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Wire and cable production
The different stages of production are as follows:
1- carpentry
This operation is performed by a rod thinning machine and a fine thinning machine in two stages.
In the first stage, the 8 mm copper wire is converted into 1/10 mm copper wire by the Rod machine, and these wires are converted into the suitable wires according to the customer’s order by the Fine machine as the input of the second stage of thin work.
2- Annealing step
All the thinned wires in the fine device are collected in a specific place on the side of the annealing furnace, according to the relevant board, and after reaching the minimum number required for annealing (54 spools), they are ready to be placed in the furnace and annealed.
3- Bunch stage (shining copper strands)
This operation is performed by the Buncher machine. The primary materials of this stage are the annealed wires on the spool, and if the number of spools and their diameter are according to the customer’s order and the relevant standard, –
4- Insulation stage (production of cable-wire sole)
In this stage, the punched strands are used as the main raw material and the insulating granule is used as another main material for the production of wire or cable core. The product produced by the extruder machine, if it is the final product of the wire, is sent to the relevant unit for packaging and If they are cable soles, they are collected on special reels to be used in the stranding stage of the soles.
5- coating stage (extruder cable)
In-line extruders are used for coating operations. The main raw materials of this stage are the stranded soles, coated granules and powder talc. The way of starting and producing the cable is as follows.
6 – Packaging stage
This stage of production, which is the last stage, the final product is packed in the size, shape and type requested by the customer. The produced wire and cable can be delivered to the customer in two forms: reel and cable.
Coil packing is also done according to the customer’s request, Nylex type, but in the automatic type, wire and cable coils are automatically vacuumed by the packaging machine.
The overall process of cable production in Iran:
Considering that the cable production process has a very complex and long cycle and was briefly explained in the first chapter, in this chapter we will briefly define the wire and cable production cycle.
At the beginning, the 8 mm copper wire, which is twisted into large spools, is placed on a special platform by a forklift and enters the rod tensioning machine at the first stage. 1.38 mm reached in the reel is called a mold, it becomes thin and finally it is twisted into large diameters. Due to the fact that a lot of heat is produced during light, all stretching devices are cooled and lubricated by liquid soap and water.
This liquid is injected in one cycle to all the working devices and is returned to the main tank through communication pipes, and this cycle is constantly repeating.
1.38 mm wires are transferred to secondary or fine tension devices and there they are converted into 0.185, 0.234, 0.285, 0.375 wire spools, the reason for converting to different diameters is manufacturing and production There are different diameters of spraying wires available in the market.
After this step, the coils of wire inside the metal tank of the assembled furnace are guided into the annealing furnace by an electric crane. Heat treatment causes the wire to lose its dry state and become soft so that it does not break when swinging and twisting in the buncher machine.
After heat treatment, the spools are arranged on a platform called PF and directed to the buncher machine. The buncher machine is responsible for winding thin strands of wire. Inside the buncher machine, a pulley is installed to twist the twisted wires.
The next step is to cover the wire with plastic insulation, which is done by an extruder. Polyethylene materials and paint are melted by the extruder and placed on the spraying wires in the form of sheaths, and then passed into the water to cool. After the wires are coated, they enter the printing machine and the specifications of the wire and the manufacturer’s factory are printed on it. In order to produce different wires, the number of strands and other specifications must be determined precisely.
After production, the wires are guided to the coiling device. This device is responsible for sorting the wires into 100 meter coils. In all production stages, there are platforms that prevent the wire from getting tangled. These platforms are called PF.
One of the most important stages of wire production is the quality control and laboratory stage, which should exist in every factory. In this stage, the electrical resistance of the wire and its coating, resistance to stretching and cold, etc. are tested and after approval, it is released to the market.