Wire and cable manufacturing process
The manufacturing of wires and cables is completely different from the production of most electromechanical products. Electromechanical products usually adopt the assembly of other parts into parts, and the assembly of multiple parts into a single product, and the products are measured by the number of units or pieces. Wires and cables are based on length as the basic unit of measurement. All wires and cables start from the processing of conductors, adding insulation, shielding, cabling, and sheathing layer by layer to the periphery of the conductor to make wire and cable products. The more complex the product structure, the more layers of overlap.

Manufacturing process characteristics of wires and cables
1. The large-length continuous superimposed combined production method has a global and controllable impact on the production of wires and cables, which involves and affects:
(1) Production process and equipment layout
Various equipment in the production workshop must be reasonably discharged according to the technological process required by the product, so that the semi-finished products in each stage can be circulated in sequence. The equipment configuration should consider the different production efficiency and balance the production capacity. Some equipment may have to be configured with two or more sets in order to balance the production capacity of the production line. Therefore, the reasonable combination of equipment and the layout of the production site must be balanced and comprehensively considered according to the product and production volume.

(2) Production organization management
The production organization management must be scientific, reasonable, thorough, accurate, strict and meticulous. The operator must meticulously implement the process requirements. Any problem in any link will affect the smoothness 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 is short, or there is a quality problem, the entire cable will be insufficient in length, resulting in scrap. Conversely, if the length of a certain unit is too long, it must be sawn to cause waste.

(3) Quality management
The production method of continuous superposition and combination of large length will cause any problem in any link of the production process to occur instantly, which will affect the quality of the entire cable. The more quality defects occur in the inner layer, and the production is not stopped in time, the greater the loss will be. Because the production of wires and cables is different from assembled products, they can be disassembled, reassembled and replaced; The quality problem of any part of the wire and cable or the process is almost irreparable and remedy for this cable. The post-event treatment is very negative, either cutting short or downgrading, or scrapping the entire cable. It cannot be disassembled and reinstalled.

The quality management of wires and cables must run through the entire production process. The quality management inspection department shall conduct roving inspections of the entire production process, self-inspection of operators, and mutual inspection of upper and lower procedures. This is an important guarantee and means to ensure product quality and improve enterprise economic efficiency.

2. There are many types of production processes and large material flow
Wire and cable manufacturing involves a wide range of processes, from smelting and pressure processing of non-ferrous metals to chemical technologies such as plastics, rubber, and paint;
Textile technology such as wrapping and weaving of fiber materials, to wrapping of metal materials, longitudinal wrapping of metal strips, and metal forming processes such as welding.

Various materials used in wire and cable manufacturing not only have many types, varieties, and specifications, but also a large number. Therefore, the amount of various materials, spare amount, batch period and batch must be approved. At the same time, the decomposition treatment, recycling, reuse and waste treatment of waste products. As an important part of management, do a good job in material quota management and pay attention to saving work.
In the production of wires and cables, the flow of semi-finished products from each process to the storage and delivery of products from the in and out and storage of raw materials and various auxiliary materials is large, and the material flow is large. Must be rationally distributed and dynamically managed.


3. Many dedicated equipment
Wire and cable manufacturing uses special production equipment with the characteristics of the industry to meet the structure and performance requirements of cable products. To meet the requirements of continuous large-length and high-speed production as much as possible, a special equipment series for cable manufacturing has been formed. Such as extruder series, wire drawing machine series, stranding machine series, wrapping machine series, etc.
The manufacturing process of wire and cable is closely related to the development of special equipment and promotes each other. New process requirements promote the production and development of new special equipment; in turn, the development of new special equipment has promoted the promotion and application of new processes. Such as wire drawing, annealing, extrusion tandem line;

Special equipment such as the physical foaming production line has promoted the development and improvement of the wire and cable manufacturing process, and improved the product quality and production efficiency of the cable.

Wires and cables are made through three processes: drawing, twisting, and coating. The more complex the model specification, the higher the repeatability.

1. Cable drawing
In metal pressure processing, the metal is forced through the mold (press wheel) under the action of external force. The metal cross-sectional area is compressed, and the technical processing method to obtain the required cross-sectional area shape and size is called metal drawing.
The drawing process is divided into: monofilament drawing and twisting drawing.
2. Stranding of cables
In order to improve the flexibility and integrity of the wire and cable, two or more single wires are intertwined in a prescribed direction, which is called twisting.
The stranding process is divided into: conductor stranding, cable formation, braiding, steel wire armoring and winding.
3. Cable coating
According to the different performance requirements of the wire and cable, special equipment is used to coat different materials on the outside of the conductor. Coating process points:
A. Extrusion: rubber, plastic, lead, aluminum and other materials.
B. Longitudinal package: rubber, corrugated aluminum tape material.
C. Winding: ribbon-shaped paper tape, mica tape, alkali-free glass fiber tape, non-woven fabric, plastic tape, etc., linear cotton yarn, silk and other fiber materials.
D. Dip coating: insulating paint, asphalt, etc.