讲讲电线电缆基本知识

讲讲电线电缆基本知识

Talk about the basic knowledge of wire and cable

电线电缆制造流程概述

Overview of wire and cable manufacturing process

讲讲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。

The manufacture of wire and cable is quite different from that of most mechanical and electrical products. Mechanical and electrical products are usually assembled into components and multiple components to be reassembled into single products. The products are measured by number or number of pieces. Wire and cable are based on the length of the basic unit of measurement. All wires and cables start from conductor processing. They are made up of insulation, shielding, cable and protective layer on the outer side of the conductor, and are made into wire and cable products. The more complex the product structure, the more layers are superimposed.

一、电线电缆产品制造的工艺特性：

1. The technological characteristics of the manufacture of wire and cable products:

1．大长度连续叠加组合生产方式

Continuous superposition combined production mode of 1. large lengths

大长度连续叠加组合生产方式，对电线电缆生产的影响是全局性和控制性的，这涉及和影响到：

The influence of the continuous superposition of large length combined production on the production of wire and cable is global and controlled, which involves and affects:

（1）生产工艺流程和设备布置

(1) production process and equipment layout

贵州电线电缆认为生产车间的各种设备必须按产品要求的工艺流程合理排放，使各阶段的半成品，顺次流转。设备配置要考虑生产效率不同而进行生产能力的平衡，有的设备可能必须配置两台或多台，才能使生产线的生产能力得以平衡。从而设备的合理选配组合和生产场地的布置，必须根据产品和生产量来平衡综合考虑。

All kinds of equipment in the production workshop must be reasonably discharged according to the technological process required by the product, so that the semi finished products of each stage will be transferred in a smooth way. The equipment configuration should balance the production capacity considering the different production efficiency. Some devices may have two or more units to balance the production capacity of the production line. Therefore, the rational selection and combination of the equipment and the layout of the production site must be taken into account according to the balance of the product and production.

（2）生产组织管理

(2) production organization and management

生产组织管理必须科学合理、周密准确、严格细致，操作者必须一丝不苟地按工艺要求执行，任何一个环节出现问题，都会影响工艺流程的通畅，影响产品的质量和交货。特别是多芯电缆，某一个线对或基本单元长度短了，或者质量出现问题，则整根电缆就会长度不够，造成报废。反之，如果某个单元长度过长，则必须锯去造成浪费。

The organization and management of production must be scientific, reasonable, precise, precise and meticulous. Operators must be meticulous in accordance with the requirements of the process. Any part of the problem will affect the smooth process and affect the quality and delivery of products. In particular, multi core cable, a line pair or basic unit length is short, or quality problems, the whole cable will not be long enough to cause scrap. On the other hand, if the length of a unit is too long, it must be sawn to cause waste.

（3）质量管理

(3) quality management

大长度连续叠加组合的生产方式，使生产过程中任何一个环节、瞬时发生一点问题，就会影响整根电缆质量。质量缺陷越是发生在内层，而且没有及时发现终止生产，那么造成的损失就越大。因为电线电缆的生产不同于组装式的产品，可以拆开重装及更换另件；电线电缆的任一部件或工艺过程的质量问题，对这根电缆几乎是无法挽回和弥补的。事后的处理都是十分消极的，不是锯短就是降级处理，要么报废整条电缆。它无法拆开重装。

The production mode of continuous superposition of large length makes any link and instantaneous problem in the production process will affect the quality of the whole cable. The more the quality defects occur in the inner layer, and the loss of production is not found in time, the greater the loss. Because the production of wire and cable is different from the assembled products, it can be reassembled and replaced. The quality problem of any part or process of wire and cable is almost irreparable to the cable. The aftertreatment is very negative, not the sawing or the downgrade, or the whole cable. It can't be reassembled.

电线电缆的质量管理，必须贯串整个生产过程。质量管理检查部门要对整个生产过程巡回检查、操作人自检、上下工序互检，这是保证产品质量，提高企业经济效益的重要保证和手段。

Wire and cable quality management, must run through the entire production process. The inspection department of quality control should inspect the whole production process, inspect the operator and check the process with each other, which is an important guarantee and means to ensure product quality and improve the economic efficiency of enterprises.

