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wire and cable manufacturing process overview
wire and cable manufacturing and most of the mechanical and electrical products is totally different. Another commonly used mechanical and electrical products will be assembled into component parts, more parts and then assembled into a single product, product number or number of units measured. Length of wire and cable are the basic units of measurement. All wire and cable conductors are processed from the beginning, the outer layer of the conductor layer to add insulation, shielding,, a cable, sheath, etc., made of wire and cable products. The more complex product mix, the more superimposed layers.
one wire and cable manufacturing process features:
1. Large length of the continuous overlay combination mode of production
large length of the continuous overlay combination mode of production, the impact of wire and cable production is global and control, which involve and affect:
(1) production process and equipment layout
workshop equipment of all types must be reasonable according to the product requirements process emissions, so that the various stages of semi-sequential flow. Device configuration to be considered for production efficiency and production capacity of the different balance, and some equipment may have to configure two or more, in order to make the production line capacity can be balanced. To mix and matching of equipment and reasonable layout of production sites, must be based on the product and production to balance into account.
(2) production organization and management
production organization and management must be scientific and rational, careful and accurate, meticulous, scrupulous operators must perform according to process requirements, any part of a problem will affect the smooth process, the impact of product quality and delivery. Especially in multi-core cable, a basic unit of a pair, or a short length, or quality problems, then the entire length of cable will be enough, resulting in scrap. Conversely, if a unit is too long, you must saw to waste.
(3) Quality Management
large length of the continuous overlay combination mode of production, so that any part of the production process, instantaneous point problem, it will affect the entire cable quality. The more quality defects in the inner layer, and no timely detection of termination of production, then the greater the loss. Because the wire and cable production is different from the assembled product, the other can open the heavy equipment and replacement parts; wire and cable components or processes of any quality problems, this cable is almost irreversible and irreparable. Post-processing is very negative, not a downgrade is sawn, or scrap the whole cable. It can not open the heavy.
quality wire and cable management, must be throughout the entire production process. Quality inspection departments to check the entire production process, tour, operator self-inspection, mutual inspection process from top to bottom, this is to ensure product quality, and improving economic efficiency and means guaranteed.
2. Many categories of production processes, material flow
wire and cable manufacturing process involved in categories ranging from non-ferrous metal smelting and pressure processing, the plastics, rubber, paint and other chemical technology; fiber material around the bag, knitting and other textile techniques to metal around the package and the metal strip longitudinally and welding of metal forming processes, and so on.
wire and cable used in the manufacture of a variety of materials, not only classes, varieties, specifications, and large quantities. Therefore, the amount of various materials, spare capacity, batch cycle and bulk material must be approved. At the same time, the decomposition of waste treatment, recycling, reuse and waste disposal, as an important part of management, good materials, quota management, attention to conservation work.
wire and cable production, from raw materials and auxiliary materials out of storage, the process of transfer to semi-finished products, storage, factory , material flow, must be rational distribution and dynamic management.
3. Special equipment and more
wire and cable manufacturing process that has the characteristics of the industry-specific production equipment, the structure of cable products to meet the performance requirements to meet the large length continuous and high-speed production requirements as much as possible, thus forming a cable manufacturing special equipment series. Such as extrusion machine, cable machine, stranding machine, around the charter series.
wire and cable manufacturing process and is closely related to the development of special equipment, and promote each other. New technology requirements, special equipment for the new generation and development; in turn, the development of new special equipment, but also to promote the new technology to improve the promotion and application. Such as drawing, annealing, tandem extrusion line; physical foaming production line and other special equipment, wire and cable manufacturing process to promote the development and improvement, improved cable product quality and production efficiency.
Second, the main wire and cable technology
wire and cable by: drawing, stranding, covering three processes to produce complete, the more complex model specifications, repetitive higher.
