I. From the Perspective of the Product Itself
(I) Specification Parameters
Conductor Specifications
The conductors of this series of cables are made of high-purity copper with a purity of over 99.95%. The conductivity of the copper core is ≥58MS/m, and this high-performance index ensures low loss during power transmission. The conductor cross-sectional specifications are rich and diverse, covering small cross-sections (10mm², 16mm², 25mm², 35mm²), medium cross-sections (50mm², 70mm², 95mm², 120mm²) and large cross-sections (150mm², 185mm², 240mm², 300mm², 400mm²). Conductors with different cross-sections have obvious differences in current-carrying capacity. Taking an ambient temperature of 30℃ and air laying as an example, the current-carrying capacity of a 10mm² copper
Core Cable is about 55A-65A; 25mm² is about 100A-115A; 50mm² is about 165A-185A; 120mm² is about 270A-300A; 240mm² is about 420A-450A; 400mm² is about 580A-620A. These current-carrying capacity data provide an accurate basis for power configuration in different construction scenarios.
Sheath Parameters
PVC Sheath: The thickness varies according to the cable cross-section. The sheath thickness of small cross-section cables is about 0.8mm-1.2mm, medium cross-section is about 1.2mm-1.6mm, and large cross-section is about 1.6mm-2.0mm. The oxygen index is ≥30, which has good flame retardancy. The temperature resistance range is -15℃ to 70℃, and the insulation resistance in a normal temperature and dry environment is ≥1000MΩ.
PE Sheath: The thickness is similar to that of the PVC sheath, with small cross-section about 0.8mm-1.2mm, medium cross-section about 1.2mm-1.6mm, and large cross-section about 1.6mm-2.0mm. It has excellent low-temperature resistance and can work normally in an environment of -40℃ to 60℃. The waterproof grade reaches IP68, which can completely resist the intrusion of water, and the insulation resistance is ≥1500MΩ.
PUR Sheath: The thickness is relatively thick, with small cross-section about 1.0mm-1.4mm, medium cross-section about 1.4mm-1.8mm, and large cross-section about 1.8mm-2.2mm. It has excellent wear resistance and can withstand more than 1 million friction cycles after testing. The temperature resistance range is -30℃ to 80℃, and the oil resistance meets ASTM D471 standard. It has stable performance in an oil-immersed environment, and the insulation resistance is ≥2000MΩ.
Insulation Parameters
The insulation layer is made of XLPE or PVC materials. The long-term working temperature of the XLPE insulation layer is 90℃, and the maximum temperature during a short circuit can reach 250℃. The insulation thickness of small cross-section is about 0.7mm-1.0mm, medium cross-section is about 1.0mm-1.4mm, and large cross-section is about 1.4mm-1.8mm; The long-term working temperature of the
PVC Insulation layer is 70℃, and the maximum temperature during a short circuit is 160℃, and the insulation thickness is similar to that of XLPE. The dielectric loss tangent of both
Insulation Materials is ≤0.003 at power frequency, ensuring good electrical performance.
Overall Dimensions
The overall outer diameter of the cable varies with the cross-section and sheath material. Taking a 10mm² cable as an example, the outer diameter of the PVC sheath is about 8mm-10mm, the PE sheath is about 8mm-10mm, and the PUR sheath is about 9mm-11mm; For a 50mm² cable, the outer diameter of the PVC sheath is about 15mm-17mm, the PE sheath is about 15mm-17mm, and the PUR sheath is about 16mm-18mm; For a 240mm² cable, the outer diameter of the PVC sheath is about 28mm-30mm, the PE sheath is about 28mm-30mm, and the PUR sheath is about 29mm-31mm; For a 400mm² cable, the outer diameter of the PVC sheath is about 38mm-40mm, the PE sheath is about 38mm-40mm, and the PUR sheath is about 39mm-41mm.
(II) Characteristic Applications
Residential Buildings
In residential buildings, small cross-section (10mm², 16mm², 25mm²)
PVC Sheathed Cables are widely used. 10mm² and 16mm² cables are often used in lighting lines and ordinary socket circuits to meet the electricity needs of daily household appliances such as home lamps, TVs, and refrigerators; 25mm² cables are suitable for special circuits of high-power household appliances such as air conditioners and electric water heaters to ensure stable power supply during the operation of these equipment. Due to the dry environment in residential buildings and mostly concealed laying, the flame retardancy and economy of PVC sheaths are fully utilized in this scenario. For example, in a three-bedroom house, the lighting lines in each room use 10mm²
PVC Sheathed Cables, the ordinary sockets in the living room and bedroom use 16mm² PVC
Sheathed Cables, and the high-power electrical circuits in the bathroom and kitchen use 25mm² PVC sheathed cables.