2．生产工艺门类多、物料流量大

2. the production process is large and the material flow is large

电线电缆制造涉及的工艺门类广泛，从有色金属的熔炼和压力加工，到塑料、橡胶、油漆等化工技术；纤维材料的绕包、编织等的纺织技术，到金属材料的绕包及金属带材的纵包、焊接的金属成形加工工艺等等。

Wire and cable manufacturing process involved a wide range of categories, from non-ferrous metal smelting and pressure processing, plastic, rubber, paint and other chemical technology; fiber material winding, weaving and other textile technology, metal materials and metal strip wrapped package, longitudinal welding metal forming process and so on.

电线电缆制造所用的各种材料，不但类别、品种、规格多，而且数量大。因此，各种材料的用量、备用量、批料周期与批量必须核定。同时，对废品的分解处理、回收，重复利用及废料处理，作为管理的一个重要内容，做好材料定额管理、重视节约工作。

All kinds of materials used in the manufacture of wire and cable are not only types, varieties and specifications, but also large quantities. Therefore, the amount of material, the amount of preparation, the period of batch and the batch must be approved. At the same time, the decomposition, recovery, reuse and waste disposal of waste products as an important part of management, we should do well in material ration management and pay attention to saving work.

电线电缆生产中，从原材料及各种辅助材料的进出、存储，各工序半成品的流转到产品的存放、出厂，物料流量大，必须合理布局、动态管理。

In the production of wire and cable, the flow and storage of raw materials and auxiliary materials, the transfer of semi-finished products from each process to the storage and export of products, and the large volume of material must be rationally distributed and dynamically managed.

3．专用设备多

3. special equipment many

电线电缆制造使用具有本行业工艺特点的专用生产设备，以适应线缆产品的结构、性能要求，满足大长度连续并尽可能高速生产的要求，从而形成了线缆制造的专用设备系列。如挤塑机系列、拉线机系列、绞线机系列、绕包机系列等。

Wire and cable manufacturing, using special production equipment with characteristics of the industry, is suitable for the structure and performance requirements of cable products, and meets the requirements of continuous and high-speed production with large length, thus forming a series of special equipment for cable manufacturing. Such as extruding machine series, wire drawing machine series, stranded machine series, wrapping machine series and so on.

电线电缆的制造工艺和专用设备的发展密切相关，互相促进。新工艺要求，促进新专用设备的产生和发展；反过来，新专用设备的开发，又提高促进了新工艺的推广和应用。如拉丝、退火、挤出串联线；物理发泡生产线等专用设备，促进了电线电缆制造工艺的发展和提高，提高了电缆的产品质量和生产效率。

The manufacturing process of wire and cable is closely related to the development of special equipment, and it promotes each other. New technology is required to 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 technology. Such as wire drawing, annealing, extrusion series line, physical foaming production line and other special equipment, promote the development and improvement of wire and cable manufacturing technology, and improve the quality and efficiency of cable products.

二、电线电缆的主要工艺

Two. The main process of wire and cable

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。

Wire and cable are made through three processes: drawing, hanging, and coating. The more complex the model and the specification, the higher the repeatability.

1．拉制

1. drawing

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。

In metal pressure processing, the technological processing method of metal forcing through metal mold (pressing wheel), cross section area of metal and obtaining the required cross-sectional area and shape and size under external force is called metal drawing.

拉制工艺分：单丝拉制和绞制拉制。

Drawing process: single wire drawing and stranding.

2．绞制

2. stranded system

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。

In order to improve the softness and integrity of the wire and cable, more than 2 single lines are interwoven in the prescribed direction, which is called the winch.

绞制工艺分：导体绞制、成缆、编织、钢丝装铠和缠绕。

Stranding process: conductor stranding, cabling, weaving, and winding steel wire armoring.

3．包覆

3. cover

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。包覆工艺分：

According to the different performance requirements of wire and cable, special equipment is used to cover different materials outside the conductor. The coating process is divided into three parts:

A．挤包：橡胶、塑料、铅、铝等材料。

A. extrusion package: rubber, plastic, lead, aluminum and other materials.

B．纵包：橡皮、皱纹铝带材料。

B. longitudinal bag: rubber, wrinkled aluminum belt material.

C．绕包：带状的纸带、

C. around the bag: strip of paper tape,