Cable extruder tools are essential in the manufacturing of cables and wires. They are used to apply various layers such as insulation, sheathing, and protective coatings to conductors. Below is a detailed list of common cable extruder tools, their applications, and examples.

1. Extrusion Head
**Application:** Used to shape and apply materials such as PVC, PE, XLPE, or other polymers around the conductor or cable core.
**Example:**
- **Tool Name:** Crosshead Extruder (for cross-linkable polyethylene in high-voltage cables).
- **Usage:** Forms a consistent layer of insulation or sheathing material around a conductor.

Components of an Extrusion Head
1. **Main Body (Housing):** Houses all the internal components and connects to the extruder. Typically made of high-strength steel or aluminum.
2. **Die and Mandrel:**
   - **Die:** Determines the outer shape of the extruded material.
   - **Mandrel:** Shapes the inner surface of the extrusion (e.g., to allow for a conductor core or cable to pass through).
3. **Flow Channel:** Guides molten material evenly from the extruder barrel to the die and mandrel assembly.
4. **Crosshead (Optional):** Used for co-extrusion or applying insulation to a core.
5. **Heating Elements:** Maintains the required temperature for the material throughout the extrusion process.
6. **Alignment Mechanism:** Ensures concentric alignment of the cable within the extrusion head.


2. Screw Extruder
**Application:** Melts and pushes the plastic or rubber material through the extrusion head.
**Example:**
- **Tool Name:** Single-Screw Extruder or Twin-Screw Extruder.
- **Usage:** Common in the production of medium and low-voltage cables, with materials like PVC or thermoplastic elastomers.

3. Caterpillar Capstan
**Application:** Pulls the cable through the extrusion line at a consistent speed, ensuring uniform coating thickness.
**Example:**
- **Tool Name:** Dual Caterpillar Capstan.
- **Usage:** Maintains tension during the extrusion of long cables.

4. Cooling Trough
**Application:** Used to cool down and solidify the extruded material, ensuring a durable finish.
**Example:**
- **Tool Name:** Water Cooling Trough.
- **Usage:** Common in the production of PVC-insulated cables.

5. Preheater
**Application:** Preheats the conductor before extrusion to improve adhesion of the insulation material.
**Example:**
- **Tool Name:** Conductor Preheater.
- **Usage:** Used in XLPE insulation processes.

6. Spark Tester
**Application:** Tests the integrity of the insulation layer for any faults or pinholes.
**Example:**
- **Tool Name:** High-Voltage Spark Tester.
- **Usage:** Commonly used in quality control for power cables.

7. Diameter Controller
**Application:** Monitors the outer diameter of the cable during extrusion to ensure compliance with standards.
**Example:**
- **Tool Name:** Laser Diameter Gauge.
- **Usage:** Provides real-time feedback in manufacturing data systems.

8. Payoff and Take-Up Stands
**Application:** Payoff supplies the conductor to the extruder, while take-up reels the finished cable after extrusion.
**Example:**
- **Tool Name:** Motorized Payoff Stand and Take-Up Machine.
- **Usage:** Supports high-speed cable production lines.

9. Stripping and Cutting Tools
**Application:** Cuts the extruded cable to specified lengths and strips outer sheaths for further processing.
**Example:**
- **Tool Name:** Cable Stripper and Cutter.
- **Usage:** Used for post-production trimming and quality inspection.

10. Triple-Layer Extrusion Systems
**Application:** Simultaneously applies multiple layers, such as conductor shielding, insulation, and outer shielding, in a single process.

**Example:**
- **Tool Name:** Triple-Extrusion Head.
- **Usage:** Widely used in the production of high-voltage cables with XLPE insulation.

Sample Application Workflow: Low-Voltage PVC Cable Extrusion
1. **Payoff Machine:** Supplies the bare conductor.
2. **Preheater:** Warms the conductor for better polymer adhesion.
3. **Extruder with Single-Screw System:** Applies a layer of PVC insulation.
4. **Cooling Trough:** Solidifies the PVC layer.
5. **Spark Tester:** Checks for insulation defects.
6. **Diameter Controller:** Ensures uniform thickness.
7. **Take-Up Machine:** Collects the finished cable.