What are the 5 processes in cable making?
Making cables and wires is an exciting and intricate procedure that guarantees the finished product will be dependable and meet quality standards. This is a simplified explanation of the procedures used in the production of cables and wires:
1. Crushing and Grinding
Raw elements like copper and aluminum are where it all begins. To extract the pure metal and get rid of any waste, these metals are crushed and ground. The conductor, the central component of any wire or cable, is created in this first step.
2. Wire Drawing
The next step is to pull the raw metal into wires. The metal is stretched into thinner, homogeneous wires that satisfy certain gauge criteria (such as AWG standards) using massive equipment. Lubricants are also used in this step to guarantee efficient processing and prolong the machinery’s lifespan.
3. Annealing (Heating)
After that, a heat treatment procedure known as annealing is used to soften the wires. Internal tensions are reduced by carefully heating and cooling the wires, increasing their flexibility and durability. Additionally, by preventing oxidation, this step maintains the wires in optimal condition.
4. Insulation
Insulating materials, usually synthetic polymers, are applied to individual wires. This insulation shields the wires from the elements and stops current leaks. Different forms of insulation are employed for flexibility, durability, and heat resistance, depending on the application.
5. Twisting and Stranding
A cable is frequently made by twisting many wires together. When compared to a single solid wire, twisting or stranding increases the cable’s electrical performance and flexibility. In order to make that the cable can withstand bending and movement in real-world applications, this step is essential.
6. Extrusion
The wire is covered with a coating of plastic or another material during the extrusion process. An extruder precisely covers the wire once it passes through it. This layer offers mechanical protection and serves as an extra insulator.
7. Cabling
Ultimately, a full cable is formed by bundling all of the prepared wires together. For extra protection, the wires are now also jacketed, or wrapped with an outer layer. In a cabling station, the cables are arranged and put together to satisfy particular functional and design specifications.
Cable making involves several crucial steps:
- Crushing and grinding the raw metals.
- Drawing the wires to the desired size.
- Softening and strengthening through annealing.
- Insulating the wires.
- Twisting and stranding multiple wires for flexibility.
- Extruding protective coatings.
- Bundling and assembling the final cable.