8 step-by-step processes of manufacturing of electrical cable

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How Are Electric Wires And Cables Manufactured?
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• The electrical wires are manufactured in several
  different sizes and using several conductive
  materials. The electrical wires are excellent
  conductors of heat.
• An electric wire is an insulating material that
  is flexible and transmits electricity. The
  conducting material mainly used is copper. Copper
  is an excellent conductor of electricity. It is
  flexible and possesses a high-malleable property.
• Power distribution boxes in Sharjah can be used
  in aerials, underground cables, and electrical
  appliances running beneath our feet in our homes
  and behind our walls. They carry the electricity
  and give us power.

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There Are Different Types Of Cables Such As

• HT and LT flame-retardant cables
• Flame-retardant low smoke cables
• Power and control cables
• Insulated cables
• Fire survival cables
• Solar cables

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Overview Of The Manufacturing Process Of Electric
Wires

• The cable is fed into a machine that draws it out
  through a series of lubricated pulleys and dies
  stretching, lengthening, and thinning it out.
• They are eventually winding it onto a giant
  bobbin. The cable once 10 mm in diameter is now 2
  mm in diameter. The bobbin is loaded. The ends of
  the bobbins are cold-welded to one another,
  guaranteeing an uninterrupted flow once the
  machine starts up.
• Multi-core flexible cables are twisted and
  sheathed with white PVC granules to obtain the
  final product. The white flexible cable is coiled
  on modern coiling machines with length measuring
  yards. 
• Each coil is packed with a suitable label and
  shrink wrapped with a polyethylene layer for safe
  and moisture-free binding. The PVC insulation is
  done in a double-layer process. The first layer
  is with Virgin PVC of Insulation and an outer
  layer which is very thin and commonly called skin
  with color PVC. 

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• It is done to avoid the adverse effect of color
  pigments on the insulation resistance value of
  PVC as virgin PVC insulation has excellent
  insulation resistance.
• At high speed, the stranding machines twist seven
  wires together, forming an electrical conductor.
  This is a low voltage conductor under 1000 volts
  the carrying you will find in cables that run
  electricity to your home. 
• Their conductors need to be insulated. So a
  plastic extrusion machine coats the conductor
  with polyethylene or PVC. The extrusion process
  has heated the conductor, so it has to be cooled
  down with water. Several conductors are mixed to
  form a cable. This plant performs a voltage
  immersing the cables in water to make sure they
  soak it. 
• They are insulated the same way as low voltage
  cables are insulated. The cable goes into a reel
  to be tested before it's shipped out to its
  destination in the middle of the table surrounded
  by copper grounding wires and a host of other
  components, which is the heart of the electrical
  cable.

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Now Let Us See The Step-By-Step Process Of
Manufacturing Of Electrical Cable

• 1. Procurement of the purest raw material
• The manufacturing process starts with the
  procurement of the purest of raw materials from
  reputed suppliers. All incoming materials are
  subjected to a series of mechanical and
  electrical checks.
• The plant is capable of drawing wire from 8 mm to
  1.6 mm consistency and resistance tensile. The
  strength and size of the wire are ensured at all
  stages of the drawing process. 
• The drawn wires are then stranded to achieve
  Co-conductors as per specifications, conductors
  are formed on sophisticated high-speed stranding
  machines and then compacted to ensure AC losses.
  To ensure optimum performance, the extensive
  focus is paid to the conductors, resistance, and
  shape.

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• 2. Insulation
• For Insulation, the unit is equipped by power
  cable suppliers in UAE with a state-of-the-art
  CCV extrusion line. The extrusion route with
  filtered air inlets and a positive pressure eyes
  closed system ensures that the insulation process
  is entirely free from impurities and
  imperfections. 
• 3. Twisting and laying 
• Insulation is followed by twisting and laying of
  multi-core cables. 
• Wires and cables manufacturers possess a massive
  drum twisting and laying up machine, which
  ensures that no tangential stress is applied over
  the Insulation this mitigates the possibility of
  any shifting or migration of the insulating
  layers, which could otherwise result in air void
  formations. 
• This prevents any chances of failure during the
  entire lifetime of the cable and the
  manufacturer's flexibility to provide longer
  cable lengths that exhibit excellent and compact
  designs.

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• 4. Inner Sheathing
• The later multi-core cables are provided with an
  inner sheathing through computerized extrusion
  lines using PVC compounds. 
• Wires and cables manufacturers provide extruded
  PVC layers over the laid-up cores to hold the
  twisted cores in their circular form. 
• 5. Extrusion Process
• The extrusion process also serves as an
  additional moisture barrier. If the outer sheath
  gets damaged as water cannot travel radically up
  to the surface of the Insulation. An armoring
  process follows this.
• 6. Armoring Process
• Wires and cables manufacturers offer standardized
  armoring with aluminum or aluminum alloy wire
  strips for core cables and steel wires and strips
  for multi-core cables, a uniform and perfect mass
  of zinc coating on the armor, and a rust-free
  armor layer.
• It also offers protection to the armor in case of
  any external damage the cables are then provided
  for the PVC polymer outer sheathing through the
  latest sheathing machines.

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• 7. Testing and Validation
• Electric wire manufacturers also have a modern
  test lab with the latest validation and testing
  equipment. Every cable manufactured at the plant
  is tested for higher conductivity, flame
  resistance, oxygen index, smoke density,
  durability, tensile properties, and thermal
  stability. 
• There are more than 30 various test parameters-
  physical, mechanical, electrical, thermal,
  chemical, and fire, that different components of
  cables have to pass before being certified, and
  that indeed puts into perspective for you.
• 8. Packing
• Then the wires and cables are packed with safe
  moisture free and good-looking packing to
  delivering the material in good condition - its
  esteemed customers.

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Conclusion

• Thus, the manufacturing process of electrical
  wires and cables is complicated. If the
  manufacturers don't give good quality products,
  the wires will not be an excellent conductor to
  produce electricity. So they should always take
  care of specific steps while making electric
  wires and cables.

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