The manufacture of wire and cable is totally different from that of most electromechanical products. Electromechanical products are usually used to assemble parts into parts and then assemble multiple parts into a single product. The product is measured in units or pieces. Wire and cable is based on the length of the basic unit of measurement. All electric wires and cables are started from conductor processing. The outer layers of conductors are insulated, shielded, cabled, sheathed, etc. to form wire and cable products. The more complex the product structure, the more layers are stacked.
First, the technical characteristics of wire and cable products manufacturing:
1. Superimposing a large length of the continuous production compositions <br> <br> large length of the continuous production superposed combination, effect on the wire and cable production is global and controllability, which involves and affects:
(1) production process and equipment layout <br> <br> production plant emissions by various devices must be reasonable process product requirements, the various stages of semi-finished products, sequential flow. The equipment configuration must consider the production efficiency to be different and balance the production capacity. Some equipment may have to configure two or more units in order to balance the production capacity of the production line. Therefore, the rational selection and combination of equipment and the layout of production sites must be balanced based on the product and production volume.
(2) production organization and management <br> <br> production organization and management must be scientific and rational, careful and accurate, rigorous and detailed, the operator must meticulously executed according to process requirements, any link problems, will affect the smooth process, the impact of product The quality and delivery. Especially for multi-core cables, if the length of one pair or basic unit is short, or the quality is problematic, the entire length of the cable will be insufficient, resulting in scrap. Conversely, if a unit is too long, it must be sawn for waste.
(3) Quality Management <br> <br> large length of the continuous superposition combinations of production, so that the production process of any one part, no problem occurs instantaneously, it will affect the quality of the whole cable. The more the quality defect occurs in the inner layer, and the failure to discover the termination of production in time, the greater the damage caused. Because the production of wires and cables is different from that of assembled products, they can be dismantled and replaced, and the quality of any component or process of the wire and cable is almost irretrievable and remediable. Afterwards, the treatment is very negative. It is not a matter of shortening or downgrading, or scrapping the entire cable. It cannot be opened and reinstalled.
The quality management of wire and cable must go through the entire production process. The quality management and inspection department must carry out a thorough inspection of the entire production process, operator self-inspection, and mutual inspection of the upper and lower processes. This is an important guarantee and means for ensuring product quality and improving the economic efficiency of enterprises.
2. Many types of production technology, large material flow
Broad categories of wire and cable manufacturing process involved, and the pressure from the smelting of the processing, the chemical technology plastics, rubber, paint and the like; fiber material around the package, weaving and other textile technology, the metallic material and the metal strip around the package The vertical package, welding metal forming process and so on.
The various materials used in wire and cable manufacturing are not only of different types, specifications, and specifications, but also large quantities. Therefore, the amount of various materials, reserves, batch cycle and batch must be approved. At the same time, the dismantling, recycling, recycling, and waste disposal of waste products are an important part of management, and do a good job in managing material quotas and paying attention to conservation.
In the production of wires and cables, from the entry and exit of raw materials and various auxiliary materials, storage, and the flow of semi-finished products from each process to the storage and delivery of products, the material flow rate is large, and it must be rationally laid out and dynamically managed.
3. Multi <br> <br> special equipment dedicated wire and cable manufacturing industry process equipment having the characteristics of the structure to accommodate the cable product, performance requirements, and to meet the large length of the continuous high-speed production as required, thereby forming a line Cable manufacturing special equipment series. Such as extrusion machine series, cable machine series, stranding machine series, around the charter series.
The manufacturing process of wire and cable is closely related to the development of special equipment and promote each other. The new process requirements promote the generation and development of new special equipment; in turn, the development of new special equipment has boosted the promotion and application of new processes. Such as drawing, annealing, extrusion series line; physical foam production line and other special equipment, promote the development of wire and cable manufacturing process and improve, improve the cable's product quality and production efficiency.
Second, the main process <br> <br> wire and cable wire and cable by: drawing, stranding, covering three processes to produce complete, the more complex model specifications, higher repeatability.
1. Technical drawing processing method <br> <br>. Press working so that the metal in the metal is forced through the die by an external force (pressure wheels), the metal cross-sectional area is compressed and obtain the required cross-sectional shape and size Metal pull.
