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The manufacturing process for these power cables

Power cables having a very complex structure and requiring good insulation performance and mechanical strength to ensure the safety and reliability of power transmission in his whole service life. As the same time, it also have a very high requirement for the working staff, his profession to understand its main features of each type raw materials, and skills for all controls during the whole manufacturing process.

The production process of power cables is complex and precise, and the following are the main production steps we need to comply with :

1.  Selection and inspection to Raw materials

The main raw materials for fabrication power cables include  copper or aluminum conductors, PVC, PE, XLPE or TR-XLPE insulation materials, sheath materials and other auxiliary materials. These raw materials need to TAKE a strict quality inspection to ensure compliance with production standards.

2. Fabrication of the conductors

It is one of the key steps in the production of power cables. Copper conductors are usually made into uniformly sized wires through continuous casting, while aluminum conductors are produced using continuous drawing machine technology. In the process of conductor making, wire drawing and annealing are also required to improve the flexibility and conductivity of the conductor. For high-voltage power cables, the conductor is usually subjected to compression twisting or wire twisting technology to ensure the roundness of the conductor and reduce moisture infiltration.

3. Fabrication of insulation materials

The production of insulation material is an extremely important during the whole process. At present, cross-linked polyethylene (XLPE) is the main material for insulation of high-voltage cables, and its production processes include catenary dry crosslinking (CCV) and tower type dry crosslinking (VCV). The extrusion of the insulation layer usually adopts a triple-extrusion process, which simultaneously extrudes the conductor shielding layer, insulation layer, and insulation shielding layer. This process can improve the concentricity and roundness of the insulation layer.

4. Processing of buffer layer and shielding layer

High voltage cables usually have buffer and shielding layers outside the insulation layer. The buffer layer can use a semi conductive buffer water blocking layer to prevent moisture infiltration and withstand thermal expansion during operation. The shielding layer is made of semiconducting material and manufactured through extrusion process to ensure uniform distribution of electric field.

5. Processing of metal sheath

Metal sheaths are usually made of continuous extruded corrugated aluminum tapes to improve the sealing and mechanical performance of cables. The processing of metal sheaths requires ensuring their compressive and bending resistance to meet the requirements of construction and operation.

6. Production of outer sheath

The outer sheath is the outer layer of protection for power cables, usually made of PVC or PE material and manufactured through extrusion technology. The outer sheath not only needs to have wear-resistant and corrosion-resistant properties, but can also be made of flame-retardant or anti termite materials according to customer requests.

7. Assembly and testing

The components such as conductors, insulation layers, shielding layers, and sheaths prepared through the above processes are assembled and formed according to the predetermined structure. After assembly, the cable needs to undergo strict testing, including electrical performance testing (such as volt ampere testing, insulation impedance measurement) and physical performance inspection (such as size, appearance, mechanical strength, etc.). Only products that pass the inspection can be packaged and shipped.

8. Post processing

Some high-voltage cables also require post-treatment, such as coating with asphalt or graphite, to prevent corrosion of the metal sheath and extend the service life of the cable.

The production process of high-voltage cables is complex and requires extremely high precision. Each link needs to be strictly controlled to ensure the performance and reliability of the cables, meeting the high requirements of modern power systems for high-voltage cables.

9. Packing & shipping for power cables.

After carried out all above-mentioned proccess, it is approved that the finished power cables are qualified & acceptable in quality; We will forward all these power cables into next step, packing to seal the drums or reels and arrange trucks or containers to ship the goods to where clients requested to deliver.