Basic knowledge of wire and cable wire and cable manufacturing process overview
Overview of wire and cable manufacturing process
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, in the outer layer by layer conductor with insulation, shielding,, a cable, jacket, etc., made of wire and cable products. The more complex product mix, the more the level of stacking.
First, the wire and cable manufacturing process features:
1. Superposition of a large length of the combination of continuous production
Superposition of a large length of the combination of continuous production, the impact of wire and cable production is global and control, which involve and affect:
(1) production process and equipment layout
Workshop products of various equipment requirements must be reasonable and discharge process, so that the various stages of semi-finished products, sequential flow. Device configuration to be considered productive capacity of the different balance of production, and some devices may have to configure two or more, to make the production line capacity can be balanced. Reasonable matching combination to the equipment layout and production sites, must be based on products and production to balance taken into account.
(2) production organization and management
Production organization and management must be scientific and rational, careful and accurate, rigorous and meticulous, the operator according to process requirements must be meticulously implemented, any link problems will affect the smooth process, the impact of product quality and delivery. Especially in multi-core cables, a basic unit of a line or a short length of, or quality problems, the entire length of cable will be enough, resulting in scrap. Conversely, if a unit is too long, it must be cut to waste.
(3) Quality Management
Superposition of a large length of the combination of continuous production, so that any one part of the production process, the instantaneous occurrence of a problem, it will affect the quality of the whole cable. The more quality defects in the inner layer, and no timely detection of termination of production, then the greater the loss. Because the production of wire and cable products is different from the assembled, you can open the other pieces of heavy equipment and replacement; wire and cable as a part or process quality problems, this cable is almost irreversible and irreparable. After the treatment is very negative, that is not sawn downgrade or scrap the whole cable. It can not open the heavy equipment.
Quality wire and cable must be throughout the entire production process. Quality inspection departments to tour the entire production process, inspection, operator self-inspection, mutual inspection process from top to bottom, this is to ensure product quality, enhance economic efficiency and means an important guarantee.
2. Multi-category production process, material traffic 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 package, weaving and other textile techniques to metal materials and metal strip around the package vertical package, welded metal forming process and so on.
Wire and cable used in the manufacture of various materials, not only the type, variety, specifications, and large quantities. Therefore, the amount of various materials, spare capacity, batch cycle and bulk material must be approved. Meanwhile, 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 accessories and materials in and out, storage, transfer to the process 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 performance requirements, meet the great length of the continuous high speed production requirements as much as possible, thus forming a series of cable manufacturing equipment. Such as extrusion machine, cable machine, wire 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, the promotion of new equipment for the production and development; in turn, the development of new equipment, but also to promote the new technology to improve the promotion and application. Such as drawing, annealing, extruding series line; physical foaming production line and other special equipment, and promoted the development of wire and cable manufacturing process and to improve and enhance the cable's product quality and production efficiency.
Second, the main process of wire and cable
Wire and Cable by: drawing, stranding, covering three processes to the finished, the more complex model specifications, the higher repeatability.
1. Drawn
The pressure in the metal processing. In the Externally forced through the metal molds (pressure roller), the metal cross section is compressed, and access to the required shape and size of cross-sectional area of technical processing method called metal drawn.
Sub-drawn process: single strands drawn system and stranding.
2. Stranding
In order to improve the flexibility of wire and cable, the overall degree, so that two or more single-line, according to the direction of the provisions of intertwined as stranding.
Stranding process points: Conductor stranding, cabling, braiding, and the winding wire armoring.
3. Coated
Based on the performance requirements of different wire and cable, the use of special equipment in the outside conductor coated with different materials. Coating in minutes:
A. Extruded: rubber, plastic, lead, aluminum and other materials.
B. Vertical package: rubber, wrinkles aluminum material.
C. Wrapping: strip the tape, mica tape, E-glass fiber tape, non-woven fabrics, plastic tapes, 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 material, at room temperature, using a drawing machine or the number of road stretching through the die hole, so that cross-section decreased, length increased, the intensity increased. Drawing is the first of the wire and cable company procedure, drawing of the main process parameters with mode technology.
2. Single wire annealing
Copper, aluminum filament heated to a certain temperature in order to improve the way recrystallization monofilament toughness and reduce the strength of a single wire, wire and cable to meet the requirements of the conductive wire core. The key is to eliminate the annealing process the oxidation of copper.
3. Conductor stranding
To improve the flexibility of wire and cable in order to facilitate the laying of installation, conductive core to multiple monofilaments twisted together. Stranded wire core from the conductive form, the rules can be divided into strands and irregular strands. Irregular Stranded Stranded is divided into concentric stranded complex, a special stranded and so on.
To reduce the area occupied by the wire, reducing the cable geometry, the use of stranded conductors, at the same time pressed in the form, so that ordinary round mutate into semi-circular, fan-shaped, tile-shaped, and pressed the round. Such conductors are used in power cable.
4. Insulation extrusion
Plastic wire and cable type used mainly extruded solid insulation, plastic insulated out the main technical requirements:
4.1. Eccentricity: the thickness of the insulation out of the deviation is embodied 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: out of the surface of the insulation required to be smooth, with no surface roughness, burning, poor quality of impurities
4.3. Density: Extrusion cross section of 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, smaller cable shape, generally need to be twisted a circle. Stranded conductor stranding mechanism similar to the larger diameter section of the stranding, they use a method without back twist. Technical requirements for cabling: First, put an end to stand shaped insulated cores twisted result of bending the cable; second is to prevent insulation from being scratched.
Most of the cable into the cable at the same time with the completion of two processes: one is filled, to ensure that after the cable into the cable round and stability; one is binding, and to ensure that the cable core is not loose.
6. The sheath
To protect the insulated core of the wart is not armored injury, the need for appropriate protection insulating layer, the sheath points: squeeze bag protection layer (isolation units) and the sheath around the bag (cushion). Wrapped with a cushion with a cable instead of banding procedures simultaneously.
7. Armoring
Laying underground cables, work may bear a certain positive pressure, you can choose the structure of steel armor. Cable laying there on the existing positive pressure Tension occasions (such as water in a large gap between the vertical shaft or soil), should be used with the structure of the type of armored steel.
8. Outer sheath
Outer sheath to protect the wire and cable insulation to prevent the erosion of the structure of part of the environmental factors. Outer sheath of the main role is to enhance the mechanical strength of wire and cable, anti-chemical corrosion, moisture, water immersion, to prevent burning, and other capabilities. According to the different requirements of the cable directly extruded by extrusion machine plastic sheath. | Updated:2010.11.09 Source: Clicks:6981