Drawing process points: monofilament drawing and strand drawing.
2. Stranding <br> <br> order to increase the flexibility of wire and cable, the overall degree of, let more than two single-line, by pressing a predetermined direction intertwined called stranding.
Stranding process points: conductor stranding, cable, weaving, wire mounting and winding.
3. <br> <br> coated wire and cable according to different performance requirements, the use of special equipment covering a different material on the outside of the conductor. Coating process:
A. Extrusion: rubber, plastic, lead, aluminum and other materials.
B. Longitudinal bag: rubber, wrinkle aluminum tape material.
C. Winding: Banded paper tape, mica tape, E-glass fiber tape, non-woven fabric, plastic tape, linear cotton yarn, silk and other fiber materials.
D. Dipping: Insulating paint, asphalt, etc.
Third, the basic process of plastic wire and cable manufacturing process 1. Copper, aluminum monofilament made of conventional wire and cable <br> <br> copper, aluminum pole member, at room temperature, drawing machine using a die orifice through a drawing die or the number of channels, so that cross section reduction, increasing the length Increased strength. Drawing is the first process of each wire and cable company, and the main process parameter of drawing is the matching technology.
2. <br> <br> filaments annealed copper, aluminum monofilament is heated to a certain temperature, recrystallization manner to improve the toughness of the monofilaments, the monofilaments reduce the strength, to meet the requirements for wire and cable's conductive core . The key to the annealing process is to eliminate the oxidation of the copper wire.
3. Conductor stranding <br> <br> order to increase the flexibility of wire cables in order to lay the installation, the conductive core to take a plurality of monofilaments twisted together. From the twisted form of the conductive core, it can be divided into regular twisting and irregular twisting. Irregular stranding is further divided into bundle stranding, concentric twin stranding, and special stranding.
In order to reduce the occupied area of ​​the wire and reduce the geometric size of the cable, a tightly-pressed form is adopted while the conductor is stranded, so that the ordinary round shape is mutated into a semicircle, a fan shape, a tile shape, and a tightly-pressed round shape. This type of conductor is mainly used in power cables.
4. <br> <br> insulating plastic extruded wire and cable type using extruded solid insulating layer, the extruded plastic insulated main technical requirements:
4.1. Eccentricity: The deviation of the extruded insulation thickness is an important indicator of the level of extrusion technology. Most of the product's structural dimensions and their deviations are clearly defined in the standard.
4.2. Smoothness: The surface of the extruded insulating layer is required to have a smooth surface, and no unfavorable quality problems such as surface roughness, burnt, and impurities are allowed. 4.3. Density: The cross-section of the extruded insulation layer should be dense and solid, with no visible pinholes, to prevent the presence of air bubbles.
5. <br> <br> to the cable into the cable core in order to ensure plurality of molding, reduce the profile of the cable, generally it needs to be stranded circular. The mechanism of stranding is similar to that of the conductor stranding system. Due to the large diameter of the twisted section, most of the twisted strands are not back-twisted. The technical requirements for cabling are as follows: First, to prevent the twisting of the cable caused by the inconvenience of the insulated wire core; and secondly, to prevent the insulating layer from being scratched.
Most of the cables are completed with the completion of two other processes at the same time: one is padding to ensure roundness and stability of the cable after the cable is laid, and the other is lashing to ensure that the cable core is not loose.
6. <br> <br> inner sheath in order to protect the insulated core armored pimple Without being wound, the need for proper protection of the insulating layer, the inner sheath points: the extruded jacketing layer (isolation units) and around the inner jacketing Layer (cushion). The padding layer instead of the binding band is synchronized with the cabling process.
7. Armoring <br> <br> laying underground cables, may be subjected in a certain positive pressure, optional interior steel armor structure. When cables are laid in places where there is both positive pressure and tensile force (such as in water, vertical shafts, or in soils with large gaps), the structural type with internal steel wire armor should be used.
