About LEDUV Cross-Linked Polyethylene Insulated Cable Equipment

 The technological process of UV Irradiation Cable Crosslinking Equipment is that UV light is used as the radiation source, and the mixed photo-crosslinking polyolefin is extruded and coated on the conductive wire core, and then it immediately enters the special irradiation equipment for melting state optical crosslinking. Photo-crosslinked polyolefin insulated wire and cable products can be obtained after the light irradiation crosslinked insulated wire core is cooled at different temperatures and other subsequent processing.

Cable UV Light Irradiation Crosslinking System Machine only needs to be slightly changed on the original ordinary extrusion production line. The equipment covers a small area, with upper traction, irradiation box, electrical control cabinet, etc., can meet the requirements to produce UV irradiation crosslinking polyethylene wire and cable products. Increase the traction, so that the conductive wire core to maintain a certain tension. Always in the center of the box during operation to ensure the best irradiation effect. The irradiation box adopts uniform configuration and characteristic design of reflective concentrated UV light source, and the electric control system ensures that the ultraviolet intensity and temperature at the center of the irradiation box are in the best working conditions. The efficient optical traction system can quickly trigger polyolefin crosslinking reaction under UV light, so that the equipment can achieve a continuous production speed of tens of meters per minute. The water temperature of hot, warm, and cold is cooled step by step to ensure the stability of the three-dimensional network crosslinking structure.

What are the advantages of LED UV Radiation Polyolefin Crosslinked Machine?

1.More Intelligent

Using intelligent detection system, real-time detection of equipment operating temperature, flexible, dual mode operational

Manual mode: simple and convenient, easy to understand, easy to operate

Automatic mode: intelligent speed measurement system of equipment, real-time online detection of production speed.

The system can follow the speed of production, adjust the UV energy intensity, effectively solve the general crosslinking in the initial stage of line change and the production speed of the tail part of the product crosslinking excessive or insufficient defects, greatly reduce the generation of waste, effective cost saving.

2.More Safety

Earth leakage circuit-breaker

Warehouse door detection system: when the warehouse door is not closed well, the system will issue an alarm to avoid accident

Light source detection system: can effectively avoid the generation of waste

Speed detection system: the system can adjust the UV energy intensity according to the speed of production, and save materials intelligently and effectively

Abnormal tracing system: when the equipment is abnormal, the system is traceable and check the records

3.More Energy-Efficient

DSXUV Intelligent LED UV Light Irradiation Crosslinking Cable Equipment adopts the new process LED, its lamp power consumption is saver 70% than the ordinary crosslinking. The crosslinking speed is more than 2 times of the original, which solves the disadvantages of thick insulation, irradiation impenetrability and slow speed. Small footprint, more reasonable design, economizing steam crosslinking process, greatly improving production efficiency, saving cost and time.

Why do we choose LED UV Crosslinking Equipment

 The advantages of Cable UV Light Irradiation Crosslinking Machine are mainly reflected in: low energy consumption, short time, low cost, small size, easy installation and operation, long life, low maintenance cost, no ozone, green environmental protection.

Why? Please browse the following articles.

1.Low energy consumption

The installed power of the UVLED Type Ultraviolet LED Polyolefin Crosslinking Equipment is equivalent to 1/4 of the original ultraviolet irradiation equipment, 1/30 of the electron accelerator, water or steam needs to be heated for a long time, and the energy consumption of heating is very high.

2.Fast production

The cross-linking uses online extrusion cross-link to reduce the subsequent cross-linking process. Compared with the time required for boiling or steam-assisted silane cross-linking and entrusted electron beam irradiation processing, it saves wire and cable manufacturing time, especially emergency task completion has obvious advantages.

3.Low production cost

Compared with warm water cross-linking and entrusted electron beam irradiation process, the price of UV-irradiated cables is low, and many complicated processes are reduced during the production process, such as the transportation cost of semi-finished cables and the corresponding operator costs.

4.Small in size, easy to installation

Just add a distance of about 2m between the extruder die of the original production line and the warm water tank, and place the irradiator in a space with a width of 2.5-3 meters.

5.Easy to operate

Pneumatic reversal to open the tunnel structure, easy to clean and thread through, simple operation, no complicated process, can be completed by the extruder operator.

6.Long life expectancy of the system, low cost of maintenance

The life of LED devices is about 30000 hours, and the life of other electrical and electronic devices is not less than life general electrical and electronic products, without frequent maintenance. Regular maintenance is to keep the optical lens clean. The consumables are industrial wipes and fume cleaner, which can be done by the operator.

7.Harmful emission radiation and pollution environment friendly

Very high wavelength selectivity, only emit useful wavelengths, no infrared radiation, low calorific value. Very low amount of visible radiation, no light pollution, no short wavelength ultraviolet radiation, no harm to human body, zero ozone emission. Only need to connect a small diameter smoke exhaust pipe and a 2KW fan to remove the low molecular smoke produced when the insulation is extruded to prevent affecting the effect of light irradiation.

8.Environment friendly

“Industrial Hygiene Standards” stipulates that ozone safety standard is 0.15ppm, the ambient air quality standard (GB3095-2012), UV LED ultraviolet Light Cross-Linking Equipment will not produce ozone, and traditional mercury lamp equipment will produce a large amount of ozone, ozone belongs harmful gas.

What Is UV LED Crosslinking Equipment?

 The process of UV crosslinking is to extrude the special UV crosslinking material onto the conduct or wire core, then immediately enter the UV irradiation crosslinking equipment. Through UV irradiation, the material is instantly cross-linked in the molten state. The whole process is fast, efficient and low energy consumption. Compared with traditional one-step and two-step processes, and silane crosslinked polyethylene insulation processes, UV cross-linking technology has outstanding characteristics.