Commercial Complexes
The electricity scenarios in commercial complexes are complex, and medium cross-section (50mm², 70mm², 95mm², 120mm²) PE sheathed cables are more suitable. 50mm² and
70mm² Cables can be used for the distribution trunk lines of shops in shopping malls, connecting various electrical equipment in the shops, such as cash registers, display cabinets, and small air conditioners; 95mm² and 120mm² cables are suitable for power transmission of medium-power equipment such as cold chain equipment in large supermarkets and large audio equipment in entertainment venues. There are humid areas such as underground garages and bathrooms in commercial complexes. The waterproof and moisture-proof performance of PE sheaths can effectively cope with these environments and ensure the long-term stable operation of cables. For example, in the underground garage of a large shopping mall, the distribution lines of the lighting and ventilation systems use 70mm² PE sheathed cables, which can effectively resist the humid environment underground.
Industrial Plants
Industrial plants have strict requirements on cable performance, and large cross-section (150mm², 185mm², 240mm², 300mm², 400mm²) PUR sheathed cables are the first choice. 150mm² and 185mm² cables can be used for power supply of motors, water pumps and other equipment in the production line; 240mm², 300mm² and 400mm² cables are suitable for power transmission of large industrial equipment such as cranes and furnaces. There is a lot of equipment vibration and oil pollution in industrial plants. The wear resistance, oil resistance and aging resistance of PUR sheaths can ensure that the cables work normally in such harsh environments, reducing production interruptions caused by cable damage. For example, in the welding production line of an automobile manufacturing plant, 240mm² PUR sheathed cables are used for power transmission of the equipment, which can withstand oil pollution and mechanical vibration during welding.
Public Buildings
Public buildings such as hospitals, schools, and gymnasiums have high requirements for the safety and reliability of cables. Small cross-section PVC sheathed cables can be used for lighting and socket circuits in classrooms and offices; medium cross-section PE sheathed cables are suitable for hospital operating room equipment, gymnasium lighting systems, etc.; for audio, projection and other equipment in large conference rooms, cables with appropriate cross-sections can be selected according to power. In humid areas of public buildings, such as hospital bathrooms and gymnasium swimming pool surroundings, PE sheathed cables can give full play to their waterproof advantages; in crowded areas, the flame retardancy of cables is crucial, and the high flame retardant grades of PVC and PUR sheaths can reduce fire risks.
(III) Material and Style
Conductor Material
The conductor is made of high-purity electrolytic copper, which is refined for many times to remove impurities to ensure a purity of over 99.95%. High-purity copper has excellent electrical and thermal conductivity, which can effectively reduce losses and heat generation during current transmission. At the same time, copper has good ductility, which is convenient for processing into various specifications of conductors, and is not easy to break during stranding, ensuring the mechanical strength of the conductor. In addition, copper has strong oxidation resistance. In normal use environment, the surface of the conductor is not easy to form an oxide layer, ensuring long-term stable conductivity.
Insulation Material
XLPE (Cross-linked Polyethylene): Polyethylene molecules form a three-dimensional network structure through chemical or physical methods, which has excellent electrical performance, heat resistance and mechanical strength. It has high insulation resistance, small dielectric loss, can work at higher temperatures for a long time, and has good aging resistance and long service life.
PVC (Polyvinyl Chloride): Made of polyvinyl chloride resin with plasticizers, stabilizers and other additives, it has good insulation performance and mechanical performance, and the price is relatively low. However, its heat resistance is not as good as that of XLPE, and its long-term working temperature is low.
Sheath Material
PVC (Polyvinyl Chloride): It has good flame retardancy, chemical corrosion resistance and mechanical strength, with simple processing technology and low cost. However, its low-temperature resistance is poor, and it is easy to harden and crack in low-temperature environments.
PE (Polyethylene): Divided into high-density polyethylene and low-density polyethylene, it has excellent low-temperature resistance, chemical corrosion resistance and waterproofness, good Flexibility and strong impact resistance. However, its flame retardancy is poor, and flame retardants need to be added to improve its flame retardant grade.