8. <br> <br> outer jacket is an insulating layer for protecting the outer sheath of the cable wire to prevent erosion moiety environmental factors. The main role of the outer sheath is to improve the mechanical strength of the wire and cable, prevent chemical corrosion, moisture, water leaching, and prevent the cable from burning. According to the different requirements of the cable, the plastic jacket is directly squeezed by the extruder.
First, the technical characteristics of wire and cable products manufacturing:
1. Superimposing a large length of the continuous production compositions <br> <br> large length of the continuous production superposed combination, effect on the wire and cable production is global and controllability, which involves and affects:
(1) production process and equipment layout <br> <br> production plant emissions by various devices must be reasonable process product requirements, the various stages of semi-finished products, sequential flow. The equipment configuration must consider the production efficiency to be different and balance the production capacity. Some equipment may have to configure two or more units in order to balance the production capacity of the production line. Therefore, the rational selection and combination of equipment and the layout of production sites must be balanced based on the product and production volume.
(2) production organization and management <br> <br> production organization and management must be scientific and rational, careful and accurate, rigorous and detailed, the operator must meticulously executed according to process requirements, any link problems, will affect the smooth process, the impact of product The quality and delivery. Especially for multi-core cables, if the length of one pair or basic unit is short, or the quality is problematic, the entire length of the cable will be insufficient, resulting in scrap. Conversely, if a unit is too long, it must be sawn for waste.
(3) Quality Management <br> <br> large length of the continuous superposition combinations of production, so that the production process of any one part, no problem occurs instantaneously, it will affect the quality of the whole cable. The more the quality defect occurs in the inner layer, and the failure to discover the termination of production in time, the greater the damage caused. Because the production of wires and cables is different from that of assembled products, they can be dismantled and replaced, and the quality of any component or process of the wire and cable is almost irretrievable and remediable. Afterwards, the treatment is very negative. It is not a matter of shortening or downgrading, or scrapping the entire cable. It cannot be opened and reinstalled.
The quality management of wire and cable must go through the entire production process. The quality management and inspection department must carry out a thorough inspection of the entire production process, operator self-inspection, and mutual inspection of the upper and lower processes. This is an important guarantee and means for ensuring product quality and improving the economic efficiency of enterprises.
2. Many types of production technology, large material flow
Broad categories of wire and cable manufacturing process involved, and the pressure from the smelting of the processing, the chemical technology plastics, rubber, paint and the like; fiber material around the package, weaving and other textile technology, the metallic material and the metal strip around the package The vertical package, welding metal forming process and so on.
The various materials used in wire and cable manufacturing are not only of different types, specifications, and specifications, but also large quantities. Therefore, the amount of various materials, reserves, batch cycle and batch must be approved. At the same time, the dismantling, recycling, recycling, and waste disposal of waste products are an important part of management, and do a good job in managing material quotas and paying attention to conservation.
In the production of wires and cables, from the entry and exit of raw materials and various auxiliary materials, storage, and the flow of semi-finished products from each process to the storage and delivery of products, the material flow rate is large, and it must be rationally laid out and dynamically managed.
3. Multi <br> <br> special equipment dedicated wire and cable manufacturing industry process equipment having the characteristics of the structure to accommodate the cable product, performance requirements, and to meet the large length of the continuous high-speed production as required, thereby forming a line Cable manufacturing special equipment series. Such as extrusion machine series, cable machine series, stranding machine series, around the charter series.
The manufacturing process of wire and cable is closely related to the development of special equipment and promote each other. The new process requirements promote the generation and development of new special equipment; in turn, the development of new special equipment has boosted the promotion and application of new processes. Such as drawing, annealing, extrusion series line; physical foam production line and other special equipment, promote the development of wire and cable manufacturing process and improve, improve the cable's product quality and production efficiency.
Second, the main process <br> <br> wire and cable wire and cable by: drawing, stranding, covering three processes to produce complete, the more complex model specifications, higher repeatability.
1. Technical drawing processing method <br> <br>. Press working so that the metal in the metal is forced through the die by an external force (pressure wheels), the metal cross-sectional area is compressed and obtain the required cross-sectional shape and size Metal pull.
Drawing process points: monofilament drawing and strand drawing.
