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The types of wire and cable and power cables for electrical equipment are mainly composed of the following seven parts:
Some special wire and cable models finally have derivative codes.
The meanings of the letters in the most commonly used wire and cable models are described below:
1) Category, use code
A-Installation Line B-Insulated Line C-Marine Cable
K-control cable N-farm cable R-cord
U-mining cable Y-moving cable JK- insulated aerial cable
M-mining
ZR-flame-retardant NH-refractory ZA-A flame retardant
ZB-B grade flame retardant ZC-C grade flame retardant WD-low smoke halogen free type
2) Conductor code
T-copper wire (slightly) L-aluminum core
3) Insulation layer code
V-PVC plastic YJ-XLPE insulation
X-rubber Y-polyethylene material
F-PTFE
4) cover code
V-PVC sleeve Y-polyethylene material
N-Nylon sheathed P-copper braided shielded P2-copperband shielded
L-cotton yarn woven wax Q-lead package
5) Feature Code
B-flat R-soft
C-Heavy duty Q-light
G-high pressure H-welder
S-twist
6) Armored layer code
2—Double Steel Strip 3—Thin Round Wire
4—Rough round wire
7) Outer cover code
1 - fiber layer 2 - PVC sleeve
3-PE sleeve
2. Models of the most commonly used wire and cable for electrical equipment and power cables
VV-copper core PVC insulated PVC sheathed power cable
VLV-aluminum core PVC insulated PVC sheathed power cable
YJV22-copper-core XLPE insulated steel tape armored PVC sheathed power cable
KVV—PVC insulated PVC sheathed control cable
227IEC 01 (BV)—BV for short, general purpose single core hard conductor non-sheathed cables
227IEC 02(RV)—RV for short, general purpose single-core flexible conductor sheathless cable
227IEC 10 (BVV)—BVV for short, lightweight PVC sheathed cable
227IEC 52 (RVV) — RVV for short, light PVC sheathed cords
227IEC 53 (RVV) - RVV for short, ordinary PVC sheathed cords
BV - copper core PVC insulated wire
BVR-copper core PVC insulated soft cable
BVVB-copper core PVC insulated PVC sheathed flat cable
JKLYJ—XLPE insulated aerial cable
YC, YCW-heavy duty rubber sheathed flexible cable
YZ, YZW—Medium rubber flexible cable
YQ, YQW-light rubber sheathed flexible cable
YH—Electric Welding Machine Cable
3, specifications and specifications by the rated voltage, the number of core and nominal cross-section.
The general rated voltages of wires and control cables are 300/300V, 300/500V, 450/750V;
The rated voltage of medium and low voltage power cables is generally 0.6/1kv, 1.8/3kv, 3.6/6kv, 6/6(10)KV, 8.7/10(15)kv, 12/20kv, 18/20(30)kv, 21 /35kv, 26/35kv and so on.
The number of cores of wires and cables is determined according to actual needs. The general power cables are mainly 1, 2, 3, 4, and 5 cores, and the wires are mainly 1 to 5 cores, and the control cables have 1 to 61 cores.
The nominal section is an approximation of the cross section of the guidance body. In order to achieve the specified DC resistance, it is convenient to memorize and define an integer value of a conductor near the cross section. China's uniform conductor cross-section has 0.5,0.75,1,1.5,2.5,4,6,10,16,25,35,50,70,95,120,150,185,240,300,400,500, 630, 800, 1000, 1200, and so on. It is emphasized here that the nominal cross-section of the conductor is not the actual cross-section of the conductor. Many of the actual cross-sections of the conductor are smaller than the nominal cross-section, and several are larger than the nominal cross-section. In the actual production process, as long as the DC resistance of the conductor can meet the specified requirements, it can be said that the section of the cable is up to standard.
4. Standard numbering Most of the countries and industries we produce now have clear standards and the main purpose is of course to make design and use uniform. Here I mainly introduce several wire and cable standard numbers related to our products.