PUR (Polyurethane): It is a polymer material with excellent wear resistance, oil resistance, aging resistance and low-temperature resistance, high mechanical strength and good elasticity. But the cost is relatively high and the processing difficulty is large.
Style Design
The cables are all of circular structure, which is conducive to reducing resistance during cable laying, and is convenient for threading and wiring. The sheath has various colors, such as black, gray, white, etc. Different colors can be used to distinguish different circuits or functions, such as black for phase lines, gray for neutral lines, and yellow-green for ground lines, which is convenient for installation and maintenance. In addition, some cables adopt an armored design, that is, adding a
Steel Tape or steel wire armor layer inside the sheath to further improve the mechanical strength and impact resistance of the cable, which is suitable for laying scenarios that need to bear large external forces.
(IV) Production Process
Conductor Manufacturing
First, high-purity electrolytic copper ingots are smelted to remove impurities to obtain pure copper liquid. Then, the copper liquid is cast into copper rods through a continuous casting machine, and the diameter of the copper rods is determined according to the required conductor specifications. Next, the copper rod is drawn into
Copper Wires of different diameters through multiple passes of a wire drawing machine. During the wire drawing process, the copper wire will produce work hardening, so it needs to be annealed. Annealing is to heat the copper wire to a certain temperature (usually 300℃-400℃) and keep it for a period of time, so that the grains inside the copper wire are rearranged, eliminate internal stress, and improve its flexibility and conductivity. Finally, multiple annealed copper wires are stranded together according to certain stranding rules to form a conductor with the required cross-section. During the stranding process, the roundness and tightness of the conductor must be ensured.
Insulation Extrusion
Select the corresponding extrusion equipment and process according to the insulation material of the cable. For XLPE insulation, add XLPE particles into the extruder, melt and plasticize at high temperature (about 120℃-150℃), and then uniformly extrude onto the conductor surface through a mold to form an insulation layer. The extruded insulation layer needs to be cross-linked. Chemical cross-linking is to put the cable into a high-temperature and high-pressure steam pipeline to make the XLPE molecules undergo a cross-linking reaction; physical cross-linking is to cross-link the molecules through electron beam irradiation. For PVC insulation, add the PVC mixture into the extruder, melt it at about 150℃-180℃, and then extrude it onto the conductor surface to form an insulation layer without cross-linking treatment. During the insulation extrusion process, it is necessary to strictly control the extrusion temperature, speed and pressure to ensure that the insulation layer has uniform thickness, smooth surface and is closely combined with the conductor.
Sheath Extrusion
The sheath extrusion process is similar to insulation extrusion, but the materials and process parameters used are different. According to the different sheath materials, adjust the temperature of the extruder. The extrusion temperature of PVC sheath is about 160℃-190℃, PE sheath is about 150℃-180℃, and PUR sheath is about 170℃-200℃. Add the sheath material into the extruder, melt it, and then extrude it onto the surface of the insulation layer through a mold to form a sheath layer. During the extrusion process, it is necessary to ensure that the sheath layer has uniform thickness, is closely combined with the insulation layer, and has a smooth surface without defects. For
Armored Cables, before sheath extrusion, it is necessary to wrap a steel tape or steel wire armor layer outside the insulation layer. The winding density and mode of the armor layer are determined according to the use requirements of the cable.
Cooling and Curing
The extruded cable enters the cooling water tank for cooling. The cooling water temperature is controlled according to the insulation and sheath materials, generally 20℃-40℃. During the cooling process, the cable should be cooled uniformly to avoid internal stress in the insulation layer or sheath layer due to too fast cooling speed. The cooled cable is pulled by a tractor and enters the take-up machine for winding.
Inspection and Testing
The finished cable needs to undergo strict inspection and testing. Appearance inspection includes checking whether the surface of the cable has scratches, bubbles, depressions and other defects, whether the thickness of the insulation layer and sheath layer is uniform, and whether the color is consistent. Dimension measurement includes measuring parameters such as conductor diameter, insulation thickness, sheath thickness, and cable outer diameter to ensure they meet the design requirements. Electrical performance tests include insulation resistance test, voltage withstand test, partial discharge test, etc., to check whether the insulation performance of the cable is good. Mechanical performance tests include tensile strength, elongation at break, bending test, etc., to evaluate the mechanical strength and flexibility of the cable. In addition, flame retardant performance tests and aging resistance tests need to be carried out to ensure that the cable meets relevant standards and use requirements. Only cables that pass all tests can leave the factory.
