The manufacturing of wire processing is completely different from the way most electromechanical products are produced. Mechanical and electrical products usually assemble another part into a part, and then assemble multiple parts into a single product. The product is measured by the number of units or pieces. Wire processing uses length as the basic unit of measurement. All wires and cables start with conductor processing, overlapping insulation, shielding, cable making, shielding, etc. on the outer periphery of the conductor to make wire and cable products. The more complex the structure, the more overlapping levels there are. So, let’s learn about the wire processing process together!

1. Process characteristics of wire processing and manufacturing:

1. Long continuous lamination production method

The impact of the ultra-long continuous lamination production method on wire and cable production is global and controllable, involving and affecting

1) Production process and equipment configuration;

Various equipment at the production site must be discharged reasonably according to the process flow required by the product, and semi-finished products at each stage must be moved in sequence. Equipment configuration needs to consider differences in production efficiency to balance production capacity. In order to balance the production capacity of the production line, some equipment sometimes needs to be configured with more than 2 units. Therefore, the reasonable material selection and combination of equipment and the configuration of the production site must be considered based on the balance of products and output.

2) Management of production organization

The management of the production organization must be scientific, reasonable, thorough, accurate, strict and meticulous. Operators must strictly follow the process requirements. Problems in any link will affect the smooth progress of the process and affect the quality and delivery of the product. Especially for multi-core cables, if the length of a certain pair or basic unit becomes short or the quality is defective, the overall length of the cable will be insufficient and it will be discarded. Conversely, if a unit is too long, the waste must be cut off with a saw.

3) Quality management

In the production method of long and continuous combination of wire processing, at any stage of the production process, as long as a problem occurs in an instant, the overall quality of the cable will be affected. Quality defects occur in the inner layer, and the longer the production stoppage is not discovered in time, the greater the loss will be. Since the production of wires and cables is different from that of assembled products, other parts can be disassembled and reinstalled or replaced. The quality problems of any parts and workmanship of the wire are almost irreparable for this cable. The aftermath was very negative, not sawing it short or degrading it, but abandoning the entire cable. Cannot be disassembled and reassembled.

Quality control of wire processing must be implemented throughout the entire production process. The quality management inspection department must conduct inspections of the entire production process, operator self-inspections, and mutual inspections of upper and lower processes. This is an important guarantee and means to ensure product quality and improve corporate economic benefits.

2. There are many types of wire processing and production techniques, and the material flow is large

The manufacturing of wire processing involves a wide range of fields from the dissolution and stamping processing of non-ferrous metals to chemical technologies such as plastics, rubber, and paints; from the wrapping and weaving of fiber materials and other textile technologies to the wrapping of metal materials and the longitudinal direction of metal strips. Packaging, welding metal forming processing technology, etc. reason. 3. A lot of special equipment

Wire processing and manufacturing uses special production equipment with industry characteristics, adapts to the structure and performance requirements of cable products, meets the requirements of long-term continuous production and high-speed production as much as possible, forming a series of special equipment for cable manufacturing. Extruder series, wire drawing machine series, twisting machine series, wrapping machine series, etc.

2. Main technologies of wire processing

Wire processing is made by three techniques: drawing, twisting, and embedding. The more complex the model and specification, the higher the reproducibility.

1. In metal stamping processing, the technical processing method of forcing the metal to pass through the mold (stamping wheel) through external force, thereby compressing the cross-sectional area of the metal and obtaining the required cross-sectional area shape and size is called metal stamping processing.

Stretching technology is divided into: monofilament drawing and twisting.

2. Stranding: In order to improve the flexibility and integrity of wires and cables, twisting two or more single wires in a specified direction is called stranding.

Twisting technology is divided into: twisting the conductor to make a rope, and adding armor to the braid and steel wire.

3. Embedding: According to different performance requirements for wires and cables, special equipment is used to embed different materials on the outer surface of the conductor.

Components of wire processing technology: a. Extrusion package: rubber, plastic, lead, aluminum and other materials.

b. Longitudinal package: rubber, pleated aluminum strip material.

c. Roll package: paper tape, mica tape, alkali-free glass fiber tape, non-woven fabric, plastic tape, etc., filamentary cotton yarn, thread and other fiber materials.

d. Dip coating: insulating coating, asphalt, etc.

The above introduction is the wire processing process. If you need to know more, you can contact us at any time!