Sales Service, Production Service

Copper and aluminum wire drawing, it is the first process to produce cable and wire. Wire drawing is a metalworking process used to reduce the cross-section of a wire by pulling the wire through a single or series of drawing die. Usually, for cable and wire production, we draw electrical copper billet, electrician round copper wire, electrical Pole and electrical round aluminum to specified wire diameter by wire drawing machine. In our factory, we have high-speed drawing machines which the max. speed can reach more than 30 meters per second, and the finished single diameter spans from 1.0mm to 4.0mm. The machine is composed of 4 parts, including pay-off part, drawing part with 13 models, annealing system and take-up part. The advanced machines guarantee that we have capacity to produce bulk products in short time and with good quality.

It is the first process to produce the overhead application cable. The wire drawing process is quite simple in concept. The wire is prepared by shrinking the beginning of it, by rolling, so that it wiil fit through the die, the wire is then pulled through the die. Its volume remains the same, so as the diameter decreases, the length increases. Usually the wire will require more than one draw, through successively smaller dies, to reach the desired size. We have special drawing machines, it is also high speed with more than 40 meters one second. As same, those machines guarantee our high efficiency.

Except the solid conductor cable and wire which the conductor consists of one piece of metal wire, normally, wire stranding is second process to produce cable and wire. Stranded wire is composed of a number of small wires bundled or wrapped together to form a larger conductor. Stranded wire is more flexible than solid wire of the same total cross-sectional area. Stranded wire tends to be a better conductor than solid wire because the individual wires collectively comprise a greater surface area. Stranded wire is used when higher resistance to metal fatigue is required. The lowest number of strands usually seen is 7: one in the middle, 6 surrounding it. The next level up is 19, which is another layer of 12 strands on top of the 7. After that the number varies, but 37 and 49 are common, then in the 70 to 100 range (the number is no longer exact). Even larger numbers than that are typically found only in very large cables. We have frame-type stranding machines with 91 bobbins, and its production range of conductor cross-sectional area is from 50mm2 to 1000mm2. We also have many other kinds of stranding machines as fork-type ones. Thus, it is easy to understand our production capacity.

It is a process applicable for XLPE extruded insulation power cable rated voltage of 6kV(U0=7.2kV) to 35kV(U0=40.5kV). Triple-layer extrusion is the three layers, including the conductor screen, XLPE insulation and insulation screen extrude in same time by a triple-layer extrusion equipment which is a most important part of CCV production line. The CCV production line is composed of pay-off parts, traction system, triple-layer extruder set, cross-linking system, cooling system and turn-on system. Our CCV production line imported from Maillefer-Nokia in Finland which is one of the most advanced cable manufacturing machine all over the world. With this advanced machine, we can produce high quality medium voltage cables.

It is the third process for insulated cable and wire with low voltage. The extrusion of insulation, the raw compound material is commonly in the form of nurdles (small beads, often called resin) that are gravity fed from a top mounted hopper into the barrel of the extruder. Additives such as colorants and UV inhibitors (in either liquid or pellet form) are often used and can be mixed into the resin prior to arriving at the hopper. We have not less than 10 extruders with code no. 35mm, 50mm, 95mm, 120mm, 150mm and 200mm, and they can extrude both XLPE and PVC insulation, the outer diameter before extrusion spans from 2.0mm to 150mm, and the insulation thickness scope is from 0.2mm to 10mm. Most of them are manufactured by famous cable equipment company in our domestic, such as Dongfang Electrical and Shenma Group, and some of them are imported from Finland and Germany. Our those equipment provide guarantee to our quality and capacity.

Pair twisting is applicable to computer cable, power cord, telephone cable, instrument cable, signal cable and communication cable which is with twin pairs, triple pairs and multi pairs structure. Twisted pair cabling is a type of wiring in which two conductors of a single circuit are twisted together for the purposes of canceling out electromagnetic interference (EMI) from external sources; for instance, electromagnetic radiation from unshielded twisted pair (UTP) cables, and crosstalk between neighboring pairs. We have high-speed twisting machines, and it is worth to say that our twisting machine is with the lapping function. It means that our equipment make the pair twisting and lapping process in same step, to save more production time, to make our production more efficient.

For more than two cores cable, after the conductor insulated, every single cable core twisted together with filling material to required core number. We have cabling machines not only for power cable, max.6 cores, but also for multi core cable up to 91 cores. The perfect equipment to make sure that our factory have strong capacity to produce almost full categories.

Wrapping is an important process after cabling. It is applicable for non-woven cloth, PVC black belt, fireproof mica tape, polyester tape, fiberglass tape, waterproof tape and other non-metallic shielding material. Usually, the main purpose for the wrapping process is to avoid the cable cores loosing. Usually, a cabling machine match with a wrapping machine, in some production line, it means that the cable cores pull through the cabling machine and then enter the wrapping machine directly. Anyway, we have high speed wrapping machines to meet our production requirement.

Braid process is applicable for screened cable and wire, usually, the screen material is tinned copper wires, aluminum-magnesium alloy wires, steel wire, fiber and other materials. We have braiding machines with 24 spindles and 48 spindles to meet the specification requirement.

This process is very important to protect the cable from the external damage, especially, for underground cable. We have relevant machines to operate the armour process. Whether for STA or SWA, our equipment is with high speed. As the video presented, it is our STA machine which can produce steel tape with thickness scope from 0.1 to 0.8mm with width 20mm to 50mm. Our capacity can meet client’s harsh requirement.

It is a critical process for manufacturing screen wrapped by copper tape, Al-plastic tape or other metallic tape in cables such as control cables, computer cables, 6kV or above XLPE insulated power cable, special cables for inverter motor and so on. Actually, the equipment for this process also is a wrapping machine, but for metallic material. Anyway, we have advanced equipment to meet the different production demand.

Actually, the sheath extrusion process is similar as the insulation extrusion process. As video presented, this extrusion machine is for both inner sheath and outer sheath, and the max. outer diameter is 150mm. We also have other sheath extrusion machines to meet production requirement for different cable specification.

Whatever any standard, the electrical resistance value of conductor is the key factor to prove the cable or wire if qualified or not. Thus, the electrical resistance test must be measured for every batch of cable and wire, usually, by electrical bridge. Besides the perfect production equipment, we also have perfect inspection equipment to inspect and control our quality. The test range and accuracy of our bridge is 0.000001 to 100ohm.

Besides the electrical resistance test, the structure and dimension test also is a very important test for cable and wire, it includes many items, such as number of core, cross section area, color of core, .thickness of the thinnest inner Steel wire armour, no. of strand diameter of single wire, overall dimension, outside diameter of the cable and so on. As the video presented, it is a thickness test by device called projector which can measure the thickness of insulation, sheath and others extruded part of cable.

The tensile strength and elongation is an important physical performance for cable and wire. As video presented, it is tensile strength test machine, it can test not only aluminum wire, but also copper wire, steel wire and most other metallic wires. The test scope is 100N and 10000N. Compared with the old machine, it is much more advanced in automatic operation and calculation, and can show the result and curve graph on the computer directly.