1.Instead of the traditional steam box or heated water tank, the UV crosslinking device is installed between the plastic machine and the water tank, requiring only 2 meters of space. Easy to install, small footprint.

2.Using special UV crosslinked polyethylene material, the price is cheaper.

3.UV crosslinked polyethylene material is extruded from the head, then immediately irradiated UV light in the UV LED Irradiation Crosslinking Equipment. The material can complete the crosslinking process, can greatly improve the production efficiency, while reducing energy consumption.

4.After irradiation by UVLED Radiation Cable Crosslinking Machine, the hot prolongation and thermal shrinkage of the material is easier to meet the standards.

5.Special low-smoke halogen-free flame retardant polyolefin UV crosslinking materials are selected, and using UV crosslinking equipment for UV irradiation crosslinking, which can replace the traditional electron accelerated irradiation crosslinking process. (except black) It can greatly reduce the cost of investment, convenient extension of wire and cable enterprise product series.

The fourth generation of intelligent LED UV Radiation Polyolefin Crosslinked Equipment developed by DSXUV adopts more advanced design concept, more friendly human-computer interaction interface and more reasonable structure design, which can not only improve production efficiency but also reduce production cost. Compared with the old and similar equipment, our products has obvious advantages.

6.Using the new process LED lamp, the power consumption is 70% less than that of the old irradiation, and the crosslinking speed is more than two times of the original, which solves the disadvantages of impenetrable insulation irradiation and low speed.

7.Stronger UV cross-linking ability of color products (expect black), increased collection device, convenient connection with the factory’s smoke exhaust system, improve the work site environment, meet the requirements of environmental protection.

LED UV Ultraviolet Irradiation Crosslinking Equipment For Cable And Wire

 UV LED devices are the most advanced UV radiation sources in the world, characterized by extremely high energy efficiency (about 30%), extremely high selectivity of effective wavelength (half-power wavelength broadband: 5nm), extremely long service life (40,000 hours), low infrared heat and no ozone, making them more suitable for the cross-linking and solidity of cross-linked polyolefin and other materials.

LED-UV type Cable UV Light Irradiation Crosslinking Machine adopts a circular cavity tunnel structure, installs a self-developed UV LED light source and forms a tunnel to the central area, whose radiant power can be infinitely set within the scope of 0~100%.

Structural Characteristics of UV LED Radiation Cable Crosslinking Equipment :

1.The tunnel structure is opened by turning over, which is convenient for operation, cleaning and thread taking

2.Using intelligent touch man-machine interface, monitoring data, operation buttons, and power setting are all completed on the touch screen interface

3.One-key start function coexists with separate start

4.The cooling method adopts refrigerator refrigeration, and the circulating medium uses automobile special antifreeze

5.It is connected to the smoke removal mechanism and discharged outside through the air duct

Characteristics of UV Light Irradiation Crosslinked Cable Equipment :

1.Wide applicability

Ultraviolet cross-link equipment is suitable for online cross-linking of polyethylene or low-smoke halogen-free flame-retardant polyolefin low-voltage wires cables. The maximum cross-linking thickness of the production can reach about 2mm (non-frame retardant type, high density or linear low density polyethylene cable material).

2.Low cost

The price of ultraviolet light crosslinking equipment is only 1/10 - 1/5 of electron beam equipment. The installation only needs to add the equipment on the original basic production line, and no other equipment investment is needed. Because the ultraviolet light production method completes crosslinking at one time, it can save other human and material resources, and its production cost is much lower than other crosslinking methods.

Performance Indicators of LED UV Irradiation Crosslinking Machine : 

Power Supply	AC380V, 10φ50HZ
Applications	UV Crosslinking of cables
Suitable Size	Effective diameter 0-60mm, effective length 1000mm
Size of Machine	1700*1050*1900mm L*W*H
UV LED Light Source	Equipped with 14 UV LED lamp sets, forming a circle. Using imported chip, water cooling heat dissipation, prolong the service life of UV LED lamp, with advanced aggregated optical system, high intensity of light source, to ensure fast light crosslinking reaction
Life of Light Source	>30000 hours
Cooling Method	External chiller, through special coolant circulation, inside circulation cooling
Cooling System	14 temperature probes intelligent control
Structure Design	Lamp source adopts front and rear, opening and closing mode, convenient for threading. Integrated design of the whole machine, beautiful, generous, and save space.
Irradiation color	Ultraviolet
Temperature Control Range	Room temperature -40℃
Temperature Measuring Point	14 pcs
Accuracy of Temperature Control	±2℃
Power Consumption	About 14KW
Material	SS41# steel plat is used the case after anti-rust treatment inside and outside.
Control Method	PLC + human machine interface (HMI)
Safety Device	Input circuit breaker, emergency stop button, real-time detection of lamp source status
Configuration	Host machine, water chiller (optional), power line 3m

Outgoing Line Speed of LED UV Radiation Polyolefin Crosslinked Machine : 

Cross-Sectional Area of Conductor (mm2)	Thickness (mm)	Production Speed (m/min)	Hot Prolongation (%)	Thermal Contraction (%)
2.5	0.7	60-110	50-100	0-3
4	0.7	60-110	50-100	0-3
6	0.7	60-110	50-100	0-3
10	0.8	40-100	50-100	0-3
16	0.8	40-100	50-100	0-3
25	0.9	40-90	50-100	0-3
35	0.9	40-90	50-100	0-3
50	1.0	30-90	50-100	0-3
70	1.1	30-80	50-100	0-3
95	1.1	25-80	50-100	0-3
120	1.2	25-70	50-100	0-3
150	1.4	20-60	50-100	0-3
185	1.6	20-50	50-100	0-3
240	1.7	15-30	50-100	0-3
300	1.7	15-25	50-100	0-3