The manufacturing of wire and cable is quite different from the way most electromechanical products are produced.
Electromechanical products are usually manufactured by assembling another piece into a component, or multiple components into a single product, and the product is measured in units or pieces.
Wire and cable are measured in length as the basic unit of measurement.
All wires and cables are processed from the conductor, in the periphery of the conductor layer by layer with insulation, shielding, cable, sheath, etc., and made of wire and cable products.
The more complex the product structure, the more layers are superimposed.
This approach to wire and cable production is global and controlling, which involves and affects:
(1) Production Process and Equipment Layout
Various equipment in the production workshop must be reasonable according to the product requirements of the process flow discharge, so that the various stages of semi-finished products, the flow in turn.
Equipment configuration should take into account the different production efficiencies and the balance of production capacity, some equipment may have to configure two or more, to balance the production capacity of the production line.
Thus, the reasonable selection of equipment and production site layout must be based on the product and production volume to balance the comprehensive consideration.
(2) Production Organization and Management
Production organization and management must be scientific and reasonable, thorough and accurate, strict and meticulous, the operator must meticulously follow the process requirements.
Especially in multi-core cables, if a certain wire pair or basic unit length is short, or quality problems, then the entire cable will be insufficient length, resulting in scrapping.
Conversely, if the length of a unit is too long, it must be sawed off resulting in waste.
(3) Quality Control
The large length of continuous stacked combination of production methods, so that any part of the production process, the instantaneous occurrence of a small problem, will affect the quality of the entire cable.
Wire and cable quality management must be consistent throughout the production process.
The wire and cable manufacturing process involves a wide range of categories, from the melting of non-ferrous metals and pressure processing to plastics, rubber, paint, and other chemical technologies.
Fiber materials such as wrapping, weaving, and other textile technology, metal material wrapped around the package and metal strip longitudinal package, welding metal forming process, and so on.
Wire and cable manufacturing of various materials used, not only categories, varieties, specifications, and a large number.
Therefore, the number of various materials, spare capacity, batch cycle, and batch must be approved.
At the same time, the decomposition of waste products, recycling, reuse, and waste disposal, as an important element of management, material quota management, and attention to saving work.
Wire and cable manufacturing using special production equipment with the characteristics of the industry process.
To adapt to the structure of the cable products, performance requirements, to meet the requirements of large lengths of continuous and high-speed production as far as possible, thus forming a cable manufacturing special equipment series.
Such as extrusion machine series, wire drawing machine series, stranding machine series, and winding machine series.
Wire and cable manufacturing processes and the development of specialized equipment are closely related to promoting each other.
New technology requirements, promote the generation and development of new specialized equipment.
In turn, the development of new specialized equipment, and improve the promotion and application of new technologies.
Such as drawing, annealing, and extrusion of tandem lines.
Physical foaming production line and other specialized equipment to promote the development and improvement of wire and cable manufacturing process, improve the quality of cable products and production efficiency.
Wire and cable are made through the pulling, stranding, and wrapping of three processes to complete, the more complex the model specifications, the higher the repeatability.
In metal pressure processing. Under the action of external forces to make the metal forced through the mold (pressure wheel), the metal cross-sectional area is compressed, and to obtain the required cross-sectional area of shape and size of the technical processing methods known as metal pulling.
The drawing process: monofilament drawing and stranded drawing.
To improve the softness of wire and cable, the overall degree, so that more than 2 single lines, according to the direction of the provisions intertwined together called stranding.
Stranding process: conductor stranding, cable, braiding, wire armor, and winding.
According to the different performance requirements of wire and cable, the use of specialized equipment in the conductor outside the coating of different materials. Covering process points:
A. Extruded package: rubber, plastic, lead, aluminum, and other materials.
B. Longitudinal package: rubber, wrinkled aluminum tape material.
C. Winding package: paper tape, mica tape, non-alkali glass fiber tape, non-woven fabrics, plastic tape, etc., threaded cotton yarn, silk, and other fiber materials.
D. Dip-coating: insulating paint, asphalt, etc.
Wire and cable commonly used copper, and aluminum rods, at room temperature, the use of a wire drawing machine through one or more stretching mold die holes, so that the cross-section reduction, length increase, and strength.
Wire drawing is the first process of each wire and cable company, the main process parameter of wire drawing is the technology of matching mold.
Copper and aluminum monofilament heated to a certain temperature, to recrystallize the way to improve the toughness of the monofilament and reduce the strength of the monofilament, to meet the wire and cable on the conductive core requirements.
The key to the annealing process is to eliminate the oxidation of copper wire.
To improve the flexibility of the wire and cable, to facilitate the installation of the laying, the conductive core to take more than one monofilament stranded and become. From the conductive core of the stranded form, can be divided into regular stranded and non-regular stranded.
Non-regular stranding is divided into bunch stranding, concentric double stranding, and special stranding.
To reduce the occupied area of the conductor, reduce the geometric size of the cable, in the stranded conductor at the same time using the form of tight pressure, so that the ordinary round variant of semicircular, fan-shaped, tile-shaped, and tightly pressed round.
This conductor is mainly used in power cables.
Plastic wire and cable mainly used extrusion of solid-type insulation, plastic insulation extrusion of the main technical requirements:
① Eccentricity: extrusion of insulation thickness deviation value is an important symbol of the level of extrusion process, most of the product structure size and its deviation value in the standard are clearly defined.
② Smoothness: the surface of the extruded insulation layer is required to be smooth, there shall be no surface roughness, burnt, impurities, or poor quality problems.
③ Density: the cross-section of the extruded insulation layer should be dense and solid, not allowed to have visible pinholes, to eliminate the presence of air bubbles.
For multi-core cable to ensure the degree of molding, and reduce the shape of the cable, generally needs to be stranded into a round. The mechanism of stranding and conductor stranding are similar, due to the stranded section diameter being large, most of the non-retractable twisted way.
To protect the insulated wire core is not armored by wounds, the need for proper protection of the insulation layer.
The inner protective layer is divided into the extruded inner protective layer (isolation sleeve) and wrapped around the inner protective layer (cushion layer).
Winding and wrapping padding layer instead of tying tape and cable formation process is synchronized.
Laying in the underground cable, the work may be subjected to a certain degree of positive pressure and can choose to armor the structure of the inner steel belt. Cable laying in both positive pressure and tensile role of the occasion.
Such as water, vertical shafts, or fall in the soil, should be selected with an internal steel wire armor structure type.
The sheath is to protect the wire and cable insulation layer to prevent environmental factors and erosion of the structural part.
The main role of the outer sheath is to improve the mechanical strength of the wire and cable, chemical corrosion, moisture, and water immersion, to prevent the cable from burning and other capabilities.
According to the different requirements of the cable using an extrusion molding machine directly extruded plastic sheath.
The above is about the detailed process of cable manufacturing process introduction, if you still want to know more, welcome to consult the ZMS cable website.
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