What technical support is needed to provide customized power cable products for customers?

Surgical support system. The following is an explanation from the perspective of core technologies:

1. Demand analysis and technical adaptation capabilities

Industry standards and working condition analysis techniques

Standard database: Establish standard libraries for power cables in various industries (such as national standards GB, international standards IEC, American standards UL, industry standards such as DL/T, YD/T, etc.) to quickly match the industry demands of customers (for example, cables used in rail transit need to meet the flame retardant and smoke density requirements of the TB/T 1484 standard).

Working condition simulation technology: By using the environmental parameters (temperature, humidity, vibration frequency, corrosive medium, etc.) provided by the customer, simulation software (such as ANSYS thermal analysis module) is used to simulate the performance of the cable under extreme working conditions, verifying the feasibility of material selection and structural design.

2. Cross-domain technology integration capability

Multidisciplinary collaboration: Combining technologies from fields such as electrical engineering, materials, mechanics, and environmental engineering to address complex customized demands. For example:

In the field of new energy: To customize photovoltaic cables that are resistant to ultraviolet (UV) and ozone for photovoltaic projects, it is necessary to integrate the anti-aging technology of high molecular materials with the electrical insulation design technology.

When designing explosion-proof cables for mining scenarios, it is necessary to integrate mechanical protection (armored structure for pressure resistance and impact resistance) with electrical explosion-proof technology (sealed design to prevent the leakage of electric sparks).

Ii. Customized design and Development Technology

Cable structure design technology

Conductor design

Customize the cross-section of the conductor (such as large-sized cables with non-standard cross-sectional areas) and the twisting method (tightly pressing circular, fan-shaped, and irregular-shaped conductors) to adapt to the laying space;

High-conductivity materials (such as oxygen-free copper, high-purity aluminum) or special coatings (tin plating, silver plating) are adopted to meet the requirements of electrical conductivity or corrosion resistance.

Development of insulation and sheath materials

Select materials such as polyethylene (PE), cross-linked polyethylene (XLPE), silicone rubber, and fluoroplastics based on temperature grades (such as 70℃, 90℃, 180℃, and 250℃), or develop composite insulation layers (such as XLPE + semiconductor shielding layer) to enhance electrical performance.

For special environments, functional additives (such as flame retardants, smoke suppressants, and anti-rat and anti-ant additives) are added to meet environmental protection and safety standards.

Armor and sheath design

Select armoring materials such as steel strips, steel wires, and aluminum strips, and combine winding and weaving processes to design tensile and compressive structures (such as double-layer steel wire armoring for submarine cables).

The outer sheath can be customized in terms of color and marking (such as printed characters including the customer's LOGO, voltage level, and meter mark) to enhance the construction recognition.

2. Digital design tools

CAD and 3D modeling: Use tools such as AutoCAD and SolidWorks to draw cable cross-sectional diagrams and reel structure diagrams, visually presenting details such as the number of conductor layers, insulation thickness, and armoring structure.

Simulation analysis software

Electrical performance: Use POWER CAD to calculate the current-carrying capacity, voltage drop and short-circuit current endurance of the cable;

Mechanical properties: By simulating the stress distribution of cables during bending and stretching through COMSOL, the structural design is optimized to avoid cracking.

Environmental performance: Use MATLAB to simulate the influence of different climatic conditions (such as high salt spray and high altitude) on the aging rate of cables and predict their service life.

Iii. Flexible Manufacturing Technology

Intelligent production equipment

Adjustable production line: Equipped with extrusion machines, stranding machines and armoring machines that can quickly change molds, it supports rapid switching of small-batch customized orders (for example, when changing from producing 10mm² cables to 500mm² cables, the mold change time is ≤30 minutes).

Precision measurement and control technology

Online detection systems (such as laser diameter gauges and spark testing machines) monitor insulation thickness, eccentricity and withstand voltage performance in real time to ensure that each meter of cable meets the customized parameters.

The Intelligent Manufacturing Execution System (MES) tracks raw material batches, process parameters, and production progress, achieving full-process traceability of customized products.

2. Special process technology

Special insulation extrusion: Such as using chemical cross-linking, physical foaming and other processes to manufacture uniform insulation layers for high-voltage cables, or producing multi-layer composite insulation through co-extrusion technology (such as simultaneous extrusion of insulation layers and semiconductive shielding layers).

