- Material Preparation
- Conductor (Copper/Wire): High-purity copper is drawn into thin strands through a wire-drawing machine. These strands are twisted together to form flexible, stranded conductors, enhancing durability and bendability.
- Insulation and Jacket Materials: Thermoplastic polymers (e.g., PVC, TPE, or rubber) are selected based on voltage requirements, flexibility, and environmental resistance.
- Conductor Processing
- The stranded copper wires are passed through an extrusion machine to coat them with an insulating layer. This ensures electrical safety and prevents short circuits.
- For shielded power cords (e.g., industrial or high-frequency applications), a metallic foil or braided shield is added over the insulation to block electromagnetic interference (EMI).
- Cable Assembly
- Multiple insulated conductors are grouped and wrapped with a protective filler or binder to maintain structural integrity.
- An outer jacket (sheath) is extruded over the assembly to provide mechanical protection, moisture resistance, and heat resistance.
- Termination (Plug and Connector Attachment)
- The cable ends are stripped to expose conductors.
- Plugs or connectors (e.g., IEC, NEMA) are crimped, soldered, or molded onto the conductors using automated machinery.
- Strain relief components are added to prevent wire damage at connection points.
- Testing and Quality Control
- Electrical Testing: Conductors undergo continuity checks, high-voltage tests (e.g., dielectric strength), and insulation resistance measurements.
- Safety Compliance: Products are certified against international standards (e.g., UL, CE, RoHS) for safety, environmental, and performance requirements.
- Packaging
- Finished power cords are coiled, labeled, and packed with protective materials for shipment.
Key Technologies:
- Precision extrusion for uniform insulation thickness.
- Automated crimping/molding for consistent connector reliability.
- Rigorous testing protocols to ensure compliance with safety regulations.
This streamlined process balances efficiency, safety, and durability to meet diverse applications, from household appliances to industrial equipment.
Post time: Feb-27-2025