2. Stranding <br> <br> order to increase the flexibility of wire and cable, the overall degree of, let more than two single-line, by pressing a predetermined direction intertwined called stranding.
Stranding process points: conductor stranding, cable, weaving, wire mounting and winding.
3. <br> <br> coated wire and cable according to different performance requirements, the use of special equipment covering a different material on the outside of the conductor. Coating process:
A. Extrusion: rubber, plastic, lead, aluminum and other materials.
B. Longitudinal bag: rubber, wrinkle aluminum tape material.
C. Winding: Banded paper tape, mica tape, E-glass fiber tape, non-woven fabric, plastic tape, linear cotton yarn, silk and other fiber materials.
D. Dipping: Insulating paint, asphalt, etc.
Third, the basic process of plastic wire and cable manufacturing process 1. Copper, aluminum monofilament made of conventional wire and cable <br> <br> copper, aluminum pole member, at room temperature, drawing machine using a die orifice through a drawing die or the number of channels, so that cross section reduction, increasing the length Increased strength. Drawing is the first process of each wire and cable company, and the main process parameter of drawing is the matching technology.
2. <br> <br> filaments annealed copper, aluminum monofilament is heated to a certain temperature, recrystallization manner to improve the toughness of the monofilaments, the monofilaments reduce the strength, to meet the requirements for wire and cable's conductive core . The key to the annealing process is to eliminate the oxidation of the copper wire.
3. Conductor stranding <br> <br> order to increase the flexibility of wire cables in order to lay the installation, the conductive core to take a plurality of monofilaments twisted together. From the twisted form of the conductive core, it can be divided into regular twisting and irregular twisting. Irregular stranding is further divided into bundle stranding, concentric twin stranding, and special stranding.
In order to reduce the occupied area of ​​the wire and reduce the geometric size of the cable, a tightly-pressed form is adopted while the conductor is stranded, so that the ordinary round shape is mutated into a semicircle, a fan shape, a tile shape, and a tightly-pressed round shape. This type of conductor is mainly used in power cables.
4. <br> <br> insulating plastic extruded wire and cable type using extruded solid insulating layer, the extruded plastic insulated main technical requirements:
4.1. Eccentricity: The deviation of the extruded insulation thickness is an important indicator of the level of extrusion technology. Most of the product's structural dimensions and their deviations are clearly defined in the standard.
4.2. Smoothness: The surface of the extruded insulating layer is required to have a smooth surface, and no unfavorable quality problems such as surface roughness, burnt, and impurities are allowed. 4.3. Density: The cross-section of the extruded insulation layer should be dense and solid, with no visible pinholes, to prevent the presence of air bubbles.
5. <br> <br> to the cable into the cable core in order to ensure plurality of molding, reduce the profile of the cable, generally it needs to be stranded circular. The mechanism of stranding is similar to that of the conductor stranding system. Due to the large diameter of the twisted section, most of the twisted strands are not back-twisted. The technical requirements for cabling are as follows: First, to prevent the twisting of the cable caused by the inconvenience of the insulated wire core; and secondly, to prevent the insulating layer from being scratched.
Most of the cables are completed with the completion of two other processes at the same time: one is padding to ensure roundness and stability of the cable after the cable is laid, and the other is lashing to ensure that the cable core is not loose.
6. <br> <br> inner sheath in order to protect the insulated core armored pimple Without being wound, the need for proper protection of the insulating layer, the inner sheath points: the extruded jacketing layer (isolation units) and around the inner jacketing Layer (cushion). The padding layer instead of the binding band is synchronized with the cabling process.
7. Armoring <br> <br> laying underground cables, may be subjected in a certain positive pressure, optional interior steel armor structure. When cables are laid in places where there is both positive pressure and tensile force (such as in water, vertical shafts, or in soils with large gaps), the structural type with internal steel wire armor should be used.
8. <br> <br> outer jacket is an insulating layer for protecting the outer sheath of the cable wire to prevent erosion moiety environmental factors. The main role of the outer sheath is to improve the mechanical strength of the wire and cable, prevent chemical corrosion, moisture, water leaching, and prevent the cable from burning. According to the different requirements of the cable, the plastic jacket is directly squeezed by the extruder.
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