Wire and cable manufacturing process flow:

Wire and cable manufacturing and production of most mechanical and electrical products are completely different. Another commonly used mechanical and electrical products will be assembled into component parts, a plurality of parts and then assembled into a single product, the products are measured by the number of units or the number of pieces. Length of wire and cable is the basic unit of measure. All are from the conductor wire and cable processing start, coupled with the insulating layer by layer in the periphery of the conductor, shielded ,, cabling, protective layer, etc. made of wire and cable products. Product structure more complex, the more superimposed layers.

First, the wire and cable manufacturing process characteristics:

1. Great combination of the length of the continuous superposition production

Great combination of the length of the continuous superposition mode of production, the impact on the global wire and cable production and controllability, which involve and affect:

(1) production process and equipment layout

Various equipment production plant must be reasonable product requirements process emissions, so that the various stages of semi-finished products, sequential flow. Device configuration to consider different balance production capacity of 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 reasonable matching device combination and arrangement of production sites, it must be based on products and production capacity to balance considered.

(2) production organization and management

Production organization and management must be scientific and rational, accurate and careful, rigorous and meticulous, the operator must meticulously executed according to process requirements, any link problems, will affect the process of smooth, affect product quality and delivery. Especially multi-core cables, a particular line of the base unit or shorter, or quality problems, the entire length of the cable will be enough, resulting in scrap. Conversely, if a cell is too long, it must be sawn wastage.

(3) Quality Management

Great length of continuous superimposed combination of production, so that any one part of the production process, no problem occurs instantaneously, it will affect the entire root cable quality. The more quality defects occur in the inner layer, and no timely detection of termination of production, the greater the losses. Because the production of wire and cable is different from the assembled product, it can open the other pieces of heavy equipment and replacement; wire and cable to any part of a process or quality problems, this cable is almost irreversible and irreparable. Post-processing is very negative, is not sawn downgrade or scrap the entire cable. It can not open the heavy equipment.

Quality wire and cable management must run through the entire production process. Quality inspection departments to manage the entire production process inspection tour operator self-inspection, mutual inspection process from top to bottom, which is to ensure the quality of products, tools and important guarantee for improving economic efficiency of enterprises.

2. Many categories of production technology, material flow

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

Wire and cable manufacturing all kinds of material used, not only the type, variety, 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 materials quota management, attention to conservation work.

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

3. Special equipment and more

Wire and cable manufacturing industry having the characteristics of equipment for the production process, in order to adapt the structure, performance requirements of cable products to meet the large length of the continuous high-speed production requirements and as far as possible, so as to form a special cable manufacturing equipment series. Such as extrusion machine, drawing machine series, stranding machine, around the charter series.

Closely related to the development of wire and cable manufacturing process and special 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 promote the improvement of the promotion and application of new technology. Such as drawing, annealing, tandem extrusion line; physical foaming production line and other special equipment, and promote the wire and cable manufacturing process development and improvement, improve product quality and production efficiency of the cable.

Second, the main wire and cable technology

Wire and cable through: drawing, stranding, covering three processes to produce complete model specifications more complicated, higher repeatability.

1. Drawn

Under pressure external force so that the metal processing metal forced through a die (pressure roller), a metal cross sectional area is compressed and technical processing method of cross-sectional shape and size of the desired metal called drawing.

Draw process point: monofilament system and stranding drawn.

2. Stranding

In order to increase the flexibility of wire cable, the overall degree, so that two or more single-line, according to a predetermined direction entwined called stranding.

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

3. Coated

According to the wire and cable different performance requirements, the use of special equipment on the outside conductor covering different materials. Coating process point:

A. Extruded: rubber, plastic, lead, aluminum and other materials.

B. Longitudinal package: rubber, aluminum material wrinkles.

C. Wrapping: tape strip, mica, E-glass fiber tape, non-woven, plastic belt, 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 monofilament system

Commonly used copper wire and cable, aluminum pole timber, at room temperature, the use of wire drawing machine drawing die through a number of channels or 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. Monofilament annealing

Copper, aluminum filament heated to a certain temperature, recrystallization of ways to improve the toughness of the monofilaments, reducing the strength of the monofilament, wire and cable to meet the requirements of the conductive core. The key is to prevent oxidation annealing step copper wire.

3. Stranding conductor

In order to increase the flexibility of wire cable in order to facilitate the laying of installation, adopt a multi-conductive core filaments twisted together. From the conductive wire core twisted form, it can be divided into rules and irregular strands twisted. Irregular Stranded Stranded divided into concentric stranded complex, special twisted like.

In order to reduce the area occupied by the wires, cables narrow geometry, while the use of stranded conductor in pressed form, so that ordinary round mutate into a semicircle, sector, tile and pressed round. Such conductors are used in the power cable.

4. Extruded insulation

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

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

   4.2. Smoothness: the surface of the insulating layer extruded required to be smooth, with no rough surface, burnt, 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. Stranding

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

Most of the cable into the cable at the same time accompanied by the completion of the other two processes: one is filled, round and ensure stability after the cable into the cable; a lashing is to ensure that the core is not loose.

6. Inner sheath

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

7. Armoring

Laying underground cables, may be subjected to some of the positive pressure, optional internal steel tape armored structure. Cables laid in both positive pressure there pulling action of the occasion (such as water, a vertical shaft or a large drop in the soil), should be used with internal structural steel armor.

8. Outer sheath

Outer jacket is a structural part of the protective wire and cable insulation layer prevents environmental factors erosion. 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 cable using an extruder directly extruded plastic sheath.