Cable manufacturing process

technological process
The manufacturing of wires and cables is different from the production methods of most electromechanical products. Mechanical and electrical products are usually assembled by assembling other parts into components, or by assembling multiple components into a single product, and the product is measured by the number of units or pieces. Wire and cable are measured in length as the basic unit of measurement. All wires and cables are made from the processing of conductors, by adding insulation, shielding, cabling, protective layers, etc. layer by layer around the periphery of the conductor to produce wire and cable products. The more complex the product structure, the more layers are stacked.
Process characteristics
1、 The impact of the long continuous stacking combination production method on the production of wires and cables is global and controllable, which involves and affects:
(1) Production process flow and equipment layout
The various equipment in the production workshop must be reasonably discharged according to the required process flow of the product, so that the semi-finished products in each stage can be circulated sequentially. Equipment configuration should consider the balance of production capacity based on different production efficiencies. Some equipment may require the configuration of two or more units in order to balance the production capacity of the production line. Therefore, the reasonable selection and combination of equipment and the layout of production sites must be balanced and comprehensively considered based on the product and production volume.
(2) Production organization management
Production organization and management must be scientific, reasonable, meticulous, accurate, and strictly detailed. Operators must strictly follow the process requirements. Any problem in any link will affect the smoothness of the process flow, the quality and delivery of products. Especially for multi-core cables, if a pair of wires or a basic unit is short in length, or if there is a quality issue, the entire cable will not be long enough, resulting in scrap. On the contrary, if a unit is too long, it needs to be sawed off, causing waste.
(3) Quality Management
The production method of continuous stacking and combination of large lengths can affect the quality of the entire cable if any problem occurs in any link or instant during the production process. The more quality defects occur in the inner layer and are not detected and terminated in a timely manner, the greater the losses caused. Because the production of wires and cables is different from assembled products, they can be disassembled, reassembled, and replaced with other parts; Any quality issue with any component or process of a wire or cable is almost irreparable and irreparable for that cable. The handling afterwards is very negative, either cutting short or downgrading, or scrapping the entire cable. It cannot be disassembled and reinstalled.
The quality management of wires and cables must run through the entire production process. The quality management inspection department should conduct patrol inspections, self inspections by operators, and mutual inspections between upper and lower processes throughout the entire production process. This is an important guarantee and means to ensure product quality and improve the economic efficiency of the enterprise.
2. Multiple production process categories and large material flow
The manufacturing of wires and cables involves a wide range of processes, from the melting and pressure processing of non-ferrous metals to chemical technologies such as plastics, rubber, and paint; The textile technology of wrapping and weaving fiber materials, to the wrapping of metal materials and the longitudinal wrapping and welding of metal strips, and so on.
The various materials used in the manufacturing of wires and cables are not only diverse in categories, varieties, and specifications, but also in large quantities. Therefore, the dosage, reserve quantity, batch cycle, and batch size of various materials must be verified. At the same time, the decomposition, recycling, reuse, and disposal of waste materials are important aspects of management, and material quota management and conservation work should be emphasized.
In the production of wires and cables, from the entry and storage of raw materials and various auxiliary materials, the circulation of semi-finished products in each process to the storage and delivery of products, the flow of materials is large, and it is necessary to layout and dynamically manage them reasonably.
3. Multiple specialized devices
The manufacturing of wires and cables uses specialized production equipment with industry process characteristics to adapt to the structural and performance requirements of cable products, meet the requirements of continuous and high-speed production of large lengths, and thus form a series of specialized equipment for cable manufacturing. Such as extruder series, wire drawing machine series, wire twisting machine series, winding machine series, etc.
The manufacturing process of wires and cables is closely related to the development of specialized equipment. The emergence and development of new process requirements and specialized equipment; In turn, the development of new specialized equipment has increased the promotion and application of new processes. Such as wire drawing, annealing, extrusion series line; Specialized equipment such as physical foaming production lines have contributed to the development and improvement of wire and cable manufacturing processes, enhancing the product quality and production efficiency of cables.
2、 Main processes of wires and cables
Power cable
Wire and cable are produced through three processes: drawing, twisting, and wrapping. The more complex the model specifications, the higher the repeatability.
1. Drawing
In metal pressure processing The technical processing method of forcibly passing metal through a mold (pressure wheel) under external force, compressing the cross-sectional area of the metal, and obtaining the required cross-sectional area shape and size is called metal drawing.
The drawing process is divided into single wire drawing and twisting drawing.
2. Twisting
In order to improve the flexibility and integrity of wires and cables, twisting two or more single wires together in the specified direction is called twisting.
The twisting process includes conductor twisting, cabling, weaving, steel wire armor, and winding.
3. Covering
According to different performance requirements for wires and cables, specialized equipment is used to wrap different materials around the conductor. The wrapping process is divided into:
A. Squeezing: Materials such as rubber, plastic, lead, aluminum, etc.
B. Vertical package: rubber, wrinkled aluminum strip material.
C. Wrapping: Ribbon paper tape, mica tape, alkali free glass fiber tape, non-woven fabric, plastic tape, etc., linear fiber materials such as cotton yarn and silk.
D. Dip coating: insulation paint, asphalt, etc