Jack knowledge about cable:knowledge of Wire and cable manufacturing process

Hello everyone, It’s time to share my knowledge of cable now,Today I will share the knowledge of Wire and cable manufacturing process.

Process

Wire and cable manufacturing and production of most of the mechanical and electrical products are completely different. Another commonly used mechanical and electrical products will be assembled into component parts , multiple parts and then assembled into a single product , the product measured by number of units or pieces . Wire and cable is the basic unit of measurement of length . All are from the conductor wire and cable processing began , with the insulation layer by layer in the periphery of the conductor, shielded cabling , protection layer made ​​of wire and cable products. The more complex structure of the product , the more superimposed layers.

Technological Characteristics

1. large length of continuous overlay combination mode of production , the impact on the global wire and cable production and controllability , which involves and affects:

( 1 ) production process and equipment layout

Various equipment production plant product requirements must be reasonable discharge process , so that the various stages of semi-finished products , sequential flow. Device configuration to be considered and balanced production capacity of different production efficiency , and some equipment may have to configure two or more , in order to make the production capacity of the production line can be balanced . Thus a combination of reasonable matching device layout and production sites , must be based on the product and production to balance considered.

( 2) The production organization and management

Production organization and management must be scientific and reasonable, accurate and careful , meticulous , scrupulous operator must perform according to process requirements , any link problems will affect the process of smooth, affect product quality and delivery. Especially multi -core cable , one pair or the basic unit length is short , or quality problems , the entire length of cable will be enough to cause scrapped. Conversely, if a cell is too long , must be sawn waste.

( 3 ) Quality Management

Large continuous length superimposed combination of production, so that any one part of the production process , some problems occur instantaneously , it will affect the quality of the entire cable . The more quality defects occur in the inner layer , but did not discover the termination of production, then the greater the losses . Because unlike the production of wire and cable products assembled , you can open other pieces of heavy equipment and replacement ; either a part or the wire and cable process quality problems, these cables is almost irreversible and irreparable. Post- processing is very negative , not sawn downgrade is either scrap the entire cable . It is not open to reload.

Quality Management wires and cables must be run through the entire production process . Quality inspection departments to manage the entire production process inspection tour , the operator self-inspection, mutual inspection process from top to bottom , this is to ensure product quality , and means an important guarantee for improving economic efficiency of enterprises .

2 . Production process multiple categories , material flow

Wire and cable manufacturing process involving a wide range of categories , and pressure from the non-ferrous metal smelting and processing, to plastics , rubber, paint and other chemical technology ; fiber material wrapping , weaving and other textile technology , the metal strip around the bag and metal materials the longitudinally welded metal forming process , and so on .

Wire and cable manufacturing a variety of materials used , not only classes , varieties , specifications, and large quantities. Therefore, the amount of various materials , spare capacity , batch and batch cycle must be approved . Meanwhile , the decomposition of waste treatment, recycling , reuse and waste disposal , as an important part of management , good material quota management , attention to conservation work .

Wire and cable production, from raw materials and various auxiliary materials and out of storage , the process of transfer to the semi-finished product storage, factory , material flow, must be rational distribution , dynamic management .

3 . Special equipment and more

Wire and cable manufacturing industry that has the technological characteristics of specialized production equipment , in order to adapt the structure , performance requirements of cable products to meet the large length of continuous high-speed production requirements as much as possible , so as to form a cable manufacturing equipment series. Such as extrusion machine, cable machine, stranding machine, around the charter series.

Closely related to the development of wire and cable manufacturing processes and equipment , and promote each other. The new process requirements, to promote the emergence and development of new specialized equipment ; conversely , the development of new equipment , but also to improve the promotion of the development and application of new technology . Such as drawing, annealing , tandem extrusion line ; physical foaming production lines and other special equipment , wire and cable manufacturing process to promote the development and improvement , improve product quality and production efficiency of the cable.
Second, the main craft wire and cable\

Power cables

Wires and cables through : drawing , stranding , covering three processes to produce finished , the more complex model specifications , the higher reproducibility.

