HDPE Microduct Optical Duct Cable Protection Casing Cod Pipe Production Line

As a professional manufacturer of plastic tube machinery in China, Comrise can provide you with an HDPE Microduct Optical Duct Cable Protection Casing Cod Pipe Production Line specifically designed for producing integrated COD (corrugated optical duct) optical cable protective tubes with HDPE silicon core microducts as inner tubes and HDPE spiral corrugated outer shells as main tubes.

Working Principle

The HDPE Microduct Optical Duct Cable Protection Casing Cod Pipe Production Line uses two independent production lines. One PE pipe machine produces inner pipes with silicon core layers and temporarily stores them in rolls. The other machine sends multiple inner pipes into the outer pipe co extrusion coating mold, and outputs the finished products through corrugated forming, cooling, traction, cutting, and winding. Both the inner and outer pipes of the entire line are made of HDPE or modified HDPE raw materials. The friction coefficient of the inner wall of the inner pipe can be reduced to below 0.1, and the outer pipe has a spiral corrugated structure with a ring stiffness twice that of ordinary solid wall PE pipes. The length of a single coil can reach 300-1000 m.

Production Process

Silicon core tube inner PE tube production line

The silicon core micro tube extrusion production line is responsible for the production of internal sub tubes in the HDPE Microduct Optical Duct Cable Protection Casing Cod Pipe Production Line.

1. The extruder of this production line adopts an automatic feeding machine and a drying hopper. HDPE raw materials are mixed with colorants and silicon core masterbatch in proportion and sent to SJ65/33 or SJ60/38 high-speed single screw main extruders. The screws are nitrided with a length to diameter ratio of 33:1 to 38:1, achieving double-layer co extrusion of HDPE outer layer and silicon core layer. The raw material is formed into micro tubes with a diameter of 7-32 mm through a double-layer machine head mold

2. Immediately enter the vacuum box and spray box for cooling and shaping. The water tank is made of 304 stainless steel, which is of good quality, not easy to leak, and has a long service life

3. We use servo control for the traction machine, with two claws for more stable traction of pipes and shapes, making them less prone to deformation

4. The single station rewinding machine coils into a roll with a length of 1000 meters, which is used for online unwinding by the second machine; The line speed of the inner pipe unit can reach 30m/min, and the silicon core layer and HDPE layer are stable

Outer layer corrugated coating pipe production line

1. COD outer corrugated sleeve coating production line, responsible for compounding the multi roll silicon core inner tube produced by the first machine into a main tube. The first end of the unit is equipped with a multi axis inner tube unwinding rack and a guide comb, which unfolds and tightens multiple inner tubes at equal intervals in a honeycomb pattern and sends them into a large wrapping mold head; The outer tube is wrapped around the outer side of the inner tube bundle by an SJ75/33 single screw high-efficiency extruder, and the rear end of the die is connected to a spiral corrugated forming mold. The outer tube is continuously extruded to form a spiral rib structure.

2. The outer tube enters the lengthened vacuum cooling tank and the spray water tank is finalized. The whole body of the water tank is made of 304 stainless steel, with good quality and long service life

3. The two claw tractor is pulled out synchronously at a speed of 1.5-3 m/min to ensure the production efficiency and continuity of the machine

4. The large coil winder is rolled into finished COD coil. The whole section is centrally controlled by Siemens PLC+HMI. The inner tube unwinding tension, outer tube extrusion amount, corrugated pitch and traction speed are fully closed loop matched.

Product parameter

Application Scenarios

It is widely used in 5G base station return, FTTH fiber to the home, high-speed highway and railway communication, and municipal communication network engineering.

 Why choose Comrise COD pipe production line?

1. Stable extrusion molding, rejecting "hole collapse" and eccentricity

Adopting an efficient single screw extruder for uniform plasticization and stable raw materials

Independently develop and produce COD special molds, opti mize design, ensure high concentricity of porous structure, smooth inner wall mirror, and reduce cable resistance by more than 30%.

Vacuum sizing and precise temperature control of the water cooling system effectively prevent deformation and ovality of the pipes during cooling.

2. High speed production, leading production capacity

The design speed of the inner tube production line can reach 35 m/min, far exceeding the industry average level.

Servo driven tractor, closed-loop control, constant traction force without slipping, ensuring stable meter weight at high speeds.

Online dual station winding/fixed length cutting, achieving continuous production and significantly reducing downtime for coil replacement.

3. Intelligent control to reduce manual dependence

Siemens/ABB/Schneider and other international first-line electrical brands, PLC centralized control, intuitive and easy to learn human-machine interface.

Full line linkage protection, fault self diagnosis, automatic alarm and shutdown for abnormalities, minimizing waste rate to the greatest extent possible.

4. Excellent pipe quality and strong market competitiveness

The stiffness of the COD pipe ring produced can reach SN4-SN8, with excellent compressive performance and adaptability to different burial depths.

Support customized three hole, four hole, five hole, seven hole and other cross-sectional structures to flexibly meet customer needs.

FAQ

Q:What is the production speed of your COD pipe production line? Is it faster than its peers?

A: The conventional specifications (such as 5 holes with a diameter of 40) have a line speed of 8-15 m/min, while the optimized process can reach 18-22 m/min, depending on the raw materials, wall thickness, and cooling length. Adopting servo traction and high-efficiency screw, the speed is about 15%~25% faster than ordinary lines under the same specifications.

Q:How long is the lifespan of the mold? Is it expensive to replace later?

A: The mold material is 38CrMoAl nitrided, and normal production takes 2-3 years without major repairs; Vulnerable parts (mouth molds, sizing sleeves) are supplied separately at a price of only 20% to 30% of the whole mold.

Q:How long does it take from ordering to production?

A: Standard configuration production line takes 40 working days to leave the factory; Customized molds or special specifications are required for 40-50 days. Including installation, debugging, and training, qualified pipes can be produced within 3-5 days after arrival at the factory.

Q;Do you package installation and debugging? What if the workers don't know how to operate?

A: Package. After the equipment arrives at the factory, the technician stays on site for 7-10 days, responsible for water, electricity, and gas connection, start-up and mold adjustment, process solidification, and providing hands-on training to operators and maintenance workers until they independently produce qualified pipes