LED Ultraviolet Irradiation Polyolefin Crosslinking Equipment

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Product Description

The new LED ultraviolet irradiation polyolefin cross-linking equipment adopts the new technology. The power consumption of the LED lamp is 70% lower than that of the old irradiation, and the cross-linking speed is more than twice of the original. The new product solves the shortcomings of the thick insulation, impervious to radiation and slow speed. Less land occupation, more reasonable design, eliminating the steam cross-linking process, greatly improving production efficiency. Significant cost and time savings based on customer response.

The process of UV irradiation polyolefin crosslinking equipment uses ultraviolet light as a radiation source, and the mixed photo-crosslinked polyolefin compound is extrusion-molded on the conductive core, and then immediately enters into a special irradiation equipment. The molten state is crosslinked by light. The light-crosslinked polyolefin insulated wire and cable products can be obtained by the light-radiated cross-linked insulated core after cooling treatment at different temperatures and other subsequent processing.

The UV irradiation polyolefin crosslinking equipment only needs to be slightly modified in the original ordinary extrusion production line, and the upper traction, radiation box, electric control cabinet, etc., which occupy a small area, can be installed to meet the operational requirements and produce UV irradiated crosslinked polyethylene wire and cable products.

Characteristics

Ultraviolet LED device is the most advanced ultraviolet radiation source in the world, with high energy efficiency (about 30%), extremely high effective wavelength selectivity (half-power wavelength bandwidth 5nm), extremely high service life (30,000 hours), infrared Low heat generation, no ozone generation, more suitable for cross-linking curing of cross-linked polyolefin and other materials.

The UV LED source uses a patented lens structure to illuminate the surface of the cable more evenly and uniformly. The substrate design is carried out by the combination of Fluent software simulation fluid and LED junction temperature test, and the LED circuit board is designed by the combination of aluminum nitride ceramic and copper base with better heat dissipation performance, and has a more efficient heat dissipation system.

The UV LED source uses a distributed network power source to drive the UV LED. The driving power supply is packaged in a vacuum potting process to ensure the reliability of the power supply. At the same time, the shape of the driving power supply adopts a narrow and long layout, and the long-type LED light source adopts a back-to-back installation mode for the LED circuit to minimize the length of the wire. Realize the light source's on, off, and dimming functions.

The UV LED irradiation polyolefin cross-linking equipment adopts a circular cavity tunnel structure, and is equipped with an ultraviolet LED light source to form a tunnel for irradiating the central region, and the power of the device can be steplessly set in the range of 10 to 100%.

Compared with traditional mercury lamp type irradiation crosslinking equipment (traditional transformer-driven UVI/UVII and electronic power-driven UVE-I), electron accelerator cross-linking, and silane cross-linking, it has the following advantages:

1 Low Energy Consumption

UV LED irradiation polyolefin cross-linking equipment installed power is equivalent to 1/4 of the original ultraviolet irradiation equipment, 1/30 of the electron accelerator, water or water vapor needs long-term heating, and the energy consumption of heating water is very high.

2 Short Time

The cross-linking adopts the online extrusion cross-linking method to reduce the subsequent cross-linking processing process, compared with the time required for boiled or steam-assisted silane cross-linking and commissioned electron beam irradiation processing, saving wire and cable manufacturing time, especially emergency The completion of the mission, the advantages are significant.

3 Low Cost

Compared with warm water cross-linking and commissioned electron beam irradiation processing, the price of ultraviolet irradiation cable is low, and many complicated processes are reduced in the production process, such as the transportation cost of semi-finished cables and the corresponding operator costs.

4 No Ozone

Very high wavelength selectivity, only emits 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 the human body, zero ozone emission. No need for high-power fan airflow cooling, no need for a particularly complicated heat-discharging and ozone-discharging air duct, only need to connect a small-diameter exhaust pipe and a 2kW fan to exclude low-molecular smoke generated during insulation extrusion. Prevent the effects of light irradiation.

5 Small Size, Easy To Install

Simply add a distance of about 2m between the original production line extruder mould and the warm water tank, and place the irradiation machine in a space of 2.5~3 meters in width, or narrower. The chiller can be placed on the spot.