Precision stranding and cabling: For multi-core cables, pre-twisting and de-twisting processes are adopted to control the stranding pitch, reducing the problem of uneven capacitance caused by loose structure. For high-frequency signal cables, methods such as twisted pair and star twisted pair are adopted to reduce crosstalk.

Environmental protection manufacturing technology: Halogen-free flame-retardant materials and water-based coatings are used, and waste gas treatment equipment is equipped to meet the environmental protection compliance requirements of customized products (such as RoHS and REACH certifications).

Iv. Full-process testing and verification technology

1. Material property testing

Basic index testing: Conduct tensile strength, elongation at break, heat distortion, dielectric constant and other tests on customized materials to verify whether they meet the design requirements (for example, the aging resistance test of silicone rubber insulation needs to pass the 168-hour hot air aging test).

Long-term performance assessment: Predict the service life of materials under actual working conditions through accelerated aging tests (such as UV aging chambers and ozone aging chambers), and provide reliable data for customers.

2. Testing of finished cables

Electrical performance test

Insulation defects are detected by DC withstand voltage test and partial discharge test (PD test).

Short-circuit current tests simulate fault conditions to verify the thermal stability of conductors and insulators.

Mechanical performance test

The structural strength is evaluated through bending tests (such as no cracking when the bending radius is 10 times the outer diameter of the cable) and flattening tests (no deformation under a pressure of 50kN).

Wear resistance tests (such as the Tabor wear test) verify the anti-friction performance of the outer sheath.

Environmental adaptability test

High and low temperature cycling tests (such as 50 cycles from -40 ℃ to 80℃) are used to test the weather resistance of materials.

Flame retardant tests (such as bundle burning test, single vertical burning test) comply with customized fire resistance grades (such as flame retardant Class A, fire resistant Class N).

3. Third-party certification support

Entrust national-level testing institutions (such as the National Quality Supervision and Inspection Center for Wires and Cables) to conduct type tests and provide certification reports that meet customer requirements (such as CCC, UL, and CE certifications) to assist customized products in entering specific markets.

V. Application and Operation and Maintenance Technical Support

1. Design of laying scheme

Based on the customized parameters of the cable (such as weight and bending radius), the construction path is designed using cable laying simulation software (such as CableLay) to avoid the risk of mechanical damage (such as lateral pressure control when passing through a curve).

Provide stress calculation reports to guide customers in choosing the appropriate traction equipment and pulley configuration, and avoid conductor pulling or insulation damage during the laying process.

2. Intelligent monitoring technology

Integrate sensors (such as temperature sensors and partial discharge sensors) for high-end customized cables. Through the Internet of Things (IoT) platform, monitor the operating status in real time, issue early warnings for abnormal temperature rise or insulation deterioration, and achieve an upgrade from "passive maintenance" to "active operation and maintenance".

3. Fault diagnosis technology

Equipped with cable fault location instruments (such as pulse method, radar method), it helps customers quickly identify high-resistance faults, low-resistance faults or flashover faults in customized cables, reducing power outage time.

Six. Technological reserves for continuous innovation

Research and development of cutting-edge technologies

Track industry trends (such as in the fields of new energy, smart grids, submarine cables, etc.), reserve technologies such as ultra-high voltage cables, superconducting cables, and materials resistant to extreme environments (such as ceramicized silicone rubber), and provide solutions for customers' forward-looking demands.

Cooperate with universities and research institutions to carry out basic research (such as the improvement of cable insulation performance by nano-fillers), and transform research achievements into the competitiveness of customized products.

2. Intellectual Property management

Establish a customized technology patent pool (such as new armored structures, composite insulating materials, etc.), enhance customers' technological dependence on the brand through technological barriers, and at the same time avoid homogeneous competition.

Summary: The core logic of technical support

The technical support for customized power cables should be centered on "precise matching of demands - reliable realization of performance - full-cycle guarantee of value", and through the integration of multiple technologies (materials, electrical, mechanical, and intelligent), full-process control (design - production - testing - application), and forward-looking layout (cutting-edge technology research and development) Transform customers' personalized demands into high-quality products that can be implemented, and at the same time enhance customer stickiness through technical value-added services (such as intelligent monitoring and fault diagnosis), ultimately forming a positive cycle of "technology-driven customization, customization creates value".