Process characteristics of wire and cable product manufacturing
1. Large-length continuous stacking combined production method
The large-length endless stacking 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 product's technological process 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 equipped with two or more units to balance the production line's production capacity. Therefore, the suitable combination of equipment and the production site's layout must be balanced and comprehensively considered according to the product and production volume.
(2) Production organization management
The production organization and 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 product's quality and delivery. Especially for multi-core cables, if the length of a particular pair or basic unit is short, or there is a quality problem, the entire line will be insufficient in size, resulting in scrap. Conversely, if a particular unit's length is too long, it must be sawn to cause waste.
(3) Quality management
The production method of continuous superposition and combination of considerable lengths will cause any problem in any link of the production process to occur instantaneously, 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. Because the production of wires and cables is different from assembled products, they can be disassembled, reassembled, and replaced; quality problems in any part of the wire and cable or the process are almost irreparable up for this cable. The post-event treatment is very harmful, either cutting short or downgrading, or scrapping the entire line. 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 production process as a whole, self-inspection of operators, and mutual review of upper and lower procedures. This is an important guarantee and means to ensure product quality and improve the enterprise's economic efficiency.
2. There are many types of production processes and large material flow
Wire and cable manufacturing involves a wide range of functions, from smelting and pressure processing of non-ferrous metals to chemical technologies such as plastics, rubber, and paint; textile technologies such as wrapping and weaving of fiber materials, to wrapping and metal strips of metal materials Longitudinal package, welding metal forming processing technology and so on.
Various materials used in wire and cable manufacturing have many types, varieties, and specifications, and a large number. Therefore, the number of multiple materials, the excess amount, batch period, and batch must be approved. Simultaneously, the decomposition, recycling, reuse, and waste disposal of waste products are an essential part of management. We should do an excellent job in material quota management and focus on saving.
In the production of wires and cables, from the entry and exit of raw materials and various auxiliary materials, the flow of semi-finished products in each process to the storage and delivery of products, the material flow is significant, and reasonable layout and dynamic management are necessary.
3. Much dedicated equipment
Wire and cable manufacturing uses special production equipment with the characteristics of the industry to adapt to the structure and performance requirements of cable products and to meet the needs of large-length continuous and as high-speed production as possible, thus forming a special equipment series for cable manufacturing, 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 special equipment development and promotes each other. New process requirements promote the production and development of new special equipment; in turn, new special equipment has announced the promotion and application of new processes. Such as wire drawing, annealing, extrusion tandem lines, physical foaming production lines, and other special equipment promote the development and improvement of wire and cable manufacturing processes, and improve the product quality and production efficiency of cables.