Cable production and optical fiber coating line

Plastics
Division

Cable production and optical fiber coating line

The line is used for producing and coating cables with plastic materials, strands and optical fibers of any diameter and shape. Devices used in the line are characterized by high linear operation speeds, high dimensional accuracy, energy efficiency and simple operation while allowing at the same time control of the entire process.

The cable production and optical fiber coating lines manufactured by ZAMAK MERCATOR are versatile, durable, eco-friendly and efficient, and work in automatic mode thanks to applied software.

Important functional characteristics

• Energy efficiency - low energy consumption
• High dimensional accuracy of coating
• Simple and ergonomic operation
• High capacity
• Environment-friendly design and functional solutions
• High durability of components
• Digital control system

The cable production and optical fiber coating lines consists of the following devices:


Traverse conveying device

The traverse device unwinds the tension controlled medium  (wire, strand, optical fiber) from a spool and feeds it to the lashing.  The traverse device while unwinding moves in such a way that the unwound medium is at all times in the axis line.

Conveying compensator

At high linear speeds the time for spool replacement in the conveying device is very limited. Therefore, the line is fitted with a compensator (battery) enabling to extend the time for spool replacement.

 

Caterpillar output haul-off

The caterpillar haul-off is a part of the cable production line responsible for feeding the medium for coating into the extruder head at a preset linear speed and appropriate tension.

Single-screw extruder

The single screw extruder is the key machine of the cable production line responsible for plastic material homogenization. Suitably selected extruder screw geometry allows coating of wire, optical fiber or strand with various plastic materials as required.

Cross-head with forming tools

A cross head in the cable production and optical fiber coating line is responsible for the coating of supplied medium with plastic material. All parts in contact with the plastic material are subjected to the nitriding process, which allows for high resistance to abrasion. The cross head is heated by a band heater equipped with sockets for connecting a temperature sensor and a pressure sensor. The cross-head is attached to the single-screw extruder by means of a wedge closure.

Heating and cooling baths system

A set of heating - cooling baths consisting of "warm" and "cold" section cools, in a strictly controlled manner, the extruded cable or optical fiber. The baths work in a completely closed system, which minimizes the consumption of water and is a highly environmentally friendly solution.

Laser diameter meter  

A laser meter measures the diameter of the extruded cable coating continuously in two axes. The measurement is displayed on the main control panel and meter.  Measurement accuracy - 0.001 mm.

Length meter

The meter measures the precise length of manufactured cable. The measurement is performed online and displayed on the control panel.

Caterpillar input haul-off                 
 

A caterpillar input haul-off is used for hauling off the extruded cable, responsible, at the same time, for the thickness of distributed coating of plastic material on cable or optical fiber. Accurately controlled linear speed allows for very precise dimensional control.

Gravity compensator

At high linear speeds that occur in the cable production process, the time for spool replacement in the input device is very limited.  This time can be extended using a compensator (battery) in the cable production and optical fiber coating line.

Traverse (output) device

The traverse device  winds the manufactured cable or optical fiber at a controlled tension. During winding the traverse device moves in such a way that the wound medium is at all times in the axis line.