1) GB 5023-1997 PVC insulated cables with rated voltage of 450/750V and below
2) JB 8734-1998 PVC insulated cables, wires and cords with rated voltages up to and including 450/750V
2)GB 5013-1997 rubber insulated cable with rated voltage of 450/750V and below
3) Extruded Insulated Power Cables and Accessories Rated Voltage 1kV to 35kV GB/T 12706-2002
4) GB/T 9330-1988 plastic insulated control cable
5, for example
a) VV-0.6/1 3×150+1×70 GB/T 12706.2-2002
Copper core PVC insulated PVC sheathed power cable, rated voltage 0.6/1kv, 3 +1 core, the nominal section of the main core is 150mm2, the fourth core section is 70mm2.
b) BVVB-450/750V 2×1.5 JB 8734.2-1998
Copper core PVC insulated PVC sheathed flat cable, rated voltage 450/750v, 2 cores, conductor nominal cross section 1.5mm2.
c) YJLV22-8.7/10 3x120 GB/T 12706.3-2002
Aluminum core cross-linked polyethylene insulated steel tape armored PVC sheathed power cable, rated voltage of 8.7/10kv, 3-core, nominal cross-section of the main core 120mm2.
Fourth, cable main material
1, copper wire:
The electrolytic copper is used as raw material, and the copper wire made by the continuous casting and rolling process is called low-oxygen copper wire; the copper wire made by the up-draft method is called oxygen-free copper wire.
The oxygen content of the oxygen-free copper wire is 100 to 250 ppm, the copper content is 99.9 to 9.95%, and the conductivity is 100 to 101%.
The oxygen-free copper wire has an oxygen content of 4 to 20 ppm, a copper content of 99.96 to 9.99%, and a conductivity of 102%.
The specific gravity of copper is 8.9 g/cm3.
2, aluminum wire:
Aluminum wires used as wires are annealed and softened. Aluminum wires used as cables are generally not softened.
The resistivity of aluminum for wire and cable is required to be 0.028264 Ω.mm2/m, and the specific gravity of aluminum is 2.703 g/cm3.
3, polyvinyl chloride (PVC):
PVC plastic is based on polyvinyl chloride resin, mixed with a variety of ingredients, such as antioxidants, antioxidants, fillers, brighteners, flame retardants, etc., and its density is 1.38 ~ 1.46g/cm3 about.
PVC material features:
Excellent mechanical properties, chemical resistance, non-flammability, good weather resistance, good electrical insulation, easy processing, etc.
Disadvantages of PVC materials:
1 There is a large amount of toxic smoke emitted when burning;
2 poor thermal aging performance.
PVC is divided into insulating material and sheath material.
4, polyethylene (PE):
Polyethylene is produced by the polymerization of refined ethylene and can be classified into low density polyethylene (LDPE), medium density polyethylene (MDPE), and high density polyethylene (HDPE) according to density.
The density of low density polyethylene is generally 0.91~0.925g/cm3; the density of medium density polyethylene is generally 0.925~0.94g/cm3; the density of high density polyethylene is generally 0.94~0.97g/cm3.
The advantages of polyethylene material:
1 high insulation resistance and voltage resistance;
2 In a wider frequency band, the dielectric constant ε and dielectric loss tangent tgδ are small;
3 Full of flexibility, good wear resistance;
4 Heat aging resistance, low temperature performance and chemical resistance stability;
5 good water resistance, low moisture absorption;
6 The cable made with it is lightweight and easy to use.
Disadvantages of polyethylene material:
1 Flammable when in contact with flames;
2 Softening temperature is low.
5, cross-linked polyethylene (XLPE):
There are mainly two types of crosslinked polyethylene used in the cable industry. One is silane crosslinker, called silane crosslinker, mainly used in the insulating layer of low voltage wire and cable. The other is a cross-linked polyethylene material with dicumyl peroxide (DCP) as a cross-linking agent, which is mainly composed of polyethylene, a cross-linking agent and an antioxidant. Mainly used in the middle and high voltage cable insulation layer, the higher the insulation pressure rating, the higher the purity required.
DCP is a peroxide, and the higher the temperature, the faster the decomposition, and the decomposition of which will catalyze the crosslinking of polyethylene. DCP also decomposes at room temperature, but the decomposition rate is very slow, but heating to a certain temperature (when the temperature exceeds 125°C) will rapidly decompose.
Silane crosslinkers also have the same properties, but it also requires water as an aid to complete the grafting reaction. There are two main types of silane cross-linked polyethylene on the market. One is a one-step method and the other is a two-step method (this is different from the academic name for silane cross-linking). The one-step insulation material is pre-mixed with the cross-linking agent and the catalyst, and is also called copolymer material. The two-step material is A and B materials. Mix A and B materials before production. The one-step method has a short material storage time. The two-step material is separated from the catalyst material, so the storage time is longer, but the mixed material must be used immediately. In addition, carbon black masterbatch can also be added in the silane cross-linking material to play a role in weather resistance, and is used in insulated aerial cable products.