6 Easy To Operate

Silent opening and closing tunnel structure, easy to clean and wear leads, easy to operate, no complicated process, can be completed by the extruder operator.

7 Long Life And Low Maintenance Cost

The lifetime of LED devices is about 30,000 hours, and the life of other electrical and electronic devices is not lower than the life of general electrical and electronic products, without frequent maintenance. Regular maintenance to keep the optical lens clean, the consumables are industrial wipes and soot cleaners, which can be done by the operator. The traditional light irradiation equipment consumables are UV lamps and reflectors, which need to be replaced in a short time. The electronic ray irradiation unit is also required to maintain the maintenance team.

8 Green

The Ambient Air Quality Standard (GB3095-2012) in the Industrial Hygiene Standard stipulates that the ozone safety standard is 0.15ppm. UVLED UV crosslinking equipment will not produce ozone, while traditional mercury lamp equipment will generate a large amount of ozone. Ozone is harmful gas.

1) Wide range of applications

Ultraviolet irradiation polyolefin cross-linking equipment can achieve a uniform cross-linking thickness of more than 2mm, which can be used for the production of various cross-linked polyethylene cables, flame-retardant cross-linked cables and other cables. The production speed is high and the application range is wide, which can match the production speed of the wire and cable production line.

2) Low cost

The price of UV-irradiation polyolefin cross-linking equipment is only 1/10-1/5 of the electron beam irradiation equipment. Installation only needs to add the equipment on the basis of the original extrusion line, no need for other equipment investment. Compared with the first-generation equipment, the annual electricity bill and production efficiency cost can save one piece of equipment.

3) Easy to install

The UV-irradiation polyolefin cross-linking equipment adopts a modular design, and only needs to be connected by pipelines between the parts, and the installation is convenient. The modular design allows for greater flexibility in the placement of the equipment, fully meeting the installation needs of various production sites.

4) High reliability

Ultraviolet irradiation polyolefin cross-linking equipment adopts advanced and stable control method, high-reliability component parts, all non-standard parts are designed with high life, strict material selection and precision processing level, assembly link has high quality requirements. Finally, after very rigorous testing, each device can operate safely and reliably, maximizing the stability and service life of the equipment.

Comparison of the advantages of new LED irradiation cross-linking and silane cross-linking:

	LED ultraviolet irradiation equipment	Silane crosslinking equipment	Cost savings
Material costs	600 kg of waste per 90 extruders per year	12 tons of waste per 90 extruders per year	Annual cost savings of 17000 USD per machine per 90 machines
Extruder power	The viscosity of the material is small, the power consumption is small, and the extrusion of 90 extruder is only about 30KW at full speed.	High viscosity of material, high power consumption, 90 KW full speed extrusion required	Save 20KW per hour, save electricity costs of 10000 USD per extruder per year
Artificial electricity bill	No need to clean the extruder	Clean the extruder for half an hour every day	Save 3400 USD per year
Cross-linking cost	Taking 35 square meters as an example, the electricity cost is 80KW for 30,000 meters.	Taking 35 square meters as an example, it takes 4 hours for 30,000 meters of steam cross-linking, and it requires 200KW of electricity.	Save about 7000 USD in electricity every year
Productivity	Simultaneously cross-linking with the extruder, the extrusion insulation is directly cabled without secondary processing	Boiled or steamed for at least 4 hours (requires special site, steam generator)	Save 8400 USD per year
Product quality	Heat shrinkage less than 4%, no prior gel, smooth surface	Severe heat shrinkage, small cross-section insulation often has a non-smooth surface and a gel
Equipment investment	Medium	Low (steam room or warm pool)
Power consumption	Low (only needs 10 KW)	High (requires long heating)
Cost of production	Low	High
Production cycle	Short (online cross-linking)	Long (requires secondary processing)
Compared with silane cross-linking, UV irradiation machine saves nearly 50000 USD per year.

