/min | 0–30 m/min |
| Cross-linking Section | ≈41 m (6 tubes) | ≈54 m (9 tubes) |
| Pre-cooling Section | 12 m (2 tubes) | 12 m (2 tubes) |
| Cooling Section | 54 m (9 tubes) | 90 m (15 tubes) |
| Installation Capacity | 750 kVA | 1050 kVA |
Extruder & Crosshead
Extruder The MV CCV Line features three high-precision extruders connected to one common three-layer crosshead, enabling simultaneous extrusion of the conductor screen layer, XLPE insulation layer, and insulation screen layer in a single pass.
Technical Data of Extruders
- 65/20D Extruder (conductor screen / inner semiconductor layer)
Max. screw speed: 46.5 rpm Gear reduction ratio: 32:1 Extrusion output: 35 kg/h
- 90/20D Extruder (insulation screen / outer semiconductor layer)
Max. screw speed: 41.5 rpm Gear reduction ratio: 36:1 Extrusion output: 60 kg/h
- 150/25D Extruder (XLPE insulation layer)
Max. screw speed: 40 rpm Gear reduction ratio: 37.5:1 Extrusion output: 250 kg/h
Technical Data of Three-layer Crosshead
- Conductor diameter: 6-34 mm
- Max. cable diameter: 70 mm
- Extrusion thickness: First layer (conductor screen): 0.5-2.0 mm Second layer (insulation): 2.0-12 mm Third layer (insulation screen): 0.5-2.0 mm
- Heating method: oil or water heating
Features of Three-layer Crosshead
The crosshead adopts a circulating distribution flow channel and restrictor ring design, greatly shortening the length of flow distributors compared to conventional three-layer heads, thereby reducing overall weight. It is easy to disassemble for convenient cleaning and provides excellent convenience and ease of alignment during the extrusion process.
Control System
The control system is engineered for high resistance to electromagnetic interference, ensuring minimum cable fluctuation inside the vulcanization tube and stable running.
It is positioned at the middle part of the heating zone to effectively protect the cable from contacting the tube wall during the heating process.
When the system receives the cable position signal, it automatically adjusts the rotation speed of the lower capstan (pulling unit) to maintain precise synchronization throughout the line.
Portal Upper Beam Travelling Pay-Off Stand
Features The gantry-type travelling pay-off stand features a mechatronic design that achieves reciprocating motion while maintaining perfect center line alignment during pay-off. The shaftless pay-off reel moves up and down between two posts, driven by an AC motor. A dancer system provides precise speed control, and the stand supports rotation in both positive and negative directions. The integrated touch screen allows operators to input technical parameters easily and conveniently. The entire pay-off stand operates independently for maximum flexibility.
Specifications
- Drum diameter: 1600-2500 mm (GB4004-84, PN Type)
- Drum width: 1180-1900 mm
- Drum weight: Max. 16 t
- Pay-off tension: 5000 N
- Main drive: 5.5 kW DC motor, 4 quadrant, Parker 590P
- Dancer: used for speed control, keeping the cable aligned with center line when paying off
Horizontal Accumulator
Specifications
- Accumulation length: 120 m
- Pulley diameter: 1600 mm
- Tension control: Siemens 200 Smart PLC + Parker 590P Drive (original Eurotherm), 300-3200 N adjustable
- Traction wheel speed: 0-2 m/min
Capstan – Lower Pull-Out Caterpillar / Capstan
Features
This unit lifts the cable conductor from the lower level to the required height and operates synchronously with the CCV line. The belt wrap capstan (or caterpillar type) works in perfect coordination with the line. A dedicated conductor positioning unit ensures accurate alignment with the crosshead center for different cable sizes. The transmission unit features a fixed base, spiral bevel gear reducer, and DC motor for reliable and stable power delivery.
Specifications
- Pulling method: belt wrap capstan
- Capstan wheel diameter: 2000 mm
- Adjusting range: 0-30 m/min (four gear shifts)
- Pulling force: max. 30 kN
- Belt contact length: 3 m or above
- Cable diameter: up to 100 mm
- Speed sensor equipped with line speed meter
- Main drive: 11 kW DC motor, Parker 590P drive
Belt-type Twister with Angle Adjustment
Features
The Belt-type Twister with Angle Adjustment is installed between the end seal and the pull-out capstan. It rotates the cable around its longitudinal axis to prevent insulation drooping and to tighten the stranded conductor during the critical cooling phase after vulcanization. This ensures uniform cable geometry, reduces internal stress, and maintains perfect roundness and concentricity of the finished cable.
Specifications
- Twister weight: 650 kg
- Overall dimensions: 1525 mm × 975 mm × 1243 mm
- 26 grooved passive wheels mounted on both sides. Distance between wheel sets on both sides is adjustable from 2 to 200 mm.
- Rollers on both sides can be adjusted by ±50 mm, calibrated by caliper. Max. wire diameter passing through: 70 mm.
- Center height: 1 m (can be adjusted by cutting footing if needed).
- Welded machine body, passive transmission mechanism, and semi-enclosed stainless steel cover.
- Installed between the end seal and pull-out capstan.
- Belt width: 150 mm, thickness: 20 mm
Accumulator & Upper Auxiliary Caterpillar
Features The Accumulator & Upper Auxiliary Caterpillar is located after the cooling section of the CCV line. It serves two critical functions:
- Accumulator function：Provides sufficient cable storage (buffer) to allow continuous production during pay-off or take-up reel changes without stopping the line.
- Upper Auxiliary Caterpillar：Acts as a synchronized pulling device that gently guides the vulcanized cable from the upper part of the catenary tube to the take-up area. It works in perfect synchronization with the lower capstan to maintain constant tension and prevent cable sag or damage.
This combination ensures smooth, uninterrupted operation, protects the freshly cross-linked insulation from mechanical stress, and maintains precise line speed throughout the entire process.
Specifications (typical for this MV CCV Line)
- Accumulation length: up to 120 m (depending on configuration)
- Pulley diameter: 1600 mm
- Tension control: Siemens 200 Smart PLC + Parker 590P Drive, adjustable 300-3200 N
- Traction wheel speed: 0-2 m/min (synchronized with main line)
- Caterpillar design ensures gentle belt contact to avoid deformation of the hot cable after cooling
Typical Applications
Cables produced on this MV CCV Line are widely used in:
- Urban and rural medium voltage power distribution networks
- Industrial plants, mining operations, and large infrastructure projects
- Underground ducts and direct burial installations
- Overhead transmission lines (with appropriate armoring and sheathing)
Why Leading Cable Manufacturers Choose Doing Cable MV CCV Line
- Superior insulation uniformity and strong interlayer bonding
- High process stability with significantly reduced scrap rate
- Faster setup time and easier daily operation
- Lower overall operating costs and energy consumption
- Proven long-term reliability with full international standard compliance
- Flexible configuration and strong technical support
Ready to upgrade your medium voltage cable production?
استفسر الآن — Get a free technical proposal, detailed quotation, layout drawing, and customized configuration for your 6-35kV MV CCV Line within 24 hours.
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