The power cable factory can enhance the tensile strength of its products by improving the production process, optimizing the structural design and selecting high-performance materials, as follows:
Optimize the production process
Stranding process: Advanced stranding equipment and techniques are adopted to ensure that the conductors are stranded tightly and evenly. Reasonably control the pitch and direction of the twisted wire to make the structure of the twisted conductor more stable, reduce the relative sliding between the conductors during the stretching process, and thereby enhance the overall tensile strength of the cable.
Insulation and sheath extrusion process: Precisely control the extrusion thickness and uniformity of the insulation layer and sheath layer to avoid excessive thickness deviation or local defects. Meanwhile, optimize the extrusion process parameters, such as temperature and pressure, to ensure that the insulating and sheathed materials have good bonding performance with the conductor. When subjected to tensile force, they can work together to jointly withstand the external force.
Heat treatment process: Appropriate heat treatment is carried out on cables, such as annealing the conductors during the production process, which can eliminate the internal stress of the conductors and enhance their flexibility and strength. For insulating and sheathing materials, heat treatment can improve their molecular structure, enhance the crystallinity and mechanical properties of the materials, and thereby increase the tensile strength of the cables.
Improve the structural design
Add reinforcing elements: Add high-strength reinforcing elements such as steel wire and glass fiber to the cable structure. These reinforcing elements are usually distributed in a spiral or parallel arrangement within the insulation or sheath layer of the cable, which can effectively bear the tensile force the cable is subjected to and enhance its tensile performance. For instance, in some large-span overhead transmission cables or submarine cables, steel wires are often used as reinforcing elements to bear the weight of the cables themselves and external tensile forces.
Adopt a multi-layer structure: Design cables with a multi-layer structure. By combining different materials and structural layers, leverage the advantages of each layer to jointly enhance the tensile strength of the cable. For instance, adding a high-strength braided layer or winding layer, such as an aramid fiber braided layer, between the insulation layer and the sheath layer of a cable can enhance the tensile strength and wear resistance of the cable.
Optimize the cross-sectional shape of the cable: Based on the usage environment and force characteristics of the cable, rationally design the cross-sectional shape of the cable. For instance, for some cables that need to withstand greater tensile force, circular or elliptical cross-sections can be adopted. This shape can make the stress distribution of the cable more uniform when it is subjected to tensile force, reduce the stress concentration phenomenon, and thereby enhance the tensile strength of the cable.
Select high-performance materials
High-purity conductor materials: High-purity copper or aluminum is selected as the conductor material. High-purity conductors have higher electrical conductivity and strength, and can withstand greater tensile force while transmitting electrical energy. For instance, when oxygen-free copper is used as the conductor material, its purity can reach over 99.95%. Compared with ordinary copper conductors, it has better mechanical properties and tensile strength.
High-strength insulation and sheath materials: Insulation and sheath materials with high tensile strength are adopted, such as cross-linked polyethylene (XLPE), ethylene propylene rubber (EPR), etc. After being processed by special formulas and techniques, these materials possess excellent mechanical properties and aging resistance, and can maintain stable tensile strength during long-term use. In addition, an appropriate amount of reinforcing agents, such as nanoparticles and carbon fibers, can be added to insulating and sheathing materials to further enhance the strength and toughness of the materials.
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