1 . Drawn

In the external force so that the metal in the metal working pressure is forced through the die ( pressure roller ) , a metal cross-sectional area is compressed to obtain technical processing method and the shape and size of the cross-sectional area required called metal drawing .

Drawing process of : single strands system and stranding drawn .

2 . Stranding

To improve the flexibility of wire and cable , the overall degree , so two or more single-wire , interwoven according to a predetermined direction called stranding .

Stranding process points : Conductor stranding , cabling , weaving , wire armouring and winding .

3 . Coated

According to the different performance requirements of the wire cable , the use of special equipment in the outside conductor covering a different material . Coating process points :

A. Squeeze bag : rubber, plastic, lead, aluminum and other materials.
B. Longitudinal package : rubber , wrinkles aluminum material.
C. Wrapping: ribbon tape , mica , E-glass fiber tape, non-woven fabrics , plastic tapes , linear cotton , silk and other fibrous materials.
D. Dip : insulating paint , asphalt , etc.

Third, the basic plastic wire and cable manufacturing process

1 . Copper, aluminum, single strands system

Commonly used copper wire cable , aluminum material , at room temperature , the tensile drawing machine using a die or a number of channels through the die orifice to reduce the cross section , increasing the length , strength. Drawing is the first procedure of each wire and cable companies , the main process parameters are brushed with mold technology.

2 . Annealed monofilament

Copper, aluminum filaments heated to a certain temperature , recrystallization of the monofilament way to improve the toughness and reduce the strength of the monofilament to meet the conductive core wire and cable requirements . The key is to prevent oxidation annealing process copper wire .

3 . Stranding conductor

In order to improve the flexibility of wire and cable in order to facilitate the laying of installation , conductive core to take a plurality of monofilaments twisted together . From the conductive core stranded form, can be divided into rules and irregular strands twisted . Irregular Stranded Stranded divided into concentric complex twist, twisted and so special .

To reduce the area occupied by wire , cable geometries shrink , while using the stranded conductor pressed form, so that variation of ordinary semi circular , fan-shaped, W -shaped and pressed round . Such conductors mainly used in the power cable.

4 . Extruded insulation

Plastic wire and cable type used mainly extruded solid insulation , plastic insulation extruded main technical requirements :

4.1. Eccentricity : extruded insulation thickness deviation is reflected important symbol extrusion process level , most of the product structure size and standard deviation values ​​are clearly defined.

4.2 . Smoothness: the surface of the insulating layer extrusion requires smooth , with no rough surface, charred , poor quality of impurities

4.3 . Density : a cross-sectional extruded insulation layer to be dense and firm, not allowed to have visible pinhole to eliminate the presence of air bubbles.

5. Cabling

For multi -core cables in order to ensure molding degrees , reducing the appearance of the cable, generally need to be twisted round . Mechanism of stranded conductor stranding similar, larger diameter section due stranding , they use no way back twist . Cabling technical requirements : First, eliminate shaped stand up and lead insulated cores twisted cables ; second is to prevent insulation from being scratched.

Most of the cable into the cable accompanied by the completion of the other two processes : one is filled to ensure stability after round into the cable and the cable ; one is lashing ensure no loose cable core .

6. Inner sheath

To protect the insulation core is not the pimple armored injury , the need for appropriate protection insulating layer , the protective layer of : extruded inner sheath ( isolation units ) and wrap the sheath ( cushion ) . Wrapping cushion with a cable instead of banding with processes simultaneously.

7 . Armouring

Laying underground cables , the work may be subject to certain positive pressure, choose the steel tape armored structure. Cable laying there in both the positive pressure pulling force occasions ( such as water , drop a large vertical shaft or soil ) , should be used with structured inner wire armouring .

8. Sheath

Structural part of the outer sheath to protect wire and cable insulation to prevent the erosion of environmental factors . The main role of the outer sheath is to improve the mechanical strength of the wire and cable , anti-chemical corrosion, moisture, water immersion , prevents cable burning capabilities. According to the different requirements of the cable directly to the use of an extruder extruded plastic sheath .

Just this today,welcome to talk about cable knowledge together!