Comparison of the advantages of the new LED irradiation and online connection with the old high-pressure mercury lamp:

	LED ultraviolet irradiation machine	Old high pressure mercury lamp irradiation machine
Power consumption	Average less than 15 kW per hour	80KW per hour
Maintenance cost	Low	High
Production speed	High	Low
Lamp life	30000 hours	400 hours
Consumables	No	Lamp, reflector, capacitor
Productivity	The extruder is not limited to high speed and can be produced by turning on the light.	Slow production speed, low efficiency, waste of labor, need to preheat for half an hour in advance
Operation and floor space	Simple operation, small footprint, no waiting	Complex operation and large floor space
LED new irradiation machine saves 34,000 USD electricity costs.17,000 USD labor costs and 8,400 USD consumables per year than the old high-pressure mercury lamp irradiation machine.

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LED and mercury lamp spectral contrast

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LED and mercury lamp life comparison

Comparison of production speed curve between mercury lamp irradiation equipment and LED irradiation equipment

UV-LED Iradiation Crosslinking Equipment Performance Parameters:

1. Power: three-phase five-wire system (380V + N + ground)
2. Total installed machine power: 20kW
3. The best diameter of the irradiation area: 30mm

4. Effective irradiation length: 1m

5. The lamp beads use the world's top imported light source, the lens uses imported quartz, so that it has lower energy loss, the lamp set uses liquid cooling technology, so that the LED light source has a longer service life.
6. The power supply adopts Taiwan Mingwei waterproof power supply, which is protected by vacuum potting technology, with overload, short circuit, over current, over voltage and over temperature protection.

7. Optical power output can be arbitrarily adjusted from 10% -100%, according to customer needs to adjust any power.

7. Light source life: 30,000 hours (provided by the manufacturer) The output light intensity is attenuated to 70% (efficiency drops to 70%). The usage time is 30,000 hours, and the calculation time is 6~10 years.

9. Irradiation box size: 1660mm*960mm*1730mm (length x width x height)

Equipment structure features:

1. Silent opening and closing tunnel structure, easy to operate and clean;
2. Using an intelligent touch man-machine interface, monitoring data, and operating button power settings are all completed on the touch screen interface;
3. The touchscreen control function and the button start to coexist separately;
4. The cooling method is cooled by a chiller, and the circulating medium is made of a special antifreeze for automobiles;
5. External smoke removal mechanism, discharged through the air duct outdoor

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Equipment layout

Production speed of cross-linked polyethylene irradiated material

Zone 1	Zone 2		Zone 3		Zone 4	Zone 5	Machine head
135℃	150℃		160℃		175℃	180℃	180℃
Conductor cross section (mm²)		Insulation nominal thickness(mm)		Natural production speed(m/min)		Heat extension (%)	Permanent deformation
1.5		0.7		50-150		50-110	0-10
2.5		0.7		50—150		50~110	0~10
4		0.7		50—150		50~110	0~10
6		0.7		50—150		50~110	0~10
10		0.8		50—140		50~110	0~10
16		0.8		50—140		50~110	0~10
25		0.9		50—100		50~110	0~10
35		0.9		50—100		50~110	0~10
50		1.0		40—100		50~110	0~10
70		1.1		40—90		50~110	0~10
95		1.1		35—90		50~110	0~10
120		1.2		35—80		50~110	0~10
150		1.4		30—70		50~110	0~10
185		1.6		30—60		50~110	0~10
240		1.7		25—45		50~110	0~10
300		1.7		25—35		50~110	0~10

Low-smoke halogen-free irradiation material production speed

Zone 1	Zone 2		Zone 3		Zone 4	Zone 5	Machine head
135℃	150℃		160℃		175℃	180℃	180℃
Conductor cross section (mm²)		Insulation nominal thickness(mm)		Natural production speed(m/min)		Heat extension (%)	Permanent deformation
1.5		0.7		50~150		35~65	0~10
2.5		0.7		50~150		35~65	0~10
4		0.7		50~150		35~65	0~10
6		0.9		30~150		25~65	0~10
10		1.0		30~100		25~65	0~10
16		1.0		30~100		25~65	0~10

Remarks: Because the extrusion equipment and production process and cable materials of different enterprises are different, the extrusion speed will be different. The 90 extruder is not limited.

On-site installation of LED ultraviolet irradiation cross-linking machine