Electrical Cable Manufacturing Process: 8 Key Stages Explained
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Author : yd export
Update time : 2025-02-14 08:40:00
Modern power transmission relies on precision-engineered cables. This guide decodes the complete production workflow certified by IEC/ISO standards, featuring critical technical parameters and innovation trends.
1. Wire Drawing (Conductor Formation)
- Diameter reduction: Copper/aluminum rods (8mm → 0.05-3mm)
- Dynamic lubrication system (±0.002mm precision)
- Optimal elongation ratio: 1.2-1.4
2. Annealing (Conductivity Enhancement)
- Copper: 450-600°C in N₂/H₂ atmosphere
- Elongation control: 35-45%
- Oxidation prevention (residual O₂ <50ppm)
3. Stranding (Flexible Core Design)
- Compact structures:
- Concentric stranding (7/19/37 wires)
- Sector-shaped compression (92% fill factor)
- Diameter reduction: 15-20%
4. Insulation Extrusion (Dielectric Protection)
- Triple-layer co-extrusion:
- Semiconductor shield (surface resistance <500Ω·m)
- XLPE insulation (30kV/mm withstand voltage)
- Eccentricity tolerance <5%
5. Cabling (Core Integration)
- Anti-twist system (95% efficiency)
- Hydrophobic tape filling
- Laser-verified circularity >90%
6. Multi-Layer Protection System
**Inner Sheath**:
- Cross-linked PE (0.8-2mm thickness)
- Hydrostatic resistance >1MPa
**Armor Layer**:
- Non-magnetic stainless steel (0.5mm)
- Eddy current loss <3W/m
**Outer Jacket**:
- UV-resistant compound (3000h QUV test)
7. Advanced Quality Assurance
- Partial discharge detection (5pC sensitivity)
- Flame resistance testing (IEC60332-3C certified)
- AI-powered 4.0 inspection systems
Innovation Trends in Cable Production
✔️ Lead-free compounds (Pb <100ppm)
✔️ Digital twin process optimization
✔️ Self-healing insulation materials
1. Wire Drawing (Conductor Formation)
- Diameter reduction: Copper/aluminum rods (8mm → 0.05-3mm)
- Dynamic lubrication system (±0.002mm precision)
- Optimal elongation ratio: 1.2-1.4
2. Annealing (Conductivity Enhancement)
- Copper: 450-600°C in N₂/H₂ atmosphere
- Elongation control: 35-45%
- Oxidation prevention (residual O₂ <50ppm)
3. Stranding (Flexible Core Design)
- Compact structures:
- Concentric stranding (7/19/37 wires)
- Sector-shaped compression (92% fill factor)
- Diameter reduction: 15-20%
4. Insulation Extrusion (Dielectric Protection)
- Triple-layer co-extrusion:
- Semiconductor shield (surface resistance <500Ω·m)
- XLPE insulation (30kV/mm withstand voltage)
- Eccentricity tolerance <5%
5. Cabling (Core Integration)
- Anti-twist system (95% efficiency)
- Hydrophobic tape filling
- Laser-verified circularity >90%
6. Multi-Layer Protection System
**Inner Sheath**:
- Cross-linked PE (0.8-2mm thickness)
- Hydrostatic resistance >1MPa
**Armor Layer**:
- Non-magnetic stainless steel (0.5mm)
- Eddy current loss <3W/m
**Outer Jacket**:
- UV-resistant compound (3000h QUV test)
7. Advanced Quality Assurance
- Partial discharge detection (5pC sensitivity)
- Flame resistance testing (IEC60332-3C certified)
- AI-powered 4.0 inspection systems
Innovation Trends in Cable Production
✔️ Lead-free compounds (Pb <100ppm)
✔️ Digital twin process optimization
✔️ Self-healing insulation materials
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