1. Drawn
pressure in the metal processing in the external force causes the metal forced through the die (roller), the metal cross section is compressed, and cross-sectional area to obtain the required shape and size of the technical process is called metal drawn.
sub-drawn process: single-system and the twisted strands drawn.
2. Twisted
wire and cable in order to improve the softness of the overall degree, so that two or more single, according to the provisions of the direction of the intertwined as stranding.
twisted craft points: Conductor stranding, cabling, weaving, wire wrapping equipment and armor.
3. Coated
wire and cable based on the different performance requirements, the use of special equipment outside of coated conductors of different materials. Sub-coating process:
A. Extruded: rubber, plastic, lead, aluminum and other materials.
B. Longitudinally: rubber, aluminum material wrinkles.
C. Wrapping: strip of tape, mica tape, with E-glass fiber, nonwoven, plastic tape, etc., line of cotton, silk and other fiber materials.
D. Dipping: insulating paint, asphalt, etc.
Third, the basic plastic wire and cable manufacturing process
1. Copper, aluminum, single strands system
commonly used copper wire and cable, aluminum timber, at room temperature, using a drawing machine or the number of road stretching through the mold die hole to cross-section decreases, the length increases, strength increases. Drawing is the first wire and cable company procedure, drawing of the main process parameters with mode technology.
2. Monofilament annealing
copper, aluminum, single-wire heated to a certain temperature, the recrystallization way to improve the toughness of a single wire, reducing the single-wire strength to meet the conductive wire core wire and cable requirements. Annealing process is critical to prevent the oxidation of copper wire.
3. Conductor stranding
wire and cable in order to improve the flexibility, in order to facilitate the laying of installation, conductive core to multi-stranded wire made of a single root. From the conductive core of stranded form, the rules can be divided into irregular strands and strands. Beam is divided into irregular strands twisted, concentric stranded complex, a special stranded and so on.
wire in order to reduce the footprint, reduce the cable geometry, stranded conductor in the same time pressed in the form used to make ordinary round mutate into semi-circular, fan-shaped, tile and pressed the round. Such conductors are used in the power cable.
4. Insulation out
plastic wire and cable type used mainly extruded solid insulation, plastic insulated out the main technical requirements:
4.1. Eccentric: out of insulation thickness deviation reflects the extrusion process is an important indicator of the level, most of the product structure in size and its standard deviation are clearly defined.
4.2. Smooth: out of insulation require a smooth surface, the surface may appear rough, charred, impurities of bad quality
4.3. Density: a cross section extruded insulation to dense and firm, not allowed to have visible pinhole to eliminate the presence of air bubbles.
5. Cabling
for multi-core cable in order to ensure shape, reducing the cable shape, generally need to be twisted round. Stranded conductors twisted with similar mechanism, as twisted section of larger diameter, they use no back-twist mode. Cabling technology requirements: First, to eliminate shaped stand which led to the insulated core cable contortion; second is to prevent insulation from being scratched.
most of the cable into the cable at the same time with the completion of the other two processes: one is filled, ensure that after the cable into the cable round and stability; one is the banding, to ensure that the cable core is not loose.
6. Within the sheath
in order to protect the insulated core of the wart is not armored injury, the need for appropriate protection insulation, inner sheath points: squeeze package within the sheath (isolation units) and the sheath around the bag (cushion). Wrapped with a cushion and into the cable instead of banding procedures simultaneously.
7. Mounted armor
laying of underground cables, work may bear a certain positive pressure, optional structure within the steel armor. Cable laying there in both the positive pressure where the role of tension (such as water, a large gap between the vertical shaft or soil), should be used with steel armor within the structure type.
8. Sheath
outer sheath to protect the wire and cable insulation to prevent the erosion of the structural elements of environmental factors. The main role of the outer sheath is to improve the mechanical strength of wire and cable, anti-chemical corrosion, moisture, water immersion, prevents cable burning capabilities. According to different requirements on the use of the cable extruder directly extruded plastic sheath. |
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