a basic knowledge of the wire and cable wire and cable manufacturing process Overview

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     Wire and cable manufacturing and the production of most of the mechanical and electrical products are completely different. Mechanical and electrical products commonly used parts assembled into components, multiple components and then assembled into a single pr oduct, the product measured in number of units or pieces. Wire and cable is the basic unit of measurement for length. All wire and cable from the conductor processing, conductor of the external layer by layer with insulation, shielding, and a cable sheath made of wire and cable products. The more complex the product structure superimposed on the more level.

A wire and cable manufacturing process characteristics:cable clamp

A. Large length of the continuous overlay combination mode of production

Large length superimposed on a continuous combination of modes of production, the impact of wire and cable production is global and control, which involve and affect:

(1) the production process and equipment layout

Production workshop of a variety of devices must be reasonable process emissions of the product requirements of the various stages of semi-finished products, sequential circulation. Device configuration to consider the productivity and the balance of production capacity, some equipment may have to configure two or more, in order to make the production line capacity to be balanced. Thus reasonable matching combinations of equipment and production space layout, considering the balance must be based on the product and production.metal cable clamp

(2) The production organization and management

Production organization and management must be scientific and rational, careful, accurate, meticulous, the operator must be meticulously performed according to process requirements, any part of a problem will affect the patency of the process, the impact of product quality and delivery. In particular, multi-core cables, a line or the basic unit of length is short, or quality problems, the entire cable length is insufficient, resulting in scr ap. Conversely, if a unit is too long, you must sawn wasteful.

(3) quality management

Large length of continuous overlay combination mode of production, so that any link in the production process, instantaneous problem will affect the quality of the cables. More quality defects in the inner layer, and there is no timely detection of termination of production losses caused by the greater. Wire and cable production is different from the assembled product, you can open the heavy equipment and replacement of the other pieces; wire and cable of any one component or process quality, these cables is almost irreversible and irreparable. After the treatment is very negative, not sawn downgrade or scrap the whole cable. It can not open the heavy equipment.

Quality management, wire and cable throughout the entire production process. The entire production process, quality inspection department inspection tour operator self, mutual inspection of the upper and lower processes, which is an important guarantee to ensure product quality, improve the economic efficiency of enterprises and means.

Two. Categories of production processes, material flow

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

A variety of materials used in wire and cable manufacturing, not only classes, varieties, specifications, and large quantities. Therefore, the amount of various materials, spare capacity, batch feeding cycle and bulk must be approved. At the same time, the decomposition of waste treatment, recycling, reuse and waste disposal, as an important element of management, good materials, quota management, attention to conservation work.

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

3. Special equipment for multi-

Wire and cable manufacturers for production equipment of the technological characteristics of the industry to adapt to the structure of the cable products, performance requirements, to meet the large length of the continuous and, as far as possible, high-speed production requirements, thus forming a cable manufacturing equipment series. Series such as extrusion machine, cable machine, stranding machine, around the charter series and so on.

Wire and cable manufacturing process and equipment development is closely related to, and promote each other. New process requirements, in turn, the development of new equipment, but a lso to improve the promotion of the promotion and application of new technology to promote the emergence and development of new equipment; Such as drawing, annealing, extrusion series line; physical foaming production line and other special equipment, promote the development and improvement of the wire and cable manufacturing process, improve product quality and production efficiency of the cable.conduit saddle

Two, the main process of the wire and cable

Wire and cable is coated with three processes to produce complete model specifications: drawing, stranding, the more complex the repeatability of the higher.

A. Drawn

Metal pressure processing, the metal under external force to force the metal cross-sectional area is compressed by mold (pressure roller), and obtain the required cross-sectional area shape and size of the technical processing method called metal draw n.

Drawn process: the drawing of the single strands system and stranding.

Two. Stranding

In order to improve the softness of the overall degree of wire and cable, so the above two singlet intertwined called stranding, according to the prescribed direction.

The process of stranding: Conductor stranding, cabling, knitting, wire armouring and winding.

3. Coated

Coated with different materials, the use of dedicated equipment outside of the conductor wire and cable performance requirements. The coating process:

A. Squeeze the packet: rubber, plastic, lead, aluminum and other materials.

B. Longitudinal package: rubber wrinkles aluminum material.

C. Around the package: the strip of tape, mica tape, E-glass fiber with non-woven, plastic bands, line of cotton yarn, silk and other fibrous materials.

D. Dipping: insulating paint, asphalt, etc.

Third, plastic wire and cable manufacturing process

A. Copper, aluminum and single strands

Drawing machine wire and cable commonly used in copper, aluminum timber, at room temperature, the use of one or a few channel of the die hole stretch, so that the cross-section decreases, the length increases, the intensity increased. The drawing is the first process of the wire and cable company, drawing the main process parameters with modeling techniques.

Two. Monofilament annealing

Copper, aluminum, single-wire heated to a certain temperature, recrystallization way to improve the toughness of monofilament, reducing the strength of the monofilament, to comply with the conductive wire core of the wire and cable. The annealing process the key is to eliminate the oxidation of the copper wire.

3. Conductor stranding

In order to improve the flexibility of the wire and cable installation, so that the laying of the conductive core is to take multi ple monofilament strands. Stranded in form of the conductive wire core can be divided into rule stranded and irregular strands. Irregular stranded divided into Stranded Concentric complex twist and special stranded.

Pressed in the form in order to reduce the footprint of the wire, narrow geometry of the cable, stranded conductors, while the ordinary circular variation of the semi-circular, fan-shaped, tile-shaped and pressed round. Such conductors are mainly used in power cables.

4. Insulation extrusion

Plastic wires and cables with extruded solid type insulation, extruded plastic insulated main technical requirements:

4.1 Eccentricity: the deviation of the thickness of the insulation extrusion is to reflect an important symbol of extrusion process level, most of the product structure, size and its deviation in the standard are clearly defined.

4.2 Smoothness: the extruded insulation surface required to be smooth, shall rough surface, char, poor quality of the impurities

4.3 Density: cross-section of extruded insulation layer is dense and firm, are not allowed to have visible pinholes, to eliminate the presence of air bubbles.

5 A cable

For multi-core cables in order to ensure the molding degree, reduce the appearance of the cable, generally need to be stranded in a circle. The mechanism of stranded conductor stranding similar to the twisting section of larger diameter, mostly with no back twist. Cabling technical requirements: First, eliminate the special-shaped insulated cores stand up and lead to the torsional bending of the cable; prevent the insulation layer is scratched.

Most of the cable in the cabling is accompanied by the completion of the other two processes: filling, guarantee to the cable after the cable round and stable; a lashing to ensure that the cable core is not loose.

6. The sheath

In order to protect the i nsulated core armored pimple injury, you need to provide appropriate protection to the insulation layer, sheath: squeeze the package within the sheath (isolation units) and sheath around the package (cushion). Around the package cushion instead of banding with and into the cable process simultaneously.

7. Armoring

Laying underground cables, may work under a certain positive pressure, selectable within the steel tape armored structure. Laying the cable in both positive pressure and pull the role of occasions (such as water, vertical shafts or the gap between the larger soil) should be used with internal steel wire armored structured.

8. Outer sheath

The outer sheath is the structural part of the protection of wire and cable insulation to prevent the erosion of environmental factors. The outer sheath of the main role is to improve the mechanical strength of the wire and cable, chemical corrosion, moisture-proof, waterproof immersion to prevent cables burning ability. According to different requirements on the cable extruder directly extruded plastic sheath.