Process innovation

The actual value of the overall outer diameter of the large-section conductor used in our new energy cable series products is different from batch to batch, making the outer diameter of the product in the overall design large. In order to further optimize the product structure, improve production efficiency, and reduce costs, it must be determined that a reasonable and feasible conductor bundle strand diameter process can be achieved.

According to the current understanding and industry situation, the conductors of the wiring connection type soft cable are generally selected to use Category 5 and Category 6 soft copper conductors, in which the production of large-section products must adopt a multi-twisted structure, usually Category 5 and Category 6 soft The common twisting structure and characteristics of copper conductors are summarized in Table 1.

Table 1 Composition and characteristics of common twisting direction of soft copper conductor (double-layer or triple-layer rewinding production method)

 

Types of	Layers	Stranding direction	Rewinding direction	Features
Mode 1 (traditional way)	Inner layer Secondary outer layer The outermost layer	right left right	- right left	Stable structure, anti-twist, compression, maximum outer diameter, low flexibility
Mode 2 (beam and strand all in the same direction)	Inner layer Secondary outer layer The outermost layer	left left left	- left left	Minimum outside diameter, high flexibility, no compression, structural instability
Mode 3 (The directions of beam and strand are opposite)	Inner layer Secondary outer layer The outermost layer	right right right	- left left	High flexibility High torsional stiffness
Mode 4 (Inner and outer layer twisting and strands are opposite)	Inner layer Secondary outer layer The outermost layer	right right right	- right left	With most of the characteristics of Mode 1, the outer diameter has been reduced, with a certain degree of flexibility

 

At present, the company's product conductor production mode is selected on the model 4 scheme in the above table. The products produced by this production method are insufficient for the soft and small outside diameter performance requirements of the customer. Referring to the several stranding methods listed in Table 1 above, it can be seen that there are great advantages in the outer diameter and flexibility of conductors stranded in the same direction, but the structural instabilities lead to easy conductors during subsequent extrusion production. Deformation, jumper, seriously affect product quality.

In view of the above situation, combined with our equipment and production methods, we will confirm the selection of sample production methods under different conditions without affecting the current product performance. We will make reasonable adjustments and optimizations in the three directions of twisting, pitch, and mold. Improve product performance.

    During conductor production, conductors of the same structure, the outer diameter of the first beam line is always smaller than the outer diameter of the re-stranded conductor. In the process of production of an all-in-twist re-twist, a reasonable mold ratio and a suitable twisting pitch make the pitch of the beam line more obvious in the production process, so that the whole layer of the multiple-stranded wire conductor is like a single strand. With the twisted wire harness, there is no obvious gap between the final finished strands and the appearance is more round and tight.

Through a variety of sample comparisons, a new type of multi-twist mode (ie mode 5) with improved flexibility, small outer diameter, and roundness has been confirmed to be able to provide greater quality for current mass-produced conductors. Improve, its structure is stable, high flexibility, anti-extrusion pull deformation ability is better.