Manufacturing Process of Cables And Wires

In this post, we’re going to talk about the common and crucial steps of cable manufacturing. First of all, let’s clarify two nouns: wire and cable.

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Generally, we call a single conductor a wire, while a cable is two or more insulated wires wrapped in one jacket. Especially, there are always multiple conductors stranded together (we’ll explain why in the following content) within a single insulating layer, and we classify it as a single conductor, i.e. a wire.

Now let’s learn the manufacturing procedures together.

Step 1: Wire drawing

In the first step, our aim is to acquire metal (usually copper or aluminum) wires that fit with AWG (American Wire Gauge). The method is to pull the copper or aluminum rod through a series of synthetic diamond dies, which gradually decrease in size, on the draw bench. And this is processing with a lubricating and cooling system that increased the life of the dies and prevents the wire from overheating.

Step 2: Annealing

During the drawing process, we apply tremendous pressure on metal rod to form a thinner wire. Thus, the wire we get is extremely brittle and can easily be fractured if flexed. The finished wire must be flexible, so in this step we’re going to soften, or to anneal the wire.

Annealing is accomplished by heating the wire to its recrystallization temperature for a period of time. The key here is to avoid oxidation of the wire.

Step 3: Twisting and stranding

As mentioned above, multiple wires often get stranded. That’s because given the same cross-sectional area, stranded wire has better flexibility and electrical performance than single wire.

In this step, two or more wires of the same gauge are twisted or stranded together using a proprietary formula to determine twist length.

Step 4: Extrusion

The wire, now soft and flexible, is passed through an extruder, where the coating of plastic or other insulating material is applied.

Materials are poured into the rear part of the extruder, and are pushed forward while heated into melt. Exiting the extruder, the coated wire passes through another cooling system and is coiled on reels.

Step 5: Cabling

The basic component of cable is now prepared. Next we need to assemble the cable according to different utilities. This process is done in a cabling station.

For the electrical and electronic cables in daily use, we just need to wrap up one or more strands of wires, together with interference-preventing layer if needed, into the protection jacket. In order to have a better forming degree, we often use filler to ensure the finished cable in a shape of round.

For power cable and other cables that need to be buried underground, there are more protective measures:

• bedding/inner sheath: usually a plastic layer to keep the inner wires together and prepare the ‘bed’ for steel armor.
• steel armor: a steel layer used to sustain the pressure and prevent pests underground.
• outer sheath: usually a layer made from the same material as inner sheath, applied over the armor for overall mechanical, weather, chemical and electrical protection.

This concludes what we have for today. If you want to know more about cable manufacturing, feel free to contact us or leave a comment. We’d be glad to hear from you.

Note: We do not own the images used in this post. Feel free to contact us if they belong to you, and we’ll take them down as quickly as we possibly can.

Cables are essential components of modern infrastructure, enabling the transmission of electricity and data across vast distances. The production of cables involves a meticulous process that combines advanced technology and skilled craftsmanship. This article provides a comprehensive overview of how cables are manufactured, from the initial stage of conductor production to the final testing and delivery.

Conductor Manufacturing

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The cable production process begins with the manufacturing of conductors, which serve as the core for transmitting electrical signals. Conductors are typically made from high-quality metals such as copper or aluminum. The process starts with the continuous casting of copper or aluminum rods, followed by extrusion or drawing to achieve the desired conductor diameter and length. These conductors are carefully inspected for quality and consistency.

Stranding

After the conductors are manufactured, they undergo stranding, where multiple conductors are twisted together according to the cable's design requirements. Stranding provides flexibility, durability, and reduces electromagnetic interference. The stranding process can vary depending on the cable type, with different stranding patterns and lay lengths employed to meet specific performance characteristics.

Insulation

Once the conductors are stranded, they proceed to the insulation stage. Insulation involves the application of a protective layer over the conductor surface to prevent electrical leakage and external interference. Various insulation materials are used, including polyethylene (PE), polyvinyl chloride (PVC), or cross-linked polyethylene (XLPE). The insulation thickness is carefully controlled to meet safety and performance standards.

Shielding and Armor

Certain cables require shielding or armor layers for additional protection against external factors. Shielding materials, such as aluminum or copper tapes or braids, are applied to mitigate electromagnetic interference. Armor, such as steel wire or aluminum-plastic tapes, provides mechanical strength and protects against physical damage. These layers are carefully applied using specialized machinery and techniques.

Jacketing

Following insulation and shielding, cables may undergo jacketing, which involves applying an outer protective layer. The jacketing material is selected based on the cable's intended application, considering factors such as UV resistance, flame retardancy, and environmental durability. PVC, PE, or thermoplastic elastomers (TPE) are commonly used for jacketing. The outer jacket provides mechanical strength, moisture resistance, and environmental protection.

Testing and Quality Assurance

Throughout the production process, cables undergo rigorous testing and quality assurance procedures. This ensures that they meet industry standards and customer requirements. Various tests, including continuity, insulation resistance, mechanical performance, and electrical characteristics, are conducted. Advanced testing equipment, such as high-voltage testers and impedance analyzers, are employed to evaluate the cables' performance and reliability.

Packaging and Delivery

Once the cables pass all quality tests, they are carefully packaged to ensure safe transportation and storage. Proper labeling and documentation are provided for easy identification and traceability. Cables are then delivered to customers or distributors, ready for installation in various applications such as power transmission, telecommunications, or construction projects.

Conclusion

The production of cables involves a complex and intricate process that combines advanced manufacturing techniques, precise engineering, and stringent quality control. From conductor manufacturing to final testing and packaging, each step plays a vital role in ensuring the reliability, durability, and performance of the cables. As technology advances, the cable industry continues to innovate, striving to meet the ever-increasing demands for efficient and reliable connectivity in a rapidly evolving world.

For more information, please visit cable compound manufacturers.