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Cable production process

Release time:

2021-09-14 11:08

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The basic structure of wire and cable is generally composed of three parts: conductive core, insulating layer and protective layer.

Wire and cable is made by drawing, twisting and wrapping three processes. The more complex the model and specification, the higher the repeatability.

1. Drawing

Under the action of external force, the metal is forced through the mold (pressure wheel), the cross-sectional area of the metal is compressed, and the required cross-sectional area shape and size of the technical processing method is called metal drawing.

2. Stranding

In order to improve the softness of the wire and cable, the overall degree, so that more than 2 single wire, according to the specified direction of intertwined together called twisted.

Stranding process: conductor stranding, cable, weaving and winding.

3. Covering

According to the different performance requirements of wires and cables, special equipment is used to cover different materials on the outside of the conductor. Cladding process:

Extrusion package: rubber, plastic, lead, aluminum and other materials.

Longitudinal package: polyester film, aluminum-plastic composite film and other strip materials.

Winding: ribbon paper tape, mica tape, alkali-free glass fiber tape, non-woven fabric, plastic tape, etc., linear cotton yarn, silk and other fiber materials.

Wire and cable production process is more complex, as follows:

1. Copper, aluminum single wire drawing.

Wire and cable commonly used copper, aluminum rod, at room temperature, the use of wire drawing machine through one or several stretching die hole, so that its cross-section is reduced, the length is increased, the strength is improved. Wire drawing is the first process of wire and cable companies, and the main process parameters of wire drawing are mold matching technology.

2. Monofilament annealing

Copper and aluminum monofilaments are heated to a certain temperature to recrystallize to improve the toughness of the monofilament and reduce the strength of the monofilament to meet the requirements of the wire and cable for the conductive core. The key to the annealing process is to prevent the oxidation of copper wire.

3. Conductor stranded

In order to improve the softness of the wire and cable, in order to facilitate the laying and installation, the conductive core is made of a plurality of monofilaments. From the stranding form of the conductive core, it can be divided into regular stranding and irregular stranding. Non-regular stranding is divided into bundle stranding, concentric complex stranding, special stranding and so on.

4. Insulation extrusion

Main technical requirements for plastic insulation extrusion:

Eccentricity: The deviation value of the extruded insulation thickness is an important indicator of the level of the extrusion process, and most of the product structure dimensions and their deviation values are clearly defined in the standard.

Smoothness: The surface of the extruded insulating layer shall be smooth, and there shall be no poor quality problems such as rough surface, scorching and impurities.

Density: the cross section of the extruded insulating layer should be dense and strong, no visible pinholes are allowed, and the existence of bubbles is eliminated.

5. Cable

For multi-core cables, in order to ensure the molding degree and reduce the shape of the cable, it is generally necessary to twist it into a round shape. The mechanism of stranding is similar to that of conductor stranding. Due to the large diameter of stranding section, most of them adopt the non-back-twisting method. The technical requirements for cable formation are: first, to prevent the twisting of the cable caused by the turning of the profiled insulated core; The second is to prevent the insulation layer from being scratched.

6. Inner sheath

In order to protect the insulation core from being cut by the armor, the insulation layer needs to be properly protected. The inner sheath is divided into extruded inner sheath (isolation sleeve) and wrapped inner sheath (cushion). Winding the cushion layer instead of the binding tape is carried out simultaneously with the cabling process.

7. Armored

Laying in the underground cable, the work may bear a certain positive pressure, can choose the inner steel belt armored structure. Cable laying in both positive pressure and tensile role of the occasion (such as water, vertical shaft or large drop in the soil), should be selected with inner steel wire armor structure.

8. External protection

The outer sheath is a structural part that protects the insulating layer of the wire and cable from environmental factors. The main function of the outer sheath is to improve the mechanical strength of the wire and cable, prevent chemical corrosion, moisture-proof, waterproof immersion, and prevent the cable from burning. According to the different requirements of the cable, the plastic sheath is directly extruded by the extruder.

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