We are producing power cords every day, with over 100000 meters of power cords and 50000 plugs. With such a large amount of data, the production process must be very stable and mature. After continuous exploration and research, as well as recognition from European VDE certification bodies, national standard CCC certification bodies, American UL certification bodies, British BS certification bodies, Australian SAA certification bodies, etc., the power cord plug has matured. Below is a brief introduction:
1. Copper and aluminum single wire drawing of power lines
The commonly used copper and aluminum rod materials for power cords can be reduced in cross-section, increased in length, and improved in strength by using a wire drawing machine to pass through one or several drawing die holes at room temperature. Wire drawing is the first process of various wire and cable companies, and the primary process parameter of wire drawing is the mold matching technique.
2. Annealing of power cord single wire
Copper and aluminum single wires are heated to a certain temperature and recrystallized to improve their toughness and reduce their strength, in order to meet the requirements of wires and cables for conductor cores. The key to the annealing process is to eliminate the oxidation of copper wires
3. Twisting of power line conductors
In order to improve the flexibility of the power cord and facilitate the installation, the conductive wire core accepts multiple single wires twisted together. In terms of the stranding method of the conductor core, it can be divided into regular stranding and non regular stranding. Irregular strangulation can be divided into bundle strangulation, concentric strangulation, and extraordinary strangulation. In order to reduce the occupied area of the wire and the geometric size of the power cord, a compression method is also used on the twisted conductor, which changes the popular circle into a semicircle, fan shaped, tile shaped, and compression shaped circle. This type of conductor is primarily used on power lines.
4. Power cord insulation extrusion
The plastic power cord mainly adopts extruded solid insulation layer, and the primary technical requirements for plastic insulation extrusion are:
1) Bias degree: The bias value of the extruded insulation thickness is the main indicator of the degree of extrusion process, and the structural dimensions and bias values of most products are clearly defined in the specifications.
2) Lubrication: The surface of the extruded insulation layer requires lubrication and should not exhibit poor quality issues such as rough appearance, burning, or impurities
3) Density: The cross-section of the extruded insulation layer should be dense and robust, with no visible pinholes and no bubbles at all.
5. Power cord assembly
In order to ensure the molding degree and reduce the appearance of the multi-core power cord, it is generally necessary to twist it into a circular shape. The mechanism of stranding is similar to that of conductor stranding, as the pitch diameter of stranding is relatively large, and most methods without unwinding are used. The technical requirements for cable formation include: firstly, avoiding the twisting of cables caused by the overturning of abnormal insulated cores; The second is to avoid scratching the insulation layer.
Most cables are completed along with two other processes during cable formation: one is filling, ensuring that the roundness and stability of the cables remain unchanged after cable formation; One is binding, ensuring that the cable core is not loose.
6. Power cord inner protective layer
In order to maintain the insulation core from being damaged by armor, it is necessary to properly maintain the insulation layer. The inner protective layer is divided into extruded inner protective layer (isolation sleeve) and wrapped inner protective layer (cushion layer). The wrapping cushion layer replaces the binding tape and is synchronized with the cable forming process.
7. Power cord armor
Laid underground power lines, capable of accepting certain positive pressure effects during tasks, can choose inner steel strip armor construction. The power cord is laid on the existing