8 step-by-step processes of manufacturing of electrical cable - PowerPoint PPT Presentation

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8 step-by-step processes of manufacturing of electrical cable

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The manufacturing process of electrical wires and cables is complicated. If the manufacturers don’t provide good quality products, the wires will not be the perfect conductor to produce electricity. – PowerPoint PPT presentation

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Title: 8 step-by-step processes of manufacturing of electrical cable


1
How Are Electric Wires And Cables Manufactured?
2
  • The electrical wires are manufactured in several
    different sizes and using several conductive
    materials. The electrical wires are excellent
    conductors of heat.
  • An electric wire is an insulating material that
    is flexible and transmits electricity. The
    conducting material mainly used is copper. Copper
    is an excellent conductor of electricity. It is
    flexible and possesses a high-malleable property.
  • Power distribution boxes in Sharjah can be used
    in aerials, underground cables, and electrical
    appliances running beneath our feet in our homes
    and behind our walls. They carry the electricity
    and give us power.

3
There Are Different Types Of Cables Such As
  • HT and LT flame-retardant cables
  • Flame-retardant low smoke cables
  • Power and control cables
  • Insulated cables
  • Fire survival cables
  • Solar cables

4
Overview Of The Manufacturing Process Of Electric
Wires
  • The cable is fed into a machine that draws it out
    through a series of lubricated pulleys and dies
    stretching, lengthening, and thinning it out.
  • They are eventually winding it onto a giant
    bobbin. The cable once 10 mm in diameter is now 2
    mm in diameter. The bobbin is loaded. The ends of
    the bobbins are cold-welded to one another,
    guaranteeing an uninterrupted flow once the
    machine starts up.
  • Multi-core flexible cables are twisted and
    sheathed with white PVC granules to obtain the
    final product. The white flexible cable is coiled
    on modern coiling machines with length measuring
    yards. 
  • Each coil is packed with a suitable label and
    shrink wrapped with a polyethylene layer for safe
    and moisture-free binding. The PVC insulation is
    done in a double-layer process. The first layer
    is with Virgin PVC of Insulation and an outer
    layer which is very thin and commonly called skin
    with color PVC. 

5
  • It is done to avoid the adverse effect of color
    pigments on the insulation resistance value of
    PVC as virgin PVC insulation has excellent
    insulation resistance.
  • At high speed, the stranding machines twist seven
    wires together, forming an electrical conductor.
    This is a low voltage conductor under 1000 volts
    the carrying you will find in cables that run
    electricity to your home. 
  • Their conductors need to be insulated. So a
    plastic extrusion machine coats the conductor
    with polyethylene or PVC. The extrusion process
    has heated the conductor, so it has to be cooled
    down with water. Several conductors are mixed to
    form a cable. This plant performs a voltage
    immersing the cables in water to make sure they
    soak it. 
  • They are insulated the same way as low voltage
    cables are insulated. The cable goes into a reel
    to be tested before it's shipped out to its
    destination in the middle of the table surrounded
    by copper grounding wires and a host of other
    components, which is the heart of the electrical
    cable.

6
Now Let Us See The Step-By-Step Process Of
Manufacturing Of Electrical Cable
  • 1. Procurement of the purest raw material
  • The manufacturing process starts with the
    procurement of the purest of raw materials from
    reputed suppliers. All incoming materials are
    subjected to a series of mechanical and
    electrical checks.
  • The plant is capable of drawing wire from 8 mm to
    1.6 mm consistency and resistance tensile. The
    strength and size of the wire are ensured at all
    stages of the drawing process. 
  • The drawn wires are then stranded to achieve
    Co-conductors as per specifications, conductors
    are formed on sophisticated high-speed stranding
    machines and then compacted to ensure AC losses.
    To ensure optimum performance, the extensive
    focus is paid to the conductors, resistance, and
    shape.

7
  • 2. Insulation
  • For Insulation, the unit is equipped by power
    cable suppliers in UAE with a state-of-the-art
    CCV extrusion line. The extrusion route with
    filtered air inlets and a positive pressure eyes
    closed system ensures that the insulation process
    is entirely free from impurities and
    imperfections. 
  • 3. Twisting and laying 
  • Insulation is followed by twisting and laying of
    multi-core cables. 
  • Wires and cables manufacturers possess a massive
    drum twisting and laying up machine, which
    ensures that no tangential stress is applied over
    the Insulation this mitigates the possibility of
    any shifting or migration of the insulating
    layers, which could otherwise result in air void
    formations. 
  • This prevents any chances of failure during the
    entire lifetime of the cable and the
    manufacturer's flexibility to provide longer
    cable lengths that exhibit excellent and compact
    designs.

8
  • 4. Inner Sheathing
  • The later multi-core cables are provided with an
    inner sheathing through computerized extrusion
    lines using PVC compounds. 
  • Wires and cables manufacturers provide extruded
    PVC layers over the laid-up cores to hold the
    twisted cores in their circular form. 
  • 5. Extrusion Process
  • The extrusion process also serves as an
    additional moisture barrier. If the outer sheath
    gets damaged as water cannot travel radically up
    to the surface of the Insulation. An armoring
    process follows this.
  • 6. Armoring Process
  • Wires and cables manufacturers offer standardized
    armoring with aluminum or aluminum alloy wire
    strips for core cables and steel wires and strips
    for multi-core cables, a uniform and perfect mass
    of zinc coating on the armor, and a rust-free
    armor layer.
  • It also offers protection to the armor in case of
    any external damage the cables are then provided
    for the PVC polymer outer sheathing through the
    latest sheathing machines.

9
  • 7. Testing and Validation
  • Electric wire manufacturers also have a modern
    test lab with the latest validation and testing
    equipment. Every cable manufactured at the plant
    is tested for higher conductivity, flame
    resistance, oxygen index, smoke density,
    durability, tensile properties, and thermal
    stability. 
  • There are more than 30 various test parameters-
    physical, mechanical, electrical, thermal,
    chemical, and fire, that different components of
    cables have to pass before being certified, and
    that indeed puts into perspective for you.
  • 8. Packing
  • Then the wires and cables are packed with safe
    moisture free and good-looking packing to
    delivering the material in good condition - its
    esteemed customers.

10
Conclusion
  • Thus, the manufacturing process of electrical
    wires and cables is complicated. If the
    manufacturers don't give good quality products,
    the wires will not be an excellent conductor to
    produce electricity. So they should always take
    care of specific steps while making electric
    wires and cables.

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