I. Process Characteristics of Wire and Cable Product Manufacturing:
1. The production method is formed by the continuous superposition of long lengths
The production method of long-length continuous superimposed combination has a global and controlling impact on the production of wires and cables, which involves and reflects:
(1) Production process flow and equipment layout
All kinds of equipment in the production workshop must be efficiently arranged in accordance with the production process required by the goods, so that the semi-finished products at each critical period can be activated in sequence. Equipment configuration should take into account the stability of production capacity based on different productivity levels. Some machines may need to be configured with two or several units to ensure that the production capacity of the production line is balanced enough. Therefore, the reasonable configuration and combination of machines and the layout of the manufacturing site must be comprehensively and evenly considered based on the products and total output.
(2) Production organization and management
Production organization and management must be scientific, reasonable, comprehensive, accurate, strict and meticulous. Operators must strive for excellence in following the process requirements. Any doubt in any link will endanger the smoothness of the process flow and affect the quality and delivery of the products. Especially for multi-core cables, if the length of a certain pair of wires or a basic unit is too short, or if there is a quality issue, the entire cable will be insufficient in length, resulting in scrapping. Conversely, if a certain unit is too long, it must be sawn off, resulting in waste.
(3) Quality Management
The production method of long-length continuous superimposed combination means that any doubt at any stage or moment during the production process will affect the quality of the entire cable. The more quality defects occur in the inner layer and are not detected in time to stop production, the greater the damage will be. Because the production of wires and cables is different from that of assembled products, they can be disassembled for reinstallation and replacement of spare parts. Any quality problem of any component or process of the wire and cable is basically irreparable and cannot be remedied for this cable. The subsequent solutions were all very dispiriting. Either the cables were sawn short, cut back for disposal, or scrapped. It can't be disassembled and reinstalled.
The quality management of wires and cables must run through the entire production process. The quality management inspection department should conduct safety inspections throughout the entire processing procedure, self-inspections by operators, and mutual reviews of the upper and lower process flows. This is also the main guarantee and approach to ensuring product quality and enhancing the economic benefits of the enterprise.
2 There are many types of production processes and a large flow of materials
The manufacturing of wires and cables involves a wide range of process categories, from the smelting and pressure extrusion forming of non-ferrous metals to chemical technologies such as plastics, silicone, and paints. From the textile technologies such as winding and weaving of textile materials to the winding of metal composite materials, the winding of metal strips, and the metal forming manufacturing process of welding, etc.
The various materials used in the production of wires and cables are not only diverse in type, variety and size, but also in large quantities. Therefore, the usage of various materials, the quantity of spare parts, the batch cycle and the batch size must be approved. At the same time, the detailed processing, recycling, reuse of waste products and the disposal of waste materials should be regarded as an important purpose of supervision. We should do a good job in material quota management and pay attention to conservation work.
In the production of wires and cables, from the entry and exit and storage of raw materials and various auxiliary materials, the activation of semi-finished products in each process flow to the storage and delivery of products, the material flow is large, and it is necessary to have a reasonable layout and dynamic management.
3 There are many specialized devices.
The manufacturing of wires and cables employs specialized production equipment with the industry's technological characteristics to understand the structure and performance of cable products, and to meet the demands of long-length continuous and as high-speed production as possible. Thus, a series of specialized equipment for cable manufacturing has been formed. Such as extrusion machine series, wire drawing machine series, stranding machine models, winding machine models, etc.
The manufacturing process of wires and cables and the transformation of professional equipment are closely related and mutually restrictive. New technical standards promote the emergence and rise of new professional equipment. Conversely, the development of new specialized equipment has further strengthened and promoted the popularization and application of new processes. Such as wire drawing, annealing, extrusion series lines; Specialized equipment such as physical foaming production lines has promoted the transformation and upgrading as well as improvement of the wire and cable manufacturing process, enhancing the product quality and production efficiency of cables.