II. From the Perspective of General Product Information
(I) Packaging
Packaging Materials
The packaging materials of cables mainly include cable reels and packaging films. Cable reels are divided into wooden cable reels and iron cable reels. Wooden cable reels are made of high-quality pine or fir, which have certain strength and toughness, light weight and low cost, and are suitable for packaging small and medium cross-section cables. The structure of the wooden cable reel includes a reel shaft, baffles and spokes. The diameter of the baffle is determined according to the length and outer diameter of the cable, generally 600mm-1200mm. The iron cable reel is welded by steel plates, with high strength and large bearing capacity, suitable for packaging large-section and long-length cables, with a diameter of up to 1500mm-2500mm. The packaging film is made of polyethylene film, which has good moisture-proof and dust-proof performance. It is used to wrap the outer layer of the cable to protect the cable from pollution and damage during transportation and storage.
Packaging Method
The cable is neatly coiled on the cable reel. When coiling, the cable must be arranged tightly and neatly to avoid crossing and overlapping. The length of each reel of cable is determined according to the cable cross-section and customer requirements. The length of each reel of small cross-section cable is usually 100m-500m, medium cross-section is 50m-300m, and large cross-section is 20m-100m. On the outside of the cable reel, the cable is fixed firmly with steel strips or plastic strips to prevent the cable from loosening and sliding during transportation. Both ends of the cable are sealed with plastic protective caps to prevent moisture and dust from entering the inside of the cable. For armored cables, it is necessary to lay a layer of buffer material, such as foam board or gunny bag, on the cable reel before packaging to avoid damage to the cable reel by the armor layer during transportation.
Packaging Marking
A label is set at a prominent position on the cable reel, which indicates the product name, model specification (such as copper core PVC sheathed
Power Cable, 10mm²), length, weight, production batch number, implementation standard, production date, manufacturer's name, address and contact information. The label is made of wear-resistant materials to ensure that it is clearly visible during transportation and storage. In addition, warning signs such as "Do not invert", "Handle with care" and "Moisture and sun protection" will be pasted on the cable reel to remind transportation and loading and unloading personnel to operate correctly.
(II) Transportation
Transportation Methods
According to the transportation distance, cable quantity and customer needs, road transportation, railway transportation or water transportation can be selected.
Road Transportation: Suitable for medium and short-distance transportation, with high flexibility, and can directly deliver cables to the destination. The transport vehicles are large trucks, and the carriage is equipped with fixing devices to fix the cable reels firmly to prevent shaking and collision during transportation. For small batches of cables, small trucks or logistics can be used for transportation.
Railway Transportation: Suitable for long-distance and large quantities of cable transportation, with low transportation cost and good stability. Cable reels are transported by railway freight cars, and need to be loaded and fixed in accordance with the regulations of the railway department to ensure transportation safety.
Water Transportation: Suitable for cross-regional or transnational transportation, with large transportation volume and low cost. When loading cable reels onto the ship, they should be stacked reasonably to avoid pressure deformation. At the same time, moisture-proof and anti-corrosion measures should be taken, such as covering the cable reels with waterproof cloth.
Transportation Precautions
During transportation, the cable reel must be kept in an upright state, and it is strictly forbidden to lay it flat or upside down to prevent the cable from being damaged by extrusion. When loading and unloading the cable reel, use special lifting equipment such as cranes and forklifts. The lifting operation should be stable to avoid collision and rolling of the cable reel. During the driving process of the transport vehicle, it is necessary to maintain a uniform speed, avoid sudden braking and sharp turns, and prevent the cable reel from sliding in the carriage. During transportation, the cable reel should be covered to prevent sun exposure, rain and dust pollution. For cables transported over long distances, the fixing of the cable reel and the appearance of the cable should be checked regularly, and problems should be dealt with in a timely manner. In addition, traffic rules and relevant regulations of the transportation department must be observed during transportation to ensure transportation safety.
(III) Delivery
Delivery Process
Order Confirmation: After the customer places an order, the sales staff will verify the product model, specification, quantity, delivery date, delivery location and other information with the customer to ensure accuracy, and sign a sales contract.
Inventory Check: The warehouse management personnel check the inventory according to the order information. If the inventory is sufficient, they will arrange for goods preparation in a timely manner; if the inventory is insufficient, they will notify the production department to organize production to ensure delivery on time.
