What is wire and cable making process?

1.  Copper, aluminum single wire drawing system  
Wire and cable commonly used copper, aluminum rod, at room temperature, the use of wire drawing machine through a or a number of tensile die hole, so that its section is reduced, length increased, strength improved.  Wire drawing is the first process of wire and cable companies, the main process parameters of wire drawing is die technology.  
2.  Monofilament annealing  
Copper and aluminum monofilaments are heated to a certain temperature and recrystallized to improve their toughness and reduce their strength, so as to meet the requirements of conductive wires and cables.  The key of annealing process is to eliminate the oxidation of copper wire.  
3.  The twisting of conductors  
In order to improve the softness of wire and cable, in order to facilitate laying and installation, the conductive wire core is made of a plurality of monofilaments twisted together.  The conductor core can be divided into regular stranding and irregular stranding.  Irregular stranding is divided into bundle stranding, concentric complex stranding, special stranding and so on.  
In order to reduce the occupied area of the conductor and reduce the geometric size of the cable, the normal circle is changed into semicircle, fan shape, tile shape and compacted circle while the conductor is twisted.  This kind of conductor is mainly used in power cables.  
4.  The insulation extrusion  
Plastic wire and cable mainly use extruded solid insulation layer, plastic insulation extrusion main technical requirements:  
4.1.  Eccentricity: the deviation of the insulation thickness is an important symbol of the level of extrusion technology. Most of the product structure size and its deviation are clearly specified in the standard.  
4.2.  Smoothness: the surface of the extruded insulation layer shall be smooth, and there shall be no bad quality problems such as rough surface, burning and impurities.  
4.3.  Density: the cross section of the extruded insulation layer should be dense and firm, no visible pinholes are allowed, and the existence of bubbles should be eliminated.  
5.  cabling  
For multi-core cables, in order to ensure the molding degree and reduce the cable shape, it is generally required to be twisted into a circular shape.  The mechanism of stranding is similar to conductor stranding, because of the large diameter of stranding, most of the stranding method is adopted.  The technical requirements of cable forming are as follows: first, the twisted and bending of cable caused by turning over of abnormal insulated wire core;  The second is to prevent the insulation layer from being scratched.  
The completion of most cables is accompanied by the completion of two other procedures: one is filling to ensure the roundness and stability of cables after completion;  One is bundling to ensure the core of the cable is not loose.  
6.  The protective layer  
In order to protect the core of the insulated wire from being damaged by the armoring, the insulation layer needs to be properly protected. The inner coating can be divided into extruded inner coating (isolation sheath) and wrapped inner coating (cushion layer).  The wrapping pad replaces the lashing tape and is synchronized with the cabling process.  
7.  Install the armoured  
Laying in underground cable, may bear certain positive pressure in the work, can choose the inner steel tape armored structure.  When the cable is laid under both positive pressure and tension (such as water, vertical shaft or soil with large drop), the structure with inner steel wire armored should be selected.  
8.  Outer sheath  
The outer sheath is a structural part that protects the insulating layer of wire and cable from environmental factors.  The main function of outer sheath is to improve the mechanical strength of wire and cable, prevent chemical corrosion, moistureproof, waterproof immersion, prevent cable burning and other capabilities.  According to the different requirements of the cable, the plastic sheath is directly extruded by the extruder 
Let's see how YIHETAI Cable making the wire and cable:
  • Step 1: Wire drawing. In the first step, our aim is to acquire metal (usually copper or aluminum) wires that fit with the gauge(AWG)
  • Step 2: Annealing. ...
  • Step 3: Twisting and stranding. ...
  • Step 4: Extrusion. ...
  • Step 5: Cabling
Here are some picture for the procession.

copper wire and cables manufacturercopper wire and cables

copper wire and cables manufacturers

 YIHETAI is a professional manufacturer with over 20 year experience engaging in various kinds of customized hook up wire ,electrical cable,wire harnesses and cable assemblies. We have our own factory located in Xianmen,China. Throughout the years YIHETAI has continued to grow, increasing products, services and capabilities to our line of goods and service. Our products are applicable to the almost any devices, appliances, electronics, machines, and equipment.
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 wire harness

1. Professional & experienced engineers
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5. More than 20years experiences.
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