Investigation of the factors affecting the capacity and power values of the extruder in the wire insulation coating process

The wire insulation coating process is the procedure of covering the circumference of conductors used in power transmission lines with thermoplastic material. This process is generally carried out on an extrusion line, the most critical equipment of which is the extruder. The extruder ensures that the plastic material is melted at high temperature and continuously coated onto the wire. In this thesis study, the design of an extruder machine used in the wire insulation coating process has been carried out, and the main parameters affecting system performance have been examined both experimentally and theoretically. The aim of the study is to reveal the effects of the variables that determine the extruder capacity and power requirements, and accordingly, to develop suitable mechanical, thermal, and flow designs. Within the scope of the thesis, a single-core cable with a nominal cross-section of 6 mm² will be produced, with the production speed of the wire insulation line set at 1000 m/min, and PVC selected as the insulation material. Based on these production parameters, an extruder capable of meeting the plastic capacity requirement has been designed. In the capacity calculations, basic flow mechanisms such as drag flow, pressure flow, and leakage flow were considered; and experimental results were compared with theoretical data. The results obtained showed that the designed extruder can operate at the desired line speeds for certain types of plastic, and that its energy consumption remains within acceptable limits. In addition, mechanical design parameters such as motor selection, power transmission components, and reduction ratio were determined at optimum levels, supported by calculations. Within the scope of the thesis, an extruder selection program was developed supported by theoretical calculations and calibrated with experimental data to enable fast and reliable selection of suitable extruders for different cable types and line capacities, thereby providing a scientific basis for machine selection and reducing production costs. This study contributes to improving the efficiency of extruder systems used in the wire insulation process and presents findings that can serve as a basis for similar engineering designs.