电线电缆的制造与大多数机电产品的生产方式是完全不同的。机电产品通常采用将另件装配成部件、多个部件再装配成单台产品,产品以台数或件数计量。电线电缆是以长度为基本计量单位。所有电线电缆都是从导体加工开始,在导体的外围一层一层地加上绝缘、屏蔽、、成缆、护层等而制成电线电缆产品。产品结构越复杂,叠加的层次就越多。电线电缆的主要工艺电线电缆是通过:拉制、绞制、包覆三种工艺来制作完成的,型号规格越复杂,重复性越高。
The manufacture of wires and cables is totally different from that of most mechanical and electrical products. Mechanical and electrical products are usually assembled into parts by other parts, and then assembled into a single product by multiple parts. The products are measured by the number of units or pieces. Wires and cables are based on length. All wires and cables start from the conductor processing, adding insulation, shielding, cabling and protective layer on the outer layer of the conductor to make wires and cables products. The more complex the product structure, the more layers it will stack. The main process of wire and cable wire and cable are made by three processes: drawing, stranding and covering. The more complex the model and specification, the higher the repeatability.
1.拉制在金属压力加工中.在外力作用下使金属强行通过模具(压轮),金属横截面积被压缩,并获得所要求的横截面积形状和尺寸的技术加工方法称为金属拉制。拉制工艺分:单丝拉制和绞制拉制。
1. Drawing in metal pressure processing. Under the action of external force, the metal is forced to pass through the mold (pressing wheel), and the cross-sectional area of the metal is compressed, and the required cross-sectional area shape and size of the technical processing method is called metal drawing. Drawing process: single wire drawing and stranding drawing.
2.绞制为了提高电线电缆的柔软度、整体度,让2根以上的单线,按着规定的方向交织在一起称为绞制。绞制工艺分:导体绞制、成缆、编织、钢丝装铠和缠绕。
2. Stranding in order to improve the flexibility and integrity of wires and cables, it is called stranding that more than two single wires are interwoven in the specified direction. Stranding process includes conductor stranding, cabling, knitting, steel wire armor and winding.
3.包覆根据对电线电缆不同的性能要求,采用专用的设备在导体的外面包覆不同的材料。
3. According to different performance requirements for wires and cables, special equipment shall be used to cover different materials outside the conductor.
包覆工艺分:A.挤包:橡胶、塑料、铅、铝等材料。B.纵包:橡皮、皱纹铝带材料。C.绕包:带状的纸带、云母带、无碱玻璃纤维带、无纺布、塑料带等,线状的棉纱、丝等纤维材料。D. 浸涂:绝缘漆、沥青等塑料电线电缆制造的基本工艺流程
Coating process: A. extrusion: rubber, plastic, lead, aluminum and other materials. B. longitudinal package: rubber, corrugated aluminum strip material. C. wrapping: Ribbon paper tape, mica tape, alkali free glass fiber tape, non-woven fabric, plastic tape, and thread like cotton yarn, silk and other fiber materials. D. dip coating: basic process flow of manufacturing plastic wires and cables such as insulating paint and asphalt
1.铜、铝单丝拉制电线电缆常用的铜、铝杆材,在常温下,利用拉丝机通过一道或数道拉伸模具的模孔,使其截面减小、长度增加、强度提高。拉丝是各电线电缆公司的首道工序,拉丝的主要工艺参数是配模技术。2.单丝退火铜、铝单丝在加热到一定的温度下,以再结晶的方式来提高单丝的韧性、降低单丝的强度,以符合电线电缆对导电线芯的要求。退火工序关键是杜绝铜丝的氧化
1. The common copper and aluminum rod materials used for drawing wires and cables with single copper and aluminum wire are reduced in cross section, increased in length and increased in strength by using wire drawing machine to pass through one or several die holes of drawing die at room temperature. Wire drawing is the first process of wire and cable companies. The main process parameter of wire drawing is die matching technology. 2. The annealed copper and aluminum single wires are heated to a certain temperature and recrystallized to improve the tenacity and reduce the strength of the single wire, so as to meet the requirements of wire and cable for conductor core. The key of annealing process is to stop the oxidation of copper wire
.3.导体的绞制为了提高电线电缆的柔软度,以便于敷设安装,导电线芯采取多根单丝绞合而成。从导电线芯的绞合形式上,可分为规则绞合和非规则绞合。非规则绞合又分为束绞、同心复绞、特殊绞合等。为了减少导线的占用面积、缩小电缆的几何尺寸,在绞合导体的同时采用紧压形式,使普通圆形变异为半圆、扇形、瓦形和紧压的圆形。此种导体主要应用在彩神8上。
. 3. In order to improve the flexibility of wires and cables and facilitate the laying and installation, the conductor core is made of multiple single wires. From the form of conductor core stranding, it can be divided into regular stranding and irregular stranding. Irregular stranding can be divided into bundle stranding, concentric compound stranding, special stranding, etc. In order to reduce the occupied area of the conductor and the geometric size of the cable, the compact form is adopted while the conductor is twisted, so that the ordinary circle is changed into semicircle, fan-shaped, tile shaped and compact circle. This kind of conductor is mainly used in power cable.
4.绝缘挤出塑料电线电缆主要采用挤包实心型绝缘层,塑料绝缘挤出的主要技术要求:4.1.偏心度:挤出的绝缘厚度的偏差值是体现挤出工艺水平的重要标志,大多数的产品结构尺寸及其偏差值在标准中均有明确的规定。4.2.光滑度:挤出的绝缘层表面要求光滑,不得出现表面粗糙、烧焦、杂质的不良质量问题4.3.致密度:挤出绝缘层的横断面要致密结实、不准有肉眼可见的针孔,杜绝有气泡的存在。
4. The extruded solid insulation layer is mainly used for the insulated extruded plastic wires and cables. The main technical requirements of the extruded plastic insulation are as follows: 4.1. Eccentricity: the deviation value of the extruded insulation thickness is an important mark reflecting the extrusion process level. Most product structure dimensions and deviation values are clearly specified in the standard. 4.2. Smoothness: the surface of the extruded insulating layer shall be smooth, and ther