Cross-linked polyethylene material advantages:
The electrical properties are also superior to those of polyethylene; its mechanical properties are better than that of polyethylene, so its application is broader than that of polyethylene. The softening temperature is higher than PVC, and the normal operating temperature of the cable can reach 90°C.
The disadvantages are difficult processing and burning.
V. Product quality requirements, common problems and solutions in the process The product quality requirements, common problems and solutions in the company's processes are detailed in the “Procedures for Inspection of Processes†and “Operation and Safety Regulations for Each Equipment†issued by the company. .
As the operator of each position must master the relevant knowledge of this operation position. By gaining experience in practice, you become a qualified operator.
Sixth, inspection and measurement
1) The Importance of Testing The following is the importance of testing.
For the enterprise, the quality of the product is the root of the company's reputation and marketing. Wire and cable product quality is mainly composed of several major factors? In summary, there are five major factors: raw materials, equipment, processes, manufacturing technologies, and inspections. Everyone often hears this: Product quality is manufactured, not tested. This is actually a typical Chinese philosopher's philosophy. In fact, product quality manufacturing technology is fundamental, and inspection is the key. Judging from the five major factors, whether the raw materials are good or not, whether they are processed according to the process requirements, whether there are quality problems in the manufacturing processes, and whether the final products can meet the requirements are determined by inspection personnel and operators according to the corresponding standards. .
Our factory inspection mainly has three links. The first is raw material inspection, the second is process inspection, and the third is finished product inspection. Do not think that inspection is the matter of inspection personnel. In fact, the process inspection is divided into two parts. One is the inspector's inspection of the semi-finished products in the production process. The other important link is the self-inspection and mutual inspection conducted by the operator. The inspector may only check the surface phenomenon. The operator's self-check and mutual inspection are the fundamental guarantee of product quality. If the operator finds quality problems during the production process, he or she can immediately make a judgment on their own. If the judgment fails, the inspection personnel or relevant technical personnel can be asked to do so. Therefore, a qualified operator must not only be skilled in operating the equipment, but also must be familiar with the quality requirements of the products to be produced, and verify whether the quality of the products meets the process requirements.
Of course, the products that have quality problems in production must be strictly examined. From small to large, from light to heavy, there is a complete set of assessment methods. Otherwise, the role of all inspection work will be weakened, and even the role of product quality control can not be achieved.
2) Tools commonly used for measuring outer diameter and thickness commonly used in measuring tools include micrometer, vernier caliper, and projector;
Commonly used tool for measuring length are vernier caliper, ring ruler, ruler, tape measure, mechanical meter meter, electronic meter meter, etc.;
Commonly used temperature measurement tools are thermometers, thermocouple thermometers, etc.
The measuring instruments commonly used by our company include electronic files, multimeters, vacuum pressure gauges, barometers, ammeters, voltmeters, and tachometers.
3) Basic measurement methods
1. Circular Conductor Size Measurement Using Tools: Outside Micrometer or Vernier Caliper Measurement Procedure:
(1) Measurement of round conductor diameter and f value Take a sample of about 1 m, straighten the wire sample, and on the same section perpendicular to the axis of the sample,
Measured in the direction perpendicular to each other, available D1 and D2, such measurements in the two ends of the sample and the middle of a total of three measurements; get 6 data, take the average.
D average = (D1+D2+...+D6)/6
(2) The value of f is the roundness of the conductor. The value of f is defined as the difference between the maximum and minimum readings measured on the same section. According to the above measurement result, the largest difference among the diameters measured on the three sections is taken as the f-value.
2. Insulation Thickness and Sheath Thickness Measurement Using Tool: Measuring Projector Measurement Procedures:
(1) Production;
(2) Measure the thinnest point of the test piece as the first measurement point;
(3) When the test piece is circular, measure 6 points along the circumference of the test piece as much as possible, as shown in Figure 4-1.
(4) When the inner surface of the test piece is a stranded core wire mark, the thickness at each point shall be measured at the thinnest part of the groove at the in-line trace as shown in Figure 4-2. Measure 6 points along the circumference of the test piece as far as possible. .
(5) The fan core should measure 6 points as shown in Figure 4-3.
January 04, 2024