Product Inspection: After the goods preparation is completed, the quality inspectors will re-inspect the cables, including appearance, size, electrical performance, etc., and confirm that the product quality is qualified before delivery.
Arrange Transportation: Select the appropriate transportation method according to customer requirements and actual conditions, sign a transportation agreement with the transportation company, and clarify the rights and obligations of both parties.
Delivery Notification: After the cable is shipped, the sales staff will promptly notify the customer of the delivery information (such as transportation method, license plate number, waybill number, estimated arrival time, etc.) to facilitate the customer's preparation for receipt.
Delivery Time
For regular model cables in stock, they will generally be shipped within 1-3 working days after receiving the customer's payment or advance payment. For customized products or large quantities of orders, the delivery time is determined according to the production cycle, usually 7-15 working days. The specific time will be communicated and confirmed with the customer in advance. In case of special circumstances such as raw material shortage, equipment failure, bad weather, etc., which may cause delivery delay, the sales staff will communicate with the customer in a timely manner, explain the reasons and negotiate a new delivery date.
(IV) Samples
Sample Provision
To enable customers to better understand the quality and performance of the product, the company can provide samples for customers. Customers can apply for samples through phone calls, emails, online consultations, etc., stating the model, specification, quantity and other information of the required samples. After receiving the sample application, the company will prepare the samples within 2-3 working days. The length of the samples is usually 1m-3m to meet the customer's needs for testing the appearance, material, size and performance of the cable.
Sample Fees
For samples of regular models, the company usually provides them free of charge, but the customer needs to bear the sample transportation cost. Customers can choose to pay the freight by cash on delivery or pay the freight to the company in advance. For specially customized samples, due to the need for special production and processing, the company will charge a certain sample fee. The amount of the sample fee is determined according to the specification and processing difficulty of the sample. After the customer places a formal order, the sample fee can be deducted from the payment.
Sample Delivery
After the samples are prepared, the company will choose an appropriate express delivery method to send the samples to the customer, such as DHL, FedEx, UPS, etc. Before delivery, the samples will be properly packaged to prevent damage during transportation. At the same time, the express tracking number will be promptly informed to the customer to facilitate the customer's inquiry of the sample logistics information. If the customer has any questions about the samples after receiving them or needs further technical parameters and test reports, the company's sales staff and technical personnel will provide detailed answers and support.
(V) After-Sales Service
Quality Assurance
The company promises that all multi-section copper core power cables with PVC/PE/PUR sheaths for construction use comply with national standards (such as GB/T 12706) and industry standards. The product quality guarantee period is 24 months from the date of delivery. During the quality guarantee period, if the product has quality problems (such as insulation breakdown, conductor fracture, sheath cracking, etc.) due to manufacturing defects, the company will provide free repair or replacement services. Customers need to provide purchase invoices, product photos with defects and other relevant materials to assist in determining the cause of the problem.
Technical Support
The company has a professional technical team to provide customers with comprehensive technical support. Customers can consult technical personnel about cable selection, installation, laying, maintenance and other issues through phone calls, emails, online platforms, etc. The technical team will provide professional solutions and suggestions according to the customer's specific situation. For large-scale construction projects, the company can dispatch technical personnel to the site to guide the installation and laying of cables, check the construction quality, and ensure that the cable installation meets the design requirements and safety standards.
Fault Handling
If the cable fails during use, the customer can contact the company's after-sales service hotline. The after-sales staff will record the fault situation in detail and respond within 2 hours. For simple faults, technical personnel can guide the customer to solve them through phone calls or video calls; for complex faults that require on-site processing, the company will dispatch technical personnel to the site within 24-48 hours (depending on the distance) to carry out fault diagnosis and maintenance. If the fault is caused by product quality problems within the warranty period, the maintenance is free of charge; if the fault is caused by improper use, man-made damage or beyond the warranty period, the company will charge reasonable maintenance fees and material fees.
Customer Feedback
The company attaches great importance to customer feedback and has established a sound customer feedback mechanism. Customers can put forward opinions and suggestions on product quality, service attitude, delivery time, etc. through the company's official website, customer service hotline, email and other channels. The company arranges special personnel to sort out and summarize customer feedback, and holds regular meetings to discuss and study improvement measures. For reasonable suggestions, the company will adopt them in a timely manner and feedback the handling results to the customer within 5 working days. The company takes customer feedback as an important basis for improving products and services, and is committed to providing customers with more satisfactory